Web portal for quality assurance in production and research
Process support with central database and secure web access in a single platform
The client
BYK is a leading global supplier of specialty chemicals. The company is part of the ALTANA Group and employs more than 2,300 people worldwide.
The project
Web portal for quality assurance processes instead of Word and Excel files.
The successfully growing company is gradually digitising its global quality management, among other things. As an important component of the digitisation strategy, GAPTEQ currently supports around 400 users in a wide variety of quality assurance processes.
Highlights
Challenge
BYK's innovative additives and differentiated solutions optimise product and material properties as well as production and application processes. The complex manufacturing processes involved in producing additives require dedicated quality assurance. This means that deviations in production are fully recorded and evaluated by various control bodies so that appropriate measures can be taken. Documentation and decision-making processes were previously handled using Word and Excel files in individual emails. This became too time-consuming and unreliable as the company grew.
André Engel, Head of Quality Control at the Kempen site and also responsible for the digitisation of quality controls at the Wesel and Kempen sites, was therefore looking for a professional IT solution as an alternative. The software needed to combine the necessary process support with a central database and secure web access for the production department, specialist departments and quality control in a single platform. The choice was not difficult, as André Engel explains: ‘GAPTEQ was exactly the right solution for our requirements, and I didn't find anything comparable during my research.’
Solution
André Engel first tested the functionalities of GAPTEQ and then decided to introduce the BUSINESS version in the company. Within two months, he had built a web application for production deviation reports based on a Microsoft SQL server. André Engel emphasises the excellent support provided by GAPTEQ: ‘The free demos and webinars on the homepage helped me get started, and GAPTEQ's support is first-class. Even when I had very specific questions, I always received quick and competent answers.’
During implementation, data structures and content that were previously stored in a Microsoft Access database were imported into the centrally available SQL Server, and the established reporting and coordination processes were mapped in the GAPTEQ workflow. The portal for deviation reporting is now used in five German plants and in the branch office in the USA. Production employees can now use it to easily report deviations that occur during production, such as the stoppage of a started reaction, at any time using the web form. The data is immediately available online on the central server, and the defined workflow automatically involves the relevant specialist department and quality control.
‘With GAPTEQ, we are providing production, research and other departments with a tool that enables them to take action themselves and make better decisions.’
André Engel, Head of Quality Control, BYK
Since production runs around the clock in shifts, the high availability of the web application is a significant advantage. Based on the centrally available deviation reports with their respective classifications, production employees can usually decide for themselves how to proceed in the event of incidents. This ensures significantly less downtime in the production facilities.
For evaluations and the visualisation of performance indicators, André Engel has also linked the SQL Server to reporting in Qlik Sense. With historical data sets dating back to 2013, which were imported into the SQL Server, meaningful analyses of production deviations can be created. Detailed reports and clear graphics help to identify deviations and their causes and correct them in a targeted manner.
Flexible software for different topics
In addition to deviation reports, further processes were gradually mapped in GAPTEQ. The following portals are now in operation:
- Creation of defect reports for raw materials
- Shelf life data for products and raw materials: checking expiry dates and possible extension periods
- Quality assurance for equipment: checking measurement and testing intervals
- Product testing requests: approval process for testing products in application technologies
- Quality control goods receipt: requesting new raw material samples for further testing in quality control
- R&D requirements: requesting operating raw materials from the research department
- R&D requirements: requesting reserve samples in the event of customer complaints
In addition to simple procedures, complex workflows were also designed in conjunction with SAP for some processes, such as the extension of raw material shelf life data. High security standards are maintained for all processes. As part of the ALTANA Group, BYK integrates its system landscape into the Group's IT infrastructure and compliance requirements. The SQL Server, which forms the basis of the GAPTEQ application, is set up in accordance with Group standards. Thanks to the centrally managed data pool, access rights stored in Active Directory, and defined worklists for employees, security regulations can be complied with much more effectively than in the previous e-mail exchange system.
Result
The GAPTEQ-based web portal digitises quality control processes and enables them to be handled in a structured and efficient manner. The departments, branches and production sites involved work with a uniform database. The ease of use of the GAPTEQ solution is important to BYK. André Engel notes that a one-hour webinar is sufficient training for new departments: ‘GAPTEQ is user-friendly and well structured. The production department and other departments can quickly operate their portals independently; we hardly ever receive any queries from users.’
Flexible development is another key advantage. Additional areas of application can be added to the existing portals at any time, and the number of users can be scaled as required. This has proven particularly useful in connecting BYK's large research department, for example. There are now 400 users working with GAPTEQ. Even under high load and with many simultaneous accesses, the system runs smoothly and stably at all times. André Engel sees a lot of potential for the solution and wants to continue expanding it with his digitalisation team and roll it out worldwide at all locations.
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