Digital production control for construction chemicals
Mortars, adhesives, admixtures, compounds. Every batch needs a test, every raw material a supplier, and the inspectorate and the customer ask by the number on the bag. The test result goes to the batch, the raw material to the genealogy, and pieces from the packing line are counted from the machine signal.
Sound familiar?
Dozens of SKUs, factory production control requirements and customers expecting repeatability batch after batch. On the left the problem, on the right what the system does with it.
Every batch needs a test
Density, consistency, setting time, moisture. Results in a lab notebook, and a question about a batch from a year ago starts a search.
A test plan per product: characteristics with a tolerance, a gauge and a testing moment. The result is saved with the batch, with a date, a lab technician and a gauge. You open a batch from a year ago by its number.
Raw material from a supplier without a history
Cement, sand, additives and packaging arrive with batch numbers on documents that nobody links to production.
A delivery is a batch with a supplier, the supplier's batch number and a quality status. Incoming inspection saves the result with the delivery, and quarantine keeps it away from the line until release.
A complaint from the site: which batch, made from what
The batch number from the bag has to be linked to the production day, the line, the shift, the raw materials and the test. On paper that takes hours.
From the batch number on the bag to the raw material deliveries, the line, the shift and the test results in one view. From a bad raw material delivery to every product batch it went into.
The result is within the standard, but the trend drifts
Every test fits the specification. Nobody sees that density rises from batch to batch until one falls outside the standard.
A control chart for batch parameters, for example density or setting time. Nelson rules raise the alarm while results are still within the standard, and Cpk says how much margin is left.
Dozens of SKUs, cleaning between products
Every product change on the line means cleaning and setup. How much time that eats per month, nobody knows.
A changeover has a start, an end and a plan on the timeline. The report shows the hours over plan per month, broken down by line, product and shift.
The packing line is down, bags are not moving
The mixer waits for the bagger, the bagger for the palletiser, the palletiser for film. At the end of the shift all you know is that the plan was missed.
The run signal and bag counter from the bagger through the gateway, the downtime reason from the operator at the moment of the event. A loss list in recoverable hours per line.
One shift with DiGi
Line L-2, tile adhesive, 25 kg bags. Data from the demo company.
The warehouse receives the delivery: a batch with the supplier and the supplier's batch number, a label, status "quarantine" until the incoming inspection result.
The operator scans the raw materials when loading the mixer. The mortar batch gets a number, and with it a list of the deliveries it is made from.
The laboratory enters bulk density and setting time. The result is saved with the batch. The density control chart shows a rising trend over three batches.
Cleaning and setup: 35 minutes on the timeline, with a 20-minute plan. The operator adds the reason from one dictionary.
The customer gives the batch number from the bag. You open the batch: cement and sand deliveries, line, shift, test results. An answer the same day, with evidence.
Modules for this industry
Every module works on its own, and together they run on one register of products, raw materials and lines.
DiGi Smart Control
Quality control
Batch testing and incoming raw material inspection in one plan. The result is saved with the batch, the control chart watches the trend, and factory production control records are created as a by-product of testing.
Density, consistency, setting time, moisture, visual check. A characteristic has a tolerance, a gauge and a testing moment.
The delivery test result saved with the raw material batch. Comparison of deliveries from the same supplier on a control chart.
A control chart and Cpk for the key parameters. An alert when the trend drifts while results are still within the standard.
A result outside the specification creates an NCR with a decision: rework, use as is, scrap. CAPA actions with an owner and a deadline.
DiGi Smart Trace
Batch traceability
From the batch number on the bag to the raw material deliveries and back. A delivery has a supplier, the supplier's batch number and a status, and links are created by a scan at loading, not in a spreadsheet afterwards.
Cement, sand, additives, packaging as batches with the supplier's batch number and the delivery document.
A delivery without an incoming inspection result will not reach the line. The batch status watches that for the warehouse.
The batch number from the bag opens the raw material deliveries, the line, the shift and the test results. A complaint answer with evidence.
A bad cement batch? The system shows the product batches and pallets it went into. You hold only those.
DiGi Smart Monitor
Production efficiency
Mixing and packing lines produce dozens of SKUs. The signal from the bagger counts bags, the operator describes stops, and the report shows how much time product changes eat.
Every line with an OEE target and the gap to target. You see whether the problem is no raw material, no packaging, cleaning or a breakdown.
Cleaning and setup on the timeline with a plan. Hours over plan per month, per line and product.
The operator picks the reason at the moment of the event, from one dictionary. Breakdowns separate from organisation, MTBF and MTTR per line.
The shift and daily report arrives by e-mail. You set up a new report breakdown in a few clicks, without a spreadsheet.
What your customers and auditors require
The system does not "grant compliance". It provides the records the auditor, the certification body and the inspectorate want to see, with a date, a person and a gauge.
Factory production control (FPC) and CE marking
A test plan per product, a result with every batch, incoming raw material inspection, gauge supervision with a calibration due date, a non-conformance workflow.
Product standards (e.g. EN 998, EN 12004, EN 13813)
You build the characteristics and tolerances in the test plan to the product standard and your own specification. The system makes sure the test happens and gets recorded.
ISO 9001
Test history, an NCR and CAPA workflow with an owner and a deadline, audits with a checklist, access by role.
Complaints and traceability
From the batch number on the bag to the raw material deliveries and test results, the batch tree to PDF on a single request.
Building a new plant?
The best moment for implementation is the start of a new line. Instead of digitising old processes, from the first batch you have tests with the batch, raw materials with a supplier and line efficiency. No paper from day zero.
Questions we hear in this industry
Yours is not here? Write or call, we reply within 24 hours.
Manufacturers that work with us
Let's talk about your production
We reply within 24 hours
Piotr will help you pick the solution that fits your production processes.
Phone: (+48) 668 211 736
Email: digismartcontrol@gmail.com