要计算过程分析器技术的 ROI,请收集购买分析器的前期成本以及持续拥有成本,以了解您的预期支出。 然后,注意分析器启用的预期好处和节省,例如增加输出和减少停机时间。 根据这个分析的结果,你的工厂应该可以这样说:”这个分析仪每天为我们节省1000美元!”

每一种分析仪的测量都旨在确保以安全和成本效益的方式生产出所需数量的按规格的产品。 多台分析仪,无论是手动操作还是自动操作,将帮助您的工厂在三个关键领域实现这一目标:安全和环境,过程控制和质量保证。 每个类别对您的 ROI 分析都有其独特的含义。

安全与环境

流体加工厂内和周围人的安全至关重要。 过程分析仪技术探测到可能危及设备和附近人员的情况。 避免可能破裂管道或容器并危及人员的潜在剧烈化学反应的唯一途径之一就是获得快速的分析数据。 仅此一项就足以证明一个质量过程分析仪甚至几个分析仪的成本是合理的。

此外,你必须遵守联邦和地方的环境法规。 例如,大多数地点需要连续排放监测系统和废水分析。 为了符合这些规定,工厂必须安装安全和环境监视器,而不管成本或投资回报率如何。

过程管理

过程分析器能够对过程流进行微调,以确保高质量产品,使工厂保持盈利。 工厂的过程控制理念常常受市场条件所左右。 当需求低且工厂的产能不足时,过程控制侧重于降低生产成本,包括能耗和废料,同时保持所期望的质量。 当需求量大,工厂能以合理的价格出售其全部产出时,吞吐量就更为重要。

任何市场条件下的期望都是精确满足客户要求的产品。 由于生产劣质产品的成本巨大,工厂必须始终生产符合或超过规格的产品,以确保销售。

通过减少产品质量的随机变化,控制系统旨在减少”赠品”或生产质量过高的成本。 上图描述了这个概念。 当产品质量变化较大(蓝色曲线),工厂生产更高的平均质量,以避免生产出规格外的产品。 增加这种额外的质量要么会增加生产成本,要么降低吞吐量,要么两者兼而有之。 分析测量和控制有助于减少质量变化(绿色曲线),使操作员能够将平均质量接近规格极限,使他们能够更高效或更丰富地生产产品。

用于控制的过程分析器的ROI可以通过计算在卖方市场增加吞吐量或买方市场降低运营成本的价值来计算。

质量控制

过程分析仪测量的精度对制造商的利润至关重要。 错误的分析可能造成灾难性的后果。 仅仅因为分析器失准,就考虑发送给客户的不良产品或完全好的产品被拒绝、丢弃或退回进行再处理。 后一种场景的有形损失可以使用工厂数据来计算,但是由于非规格产品而损失客户的成本可能对业务造成重大打击,并对您的业务产生重大影响。 流程分析器帮助减轻两种情况,这很容易说明它的成本和持续拥有成本。
其他报告
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