See where quality is heading
Real-Time Prediction forecasts quality every 30 seconds, long before the lab result comes back.
Real-Time Prediction →Cut quality variability by more than 20%. Without adding headcount.
Measured in pulp & paper deployments. ProcessMiner predicts quality every 30 seconds from the process data you already collect, so every grade runs closer to target with less giveaway and off-spec.
Read the transcript
Your lab tells you what already happened. By the time the result comes back, the product’s already made. Real-Time Prediction forecasts where quality is heading every thirty seconds, for the grade you’re running. When the trend heads out of bounds, your team gets one specific correction. Inside the band, it stays quiet. So you correct course before product goes out of spec.
Where the margin goes
You can’t shrink the spec limit. You can shrink the margin you keep from it.
Lab results arrive 30 to 60 minutes after the product is made, so plants keep a wide margin between their average and the spec limit. It shows up as giveaway above spec, off-spec below it and shift-to-shift variation.
>20%
Less quality variability
Pulp & paper deployments
28% → 77%
Clarifier blanket time in its target band
Water reclamation pilot, open-loop recommendations
25%
Scrap-rate reduction
Injection molding, single-machine pilot
Deployment and pilot results, each measured against that plant’s own baseline and labelled with its industry. Results vary; past performance is not a guarantee of future results. How we measure →
How it works
See the drift, find the cause, move back to target
Know what’s pushing it
Root Cause Analysis ranks the top 10 likely causes by influence when quality moves off target.
Root Cause Analysis →Move back to your best run
PM Vector shows each crew the setpoint that returns the line to your best run. Operators make the move.
PM Vector →By industry
What quality means on your line
Pulp & paper
Tensile, moisture and basis weight held through every grade change. 63% better target adherence vs. operator baseline, one paper machine.
Water & wastewater
Effluent quality and clarifier stability held inside your permit as loads change through the day.
Plastics
Dimensional consistency held shot after shot, so less of each run ends up as scrap.
Free Data Health Assessment
See where your quality has room to tighten.
Start with a free Data Health Assessment. We’ll take a closer look and let you know exactly what your own data can do.
Needs 6–12 months of process history with timestamped lab results.
Questions, answered
Frequently asked questions
How is this different from SPC and soft sensors?
SPC flags a variable after the lab result proves it left its limits. A conventional soft sensor estimates between lab tests but is built once and quietly decays. ProcessMiner’s prediction retrains on every new lab value and adds what SPC never had: a ranked cause and a recommended adjustment back to your best run.
Do we still need the lab?
Yes. Lab results are what the models learn from; every new value retrains them. What changes is the lab’s role: from the alarm that reveals a problem 30 to 60 minutes after the fact to the referee that confirms the prediction was right.
Does tighter quality mean running closer to the spec limit?
No. It means running closer to the target, with less spread around it. Giveaway falls because you no longer need a wide safety margin to stay in spec, and off-spec falls because drift is caught before it reaches the limit.
How much can we expect quality variability to fall?
More than 20% across pulp and paper deployments; one paper machine measured 23% less quality variation over 12 months against its own operator baseline. Your figure depends on how much of today’s variation comes from the process rather than raw material, which the free Data Health Assessment looks at on your own historical data.
Get in touch
Have a question?
Whether it's our platform, your process, or a free Data Health Assessment you'd like to start, let us know.
Rather talk? Call +1 (470) 910-0770.