Digital batch records and batch release results in
improved product quality and compliance

In the process industry batch records are key to keep track of the quality of a production batch. Batch records are common in batch production industries such as the food industry. They are typically paper forms, sometimes more than 10 individual sheets, I have even encountered a two sided A3 sheet. A batch record contains all the relevant data of the manufacturing process of a given batch. Typically it contains a start-up inspection on cleanliness, product related data such as recipes, lot numbers and quality related inspections such as CCP controls (eg metal detection), labeling inspections, packaging inspections and lab analyses.

Batch records are important for traceability purposes and to generate KPIs on production (eg quantities) and production efficiency. Indeed, by logging failure of equipment in a structured manner OEE can easily be calculated.

Currently, batch records are typically paper forms at the production line and handed over to the next shift. Paper forms have some disadvantages:

  • data is not available. paper forms need to be handed in at the supervisor for verification
  • paper forms are static and not very visual or interactive resulting in low quality registrations
  • shift handover requires paperwork to be handed over

Digital batch records allow to go much further. 

  • record photos at the production line using tablet or smartphone
  • assist operator step-by-step by means of documents and photos
  • review the status of the batch in real time anytime and anywhere
  • send notifications to the back office when something is wrong

This avoids unnecessary delay of batch release and real-time transfer of issues and data to your colleagues.

How does it relate to MES and can you calculate OEE?

MES systems are effective in controlling machines and collecting machine data. However, MES are overshoot when your machinery is not equipped to collect data and when you rely on manual registrations and visual inspections. GoRound will come in as an efficient and affordable solution to manually track the start and stop of the production and to record failures. Thanks to an extensive audit log which is collected automatically in GoRound you can calculate the time of availability, production and the time of failure.

Rely on custom dashboards

We know that every production plant is different, that every plant has its specificities and typical workflows. All data collected digitally can be visualized just the way you want. Think of KPIs showing the production batches, volumes and efficiency, an overview of CCP inspections or used packaging or ingredients.