Tools for Process Improvement and Troubleshooting

digital process automation as the subject of quality control evaluation
All processes should be well understood and evaluated for
maximum performance.
In the process control and engineering world, professionals are constantly seeking ways to optimize their systems and particular process strategies. Quality-related issues and systems provide chances for process operators to not only identify potential areas for improvement or correction, but also employ troubleshooting techniques to make systems perform at the highest level possible. Traditionally, seven basic tools have been utilized in order to troubleshoot quality related issues, and serve as simple, yet extremely effective ways to find solutions.

The cause and effect diagram is used to investigate and systematically list potential causes which contribute to an identified effect. Grouping the causes into different categories visually when attempting to determine the root cause of a process issue allows the controller to view every component of a system, and then subsequently investigate how the individual parts act together. This can be extremely useful when attempting to troubleshoot process control systems.

Check sheets allow for real-time data collection, either quantitative or qualitative. A multitude of potential issues, such as dimensions being incorrect in a product or malfunctions in system technology, are trackable via the check sheet. The data collected by these sheets allows for an operator to make sequential decisions regarding the process based on hard data, from which decisions for optimization can be derived and executed.

The control chart is a process control tool based on statistics. The basic function of the chart is to determine whether or not an industrial process is correctly operating in a state of control, or if the process should be evaluated for quality-related problems. Basically, the goal of this chart is to determine the efficacy of the process system and its associated control limits. If the variation of the process system deviates too much from the expected behavior of the system, an investigation into the system is required. These charts can be essential to monitoring process health.

Histograms are a basic quality tool due to their ability to allow controllers a rough estimation of probability distributions related to the process in question. If the variable in question being assessed by the histogram matches the expected behavior, then the histogram will show said correlation – likewise, if the process is behaving in an unexpected manner, the histogram will reflect these details. The Pareto chart is a chart specifically helpful in tracking defects, by category, which occur most frequently in a certain process. In a process where the resulting product is defective, the Pareto chart will highlight the defect of highest occurrence or the most frequent deviation from the expected result.

The scatter diagram is a tool which allows process controllers to identify whether a relationship exists between two different quantitative variables and, if there is a relationship, to help identify what kind of relationship exists between said variables. The control parameters are established on one axis, while the dependent variables are established on the other. If the plot can correctly show the relationship between the variables, then any alterations in said relationship are identifiable and the related processes can be immediately examined for cause.


The last basic tool for process control and quality-related troubleshooting is the flow chart, which allows for the diagramming of relationships in the process to track and examine the workflow of the process in question. Together, these seven items constitute a basic toolbox for optimization and correction of processes, where their simplicity correlates to effectiveness in understanding particular process systems.

Analynk Wireless manufactures wireless communications equipment for process measurement and control.

Wireless Communications in Hazardous Areas - Special Antennas

wireless communication antenna for hazardous locations
Industrial wireless communications in hazardous areas is
made possible by the Analynk CTM and CTX series antennas.
Wireless communication has seen increasing prevalence in the industrial process measurement and control field for a number of years. Many industrial process control operations can benefit from wireless connections between measurement and control devices. The absence of cables saves space, reduces potential for damage, and simplifies modifications to the process equipment layout. Implementing wireless communications in hazardous areas, whether through WiFi or other radio frequency channels, presents a particular set of challenges to successful implementation. Points of network access and other transmission and receiving equipment can require a level of isolation and hardening appropriate for the hazardous environment. Vendors, in response to customers' desire to incorporate the technology across an ever widening array of application scenarios, continue to develop and release new products and technologies that expand the potential for industrial wireless communication. Analynk Wireless, is now shipping the latest version of their patented wireless antenna for hazardous areas.

The newest Analynk Hazardous Area Antenna provides remote data links for customers using 900MHz, 2.4GHz, Cellular, GPS, Iridium, GLONASS and dual bands. The Analynk antennas are operable across a very wide temperature range and provide substantial impact resistance, signal output, and third party ratings for hazardous environments. These rugged antennas are intended for global application in the industrial process control field. Analynk hazardous area antennas are UL listed for Class 1, Groups C & D and have ATEX/IECEx Certification. The company's entire line of hazardous area antenna products are RoHS compliant and carry a NEMA 4X rating.

