Effective Technologies has developed a production process control system for RusVinyl

2023: Establishment of a Process Control System

Effective Technologies developed and implemented a process control system for SIBUR RusVinyl. Effective Technologies reported this on February 5, 2024.

Effective Technologies

The Process Control System is designed to monitor the performance of equipment operations in real time according to the company's internal regulations.

The most important factors of successful production in industries where complex, multi-step production chains are implemented are:

1. Follow the correct process sequence.
2. Correct execution of each specific step.
3. Prompt communication between all participants in the process.

The problem is especially acute in enterprises where one iteration of the production cycle is carried out for a long time, in different shifts.

The main goal of the project was to design and develop a system that allows you to solve 3 key tasks:

• Employees involved in the production chain should have clear and understandable instructions about the current stage of production and the actions that they need to take (that is, have comprehensive instructions for each step of the production chain).
• Shift managers responsible for the operations performed during the work of their shift should receive all information about the operations performed by the employee with the equipment in real time.
• For the company's management, collect statistics on the work of shifts, including:
  • Number of production chain operations performed per shift.
  • The result of each operation (including any metadata left by participants: comments, attachments, photos, etc.)
  • Problems encountered during each specific operation.

Effective Technologies

The result of the project was the development and implementation of a system for controlling production processes, made in the form of a web-based application for creating and managing a set of checklists, where each checklist is one iteration of a technological cycle consisting of a set of operations. An operation is a set of instructions in which an employee can get all the necessary information about how to properly perform a specific operation and the place where the employee can record the result of his work.

The application allows you to configure an unlimited number of checklists with any set of operations, thereby allowing you to configure the checklist for any production cycle.

A pleasant bonus was the adaptability of the application for any screen resolution out of the box. This property allows you to use the system on any device (that is, employees can receive instructions and record the results of operations both on their personal mobile devices and on the company's stationary equipment).