Deviation Risk
Catch off-spec conditions hours before dispatch — not after the batch closes.
By the time a deviation is visible in logs or ERP, the batch is already in loss and the report is a post-mortem. PlantIQ flags the risk pattern hours earlier, while operators can still act.
The lag is the loss
In current setups it typically takes 6–18 hours before a deviation is caught — long after the conditions that caused it. That lag is the whole problem: the batch is compromised before anyone knows, and the documentation that follows is an explanation rather than a prevention. Closing the gap between condition and detection is where the yield and compliance value sits.
Risk patterns learned from your own batches
PlantIQ correlates process variables across 30–50 of your batches to learn what an off-spec batch looks like before it fails — a temperature drift, a timing slip, a lot that consistently under-performs. When a live batch starts tracing that pattern, operators get an early warning they can act on, not an alarm after the fact.
Early warning, not another alarm wall
Plants already drown in alarms. PlantIQ's value is that its flags are predictive and specific — 'Lot C-0892 below threshold, three batches affected, consider a supplier hold' — tied to the batch, the lot and the likely consequence, so the signal is a decision rather than noise.
Frequently asked
How does deviation prediction work?
PlantIQ correlates process variables across your batch history to identify the patterns that precede an off-spec batch, then flags a live batch as soon as it begins tracing one of those patterns — hours before failure would show up in logs.
How much batch history does it need?
PlantIQ builds useful risk patterns from roughly 30–50 batches of your own data, and its accuracy improves as more batches accumulate.
Does it replace my QA process?
No. It is an early-warning layer that gives QA and operations more time to act; it does not replace review, sign-off or your quality system.
See your plant's true profitability
30-day structured pilot on your process, your batches, your baseline. No disruption. If PlantIQ doesn't show measurable yield or compliance value, we walk away.
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