A programmable logic control unit, which helps monitor an automated process.
Continuous process control is a method used by manufacturers to precisely control the quality or properties of a product without interrupting production to make minor process changes. In general, whenever there is mass production, there is inevitably some form of automation because manual inspection of the output of a continuous process can be time consuming and ultimately reduce output. Continuous process control allows the uninterrupted monitoring of the variables involved in mass production and the supervision of a series of processes is the key to controlling the result. Without some control over the process in which products are created, end results can vary widely. Continuous process control provides the ability to change variables that affect a finished product.
Continuous process control allows uninterrupted monitoring of numerous variables during the manufacturing process.
Looking at a simple automated process can reveal just how innovative this method can be. For example, the continuous process control method can be used on an automated assembly line that manufactures common fireplace bricks to ensure that the finished bricks meet certain criteria. As the bricks reach the end of the production process, an automated scale can check the weight. Any weight outside of the desired specifications may indicate the need for a process adjustment, such as increasing the temperature or reducing a portion of the mix.
In this scenario, a machine monitors the automated process. This machine is almost always part of a larger system known as a programmable logic control (PLC) unit. The PLC unit is responsible for comparing the information that the scale enters, such as the weight of a brick, with a certain set of parameters. When the PLC unit receives unacceptable information, the instructions automatically direct it to adjust certain parts or steps in the continuous control of the process, ultimately affecting the finished product.
Automation has only increased the output of any industry that uses it. Without mass production and continuous processes, everything would require manual labor. The time it takes for a human to physically verify the properties of a product and make corresponding adjustments to processes can be detrimental to efficiency and production standards. Automated systems, especially those that employ PLC units, can make these decisions and make adjustments in a fraction of the time it takes to do so manually.
Some simple examples of mass production variables might include the weight, temperature, size, or any other physical property of a given product. Maintaining desired results often requires frequent adjustments. Simply allowing an automated process to continue unchecked can lead to excessive production costs or poor product quality. Human supervision therefore remains an integral part of continuous and efficient process control.