Detecting Quality Losses – Reducing Low Weight Complaints

The Challenge

During product changeovers, the chocolate tank empties, slightly lowering the dosage. This can lead to low-weight products and customer complaints. Operators must manually increase rotor speed, but it's hard to verify if they do it.

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The Goal

• Detect emptying events >15 min
• Verify rotor speed adjustments
• Enable traceability
• Support daily ops with a dashboard

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The Approach

• Aggregations in TM: calculated the range of the rotors and the maximum tank level over 20minute moving windows to capture process dynamics.
• ValueBased Search (TM): automatically detected good and bad emptying periods (≥15 min) by combining level conditions ( max > 60 & current < 50 ) with rotor activity ( range > 0 / range = 0 ).
• Event Contextualization: used the contextualization enhanced data layer in TM to label and directly compare successful vs. failed emptying events within the historical signals.
• Dashboard in TM: integrated event counters, historical trends, and realtime tiles of key variables into a single view.

Insight: With these TM features, you gain a clear, contextualized view of operator actions during emptying, improving quality control and operational efficiency.

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The Results

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The Takeaway

Real-time monitoring improved traceability, reduced complaints, and ensured consistent dosing during critical periods.

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