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Problem
Undetected process and quality deviations or micro-stoppages lead to quality risks and hidden efficiency losses.
Solution
OSPHIM automatically detects anomalies in process and quality data and notifies the users.
Result
Early identification of process changes, improved OEE transparency, and targeted optimization without unplanned downtime.
RESULT
Detecting Microstops in Production
In a joint project with the Kurz Group, OSPHIM identified irregularities in cycle times and data gaps. These patterns revealed recurring microstops in the production process that had previously gone unnoticed.
Irregular cycle time patterns detected
Hidden interruptions identified as microstops
Root cause linked to recurring manual interventions
Example: cavity surface polishing when processing PCR materials
SOLUTION
Automated Anomaly Detection Across Process and Quality Data
OSPHIM continuously monitors key process parameters to detect deviations and non-stationary behavior. Combined with quality and environmental data, the process is autonomously, wholistically observed.
Monitoring of all relevant process parameters
Integration of quality data (QS)
Detection of non-stationary process behavior
Identification of hidden anomalies and patterns
PROBLEM
Hidden Process Instabilities Go Unnoticed
Process deviations and micro-interruptions often remain undetected. These hidden inefficiencies can accumulate, leading to quality issues, reduced OEE, and unnecessary manual intervention.
Process changes are detected too late
Microstops are not systematically tracked
Quality deviations lack clear root cause
OEE calculations miss hidden losses
BUSINESS IMPACT
From Reactive to Proactive Production Control
By making process instabilities visible at an early stage, companies can shift from reactive troubleshooting to proactive optimization. This reduces unplanned interventions and improves overall process reliability.
Reduced unplanned downtime
More stable production processes
Better decision-making based on data
Increased efficiency without additional investment
