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Manufacturing Operations Management

Factova OCAP

A process abnormality management system that provides standard response guides

01 MES 02 iPharmMES 03 SPC 04 FDC 05 OCAP 06 RTS 07 RTD 08 RMS 09 AI Vision
WHY

Why Is It Needed?

Responding to abnormalities during the process depends on operators' skill and experience, so the level of corrective action varies with the availability of senior staff.

Based on predefined standard response procedures, Factova OCAP helps operators carry out the necessary actions step by step by following guides. This enables more consistent and faster action regardless of individual skill. Repetitive, standardized action steps can be extended to automation, laying the foundation for operational efficiency and process optimization.

WHERE

Where Is It Used?

Target Industries
Manufacturers that need fast response to and management of in-process abnormalities Fields where regulatory compliance and traceability management matter, such as pharmaceuticals and medical devices
Target Customers
Companies pursuing standardization and advancement of process abnormality response systems Companies that need an efficient abnormality management environment integrated with existing detection systems such as SPC and FDC
DETECT · ANALYZE · ACT

Factova SPC + FDC + OCAP

Factova links FDC, SPC, and OCAP to provide an end-to-end process management environment, from anomaly detection (Detect) and root-cause analysis (Analyze) to response execution (Act).

Process Anomaly Detection
SPC · Inspection and Metrology CTQ anomaly detection, defect anomaly detection
FDC · Equipment CTP anomaly detection, CTE anomaly detection
→
Anomaly Notification
OCAP Process Anomaly Intake Anomaly Response Procedure Guide Action Execution Integration
→
Process Event and Status Delivery
MES Anomaly Action Execution Action Status Update Anomaly Cleared
AI Assistant Built In
SPC AI Assistant Natural-language queries provide control chart analysis, process capability evaluation, term explanations, and process status summaries for a given period, helping you understand data intuitively.
Super Agent Integrates with SPC and FDC manuals, OCAP, and MES to enable root-cause analysis based on diverse data such as recipe change history, equipment events, and lot history.
IMPACT

What improves with OCAP?

Actual Impact of SPC, FDC, and OCAP
Finished product defect rate
60% Reduced
Actual Impact of SPC, FDC, and OCAP
New plant yield
90% Achieved
Actual Impact of SPC, FDC, and OCAP
Real-time inventory accuracy
90% improvement
Actual Impact of SPC, FDC, and OCAP
Scrap rate
30% Reduced
Actual Impact of SPC, FDC, and OCAP
Abnormality detection time
Before At least tens of minutes → After Real-time
99% Reduced
Actual Impact of SPC, FDC, and OCAP
End-to-End traceability
90% Achieved
Applied industries: displays, batteries, chemicals
01
Guides process abnormality action procedures through the system to prevent missed or delayed responses and raise the level of action across the board.
02
Integrates with N abnormality detection systems and serves as the process abnormality action portal, connecting abnormality intake, procedure, and action.
03
Systematically accumulates action history and results, turning them into an operational asset that can be reused for similar cases.
04
Based on automated action rules, the system handles some activities on its own and reports the results, improving response speed and operational efficiency.
CUSTOMER VOICE

Voice of the Customer

"Thanks to FDC's real-time anomaly detection, line stoppages are gone, and even chronic quality defects and delivery delays have been resolved."
Head of Production Operations, Display Manufacturer
WHY LG CNS

Why LG CNS

01 Integrated Monitoring of Plant Abnormalities

Integrates abnormality data detected by various systems such as SPC and FDC, so the dashboard shows plant-wide abnormalities at a glance. Grouping abnormalities of the same type supports efficient batch response.

02 Screen Integration with Other Systems

Linking with screens of other systems such as FMCS reduces the burden of switching between systems during abnormality response and enables OCAP-centered action.

03 Action Automation

For some action steps, the system handles activities automatically without human intervention.

REFERENCE

References

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