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All of the plants that saved money after installing PRODAC had paper and pencil log book and production reporting methods. Most had SCADA systems. However, none of the long-standing problems were discovered until PRODAC was installed.
PRODAC provided a practical way to record, tabulate and retrieve the thousands of exception samples and throughput figures needed to understand a complex production operation. PRODAC provided easy to use, intuitive displays and summaries, making it easy to view different cross-sections of the data, and to correlate histories of different parameters.
PRODAC on-line displays and exception checking also helped detect and trace acute problems as they arose, before they had caused extensive losses. SCADA line-monitoring systems would not have helped to find these problems because they do not keep extensive histories and do not perform integrated analysis across different lines and shifts.
One customer reported that PRODAC provided ten times the benefits of other recording methods, and saved hundreds of hours annually in manual recording time.
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