Achieving Superior Bitumen Quality with Qsee Insights and Zer0-Defect

The Challenge: Improving Bitumen Penetration Consistency

A leading refinery struggled with consistently meeting product specifications for its bitumen (BIT-50-70). Bitumen penetration, a critical quality indicator measured in decimillimeters (dmm), was frequently outside specification limits (50-70 dmm). The process demonstrated significant variability, poor centering, and a negative capability index (Cpk), meaning it was incapable of reliably meeting customer requirements.

Qsee Insights and Zer0-Defect Approach

Leveraging Qsee's advanced AI-driven platforms—Qsee Insights for comprehensive performance analytics and Zer0-Defect for predictive quality control—the refinery implemented a transformative operational strategy:

AI-Powered Performance Analysis

Qsee Insights provided an in-depth KPI analysis of the refinery’s low-pressure thermal processing system, specifically targeting the BIT-50-70 penetration characteristics. By analyzing raw sensor logs, temperature, pressure, and various critical parameters, Qsee pinpointed significant process deviations.

Real-time Predictive Quality Control

Integrating Zer0-Defect's predictive analytics into daily operations, the refinery was equipped to predict quality outcomes in real-time. This enabled proactive adjustments to process parameters before deviations turned into costly production errors.

Key Benefits Realized

Immediate Process Optimization

With real-time alerts and predictive insights, operators quickly identified and corrected process centering and variability issues. Within just three months, the refinery successfully shifted its process mean closer to the target penetration of 60 dmm, improving product consistency and reducing waste.

Substantial Financial Savings

Through optimized operations, the refinery realized significant financial gains:

• A 15% reduction in process standard deviation yielded a nearly 3% improvement in product yield.

• Achieved monthly savings of approximately $34,082, amounting to nearly half a million dollars annually.

• Projected five-year cumulative savings exceed $2 million.

Improved Operational Reliability

Predictive monitoring identified and mitigated anomalies months in advance, enhancing operational stability and product reliability. The refinery experienced a dramatic reduction in unexpected downtimes and quality deviations, directly translating into enhanced customer satisfaction and market competitiveness.

Real-World Impact

"With Qsee Insights and Zer0-Defect, we've seen a remarkable improvement in our operational performance. Our ability to proactively manage product quality has significantly increased, reducing quality-related losses and generating impressive cost savings," remarked the Plant Director of the refinery.

Continuous Improvement Loop

The refinery established an ongoing improvement process using Qsee's continuous feedback loop:

1. Data Integration: Seamlessly connected refinery data sources, including MES and SCADA systems.

2. Automated Analysis: AI-driven anomaly detection and root cause analysis highlighted key areas needing attention.

3. Prescriptive Recommendations: Specific, prioritized actions provided clear pathways for operational enhancement.

4. Benchmarking: Periodic reviews and recalibration of the AI model ensured continuous refinement and adaptation to changing operational conditions.

Conclusion

Integrating Qsee Insights and Zer0-Defect into their operational routine has empowered the refinery to consistently meet quality standards, substantially reduce production costs, and achieve unprecedented operational efficiency. Manufacturers adopting Qsee's technology can expect similar transformative results, significantly boosting their competitive edge.