The BES report was excessive, containing all batch-related information, only a fraction of which was quality-critical.
The end result was a report up to 80 pages long.
As a result, quality reviewers had to sift through the reported data to find the valuable information. This also necessitated specific training to identify those report sections and Critical Process Parameter (CPP) data required for batch release decisions.
This was achieved without any changes to the underlying control system..
TQS developed a streamlined batch report using RtReports and PI System Data, focusing on the CPPs & CQAs identified by the client. The report only displayed alarms that were quality or process critical.
TQS then performed a data audit — to ensure all data for the new RtReport data was integrated to the OSI PI system and validated.
Aggregated data values such as min, max and average were calculated directly in RtReports.
TQS also developed advanced calculations using AF Analytics to calculate aggregated data over time periods not provided by the BES batch context.
"RT Reports has made everything easier — all the relevant information, streamlined, automated, and easily accessible in electronic reporting. Now, we can get straight to focusing on what’s important. It’s resulted in a much smoother and quicker batch release process for us.” — QA Manager"
As the RtReport contained logic for automatic checking of Batch Data excursions and quality-critical alarms, the same logic was applied in an exception report variation of the detailed RtReport.
This exception-based report provided detailed information for batch steps containing exceptions/excursions — and summary information with excursion/violation status for all other steps.
By only focusing on relevant information, the review process became quicker and easier.