In most cases, the aim is to compare different periods of production. These periods need to be defined for some specific process chemistry to be investigated. For example, questions about the effects of a change in process chemistry or control strategy. Based on years of process chemistry consulting experience in industry, the founder of PCA holds discussions with the client to define the objectives and scope of work. Any process chemistry issues that need investigating and the types of process data available at the site are discussed. The specific unit processes to focus on are defined. If the client is concerned about data security, PCA can sign a Non-Disclosure Agreement.
When PCA has an ongoing contract with the client, PCA is able to review and compare fresh production data with historical periods. This enables issues to be identified earlier and is therefore recommended. The founder of PCA is available to discuss each report and the implications for the process chemistry. A database is accumulated over time that can be used to benchmark your process and identify optimum process chemistry parameters. In most cases, we are looking to identify conditions with the best average performance, whilst minimising the process variance. Management can then decide what actions to take to improve process chemistry performance.
The previously defined, relevant process chemistry data is uploaded by the client to PCA’s cloud storage using a customised form in their web browser (if you have slow, unreliable Internet, other methods can be used for sending large data sets). PCA is using the latest, high security Google infrastructure, where data is end-to-end and endpoint encrypted. Only PCA can access the data. Data sharing is controlled by PCA using administrator privileges. Customised data collection forms are available to the client for logging key changes in process chemistry and, the data stored in the PCA cloud ready for analytics reporting.
Based on the previously defined process chemistry objectives, the data is processed through data management and statistical algorithms to produce a PCA report. This report summarises the process data to highlight statistically significant differences between production periods and process chemistry. The aim is to answer questions by interpreting the data at a deeper level and provide recommendations that management can action. Sometimes, the analytics raises more questions, but the aim is to identify answers, or at least potential answers that can be tested. PCA uses the leading, trusted advanced analytics tools, for example R, Python, Bash, SAS and others. PCA reports are digitally signed to prove they originate from PCA and have not been altered by a third party. The signature can be verified by the client or PCA.
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There is a need in the industrial marketplace for a trusted, independent, data-based service to assist suppliers and industrial sites to improve process and chemistry performance. PCA’s mission is to provide your business with that service.