Analynk Wireless provides patented hazardous area explosion proof antennas for industrial installations. Their CTX and CTM series antennas carry an array of third party approvals and are suitable for use in a broad range of hazardous environments. Models can accommodate WiFi and other RF communications across frequency bands commonly utilized in industrial settings, as well as cellular and satellite communications.

Share your industrial wireless connectivity challenges with the experts at Analynk, combining your own knowledge and experience with their expertise to develop effective solutions.


Wireless Access Point Enclosures for Explosive Atmospheres

wireless access point enclosure for hazardous locations
Rated enclosures and antennas permit installation of
wireless access points in hazardous industrial locations.
Hazardous area wireless access point enclosures are designed and certified for use in hazardous locations such as chemical plants, refineries, oil & gas platforms, mining facilities, grain processing, and plastics processing. These enclosures also provide an additional level of security for your wireless access point by preventing tampering, vandalism, and theft.

Industrial wireless access point enclosures designed for Class 1, Division 1, Hazardous Locations, Groups C & D, ATEX Zone 1, and are available for a range of  Symbol, Cisco, Meru, Aruba, HP, and Motorola access points.
  • Designed for Class 1, Division 1, Hazardous Locations 
  • 802.11 b/g 
  • Available for Symbol, Cisco, Meru, Aruba, HP, and Motorola access points 
  • Explosion proof antennas 
  • ATEX certification for Explosion Proof enclosure and antennas available
Analynk access point enclosures accommodate specific wireless access points from a range of manufacturers, facilitating easy installation. Every model includes UL listed explosion proof antennas, a mounting bracket custom tailored for the access point equipment, and RF cables to make the antenna connections. Enclosures have penetrations located to match up with the specified access point. Models are included to house a range of units from Symbol, Cisco, Meru, Aruba, HP, and Motorola, with more models added regularly to accommodate additional wireless access points.

A listing of all the wireless access point devices and their companion enclosures is found on the Analynk website. Contact Analynk if an access point you wish to use is not on the list, as many can be accommodated with a small modification to an existing product.

Analynk Wireless specializes in industrial wireless communications. Your wireless communication challenges are welcome at Analynk, so make contact and share your requirements. Combining your process expertise with Analynk's product specialization will produce an effective solution.

Test Run That Wireless Connection

symbol for wireless process communications or industrial wireless
The application of wireless connectivity among process measurement and control devices continues to expand throughout all industrial spheres. While wireless transmission of process measurement and control signals has not been new technology for quite some time, there are still many opportunities for its application.

Wireless communication for industrial applications is well beyond the point of early technology adoption. Protocols are in place, products for the transmitting and receiving of wireless process signals are mature. As a designer, engineer, manager, or operator of a process, you should confidently consider wireless connections between measurement and control or recording devices as part of any new installation or upgrading of existing facilities.

As part of the implementation of a wireless connection, the questions concerning range and signal attenuation usually come up. Basically, will the signal remain sufficiently strong across the distance necessary to make the connection?

Analynk's wireless demo kit includes a model A750 receiver and A753 transmitter both housed in NEMA 4 enclosures. The kit operates at 900 MHz with full 1W power. Locate the transmitter and receiver at points where you wish to establish a wireless connection. You can provide your own input signal, or use the provided simulator to show that a wireless connection can be established and function in a manner that will give you confidence to move forward with implementation. The kit is useful for testing out possible new locations for distance and signal strength. You will use it as wireless communications expand through your facility. Test the location first, then order the needed wireless equipment. It's a solid low risk solution.

Analynk is a manufacturer of both wireless and wired devices for process measurement and control. The company's offering includes a wide array of standard products, as well as integration and customization to meet specific project requirements. Contact the specialists at Analynk to discuss your industrial wireless application requirements.