Execution of work instructions and inspections made error-proof with dynamic calculations

04.21.2020 | By Mark Speyers

Our Proceedix 3.6 release contains a new workflow function requested by different industries: dynamic calculations. In this feature update we explain how it will reduce human errors during execution of work instructions and inspections.

The aim of an effective step-by-step work instruction or inspection is to assure that a job or task is done right the first time. Despite the effort companies invest in the creation and maintenance of solid Standard Operating Procedures and instructions, the execution is done by humans. And…making errors is human. To prevent human errors during the execution of work instructions and inspections, we incorporated various Poka-Yoke (mistake proofing) elements in the Proceedix workflow editor. Input values by inspectors or operators can be automatically displayed in a color indicating whether the value is considered normal or abnormal. Input values can be checked and conditionally be double-checked. Deviating input values can automatically trigger a follow-up action by a supervisor.

What must be done in a specific task often depends on process measurements that were made by the operator or inspector in previous tasks of the procedure. A clear instruction can tell the person how to process these previous values through a calculation. Yet, this calculation activity can be the source of a human error.

This is the reason why the Proceedix workflow editor now allows to configure an input value card to perform a mathematical calculation with input values that have been provided on previous tasks during the procedure execution. The new calculation functionality will greatly benefit several use cases. We like to highlight two of them.

Example of a dynamic calculation card in Proceedix

In both the process and in pharma manufacturing, inspectors and operators record input values on specific tasks (e.g. the sample volume consumed). A few steps further down the procedure, a text instruction can request them to calculate another parameter (e.g. volume to add to achieve a target sample dilution) and request them to input the value they applied or used. The calculation feature allows Proceedix to calculate and display the result automatically instead of requesting it to the operator. The operator can simply confirm that the calculated value was applied correctly. By automating this calculation, you not only save valuable time, but it will also reduce human errors.

In some inspection or audit workflows, inspectors are required to input a score value on each inspection task. The calculation feature allows the administrator to define a formula that automatically calculates an average overall score at the end of the inspection workflow. The inspector can confirm the calculated value or overrule if allowed, the final score. It enables the inspector to easier evaluate whether an audit was passed.

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