Nuplex Resins uses Alis to continuously monitor quality, whilst visualizing the production trends of all 500 resins. This has resulted in a more consistent product and a marked reduction of the rejection percentage.


Continuous Quality Monitoring

Until recently, Nuplex Resins in the Netherlands used Excel sheets to control their static processes. This was only ever applied to products requiring additional attention.


The quality data of all 500 different products are now continuously monitored. With the Alis Quality Management program, Nuplex has a constant quality monitoring system in place, which also visualizes the production trends of all resins. This has resulted in a more consistent product and a marked reduction of the rejection percentage.


Peter Dousma is Nuplex Resins’s quality control manager. The company started using Alis a couple of years ago, as a system to enable them to process analyses results, into useful information for production quality management.


Alis is web based software created by Asystance in the Netherlands, the developer of superior quality management software for production companies. Alis is primarily used in the chemical, food and automotive sectors.

The speed of Alis surprises us every time. Just log in, and all data is right in front of you.

Peter Dousma, Manager Quality Control Nuplex Resins



Intensive QA/QC process

Nuplex manufactures over 500 different resins based on petrochemical and natural raw materials. The company supplies ninety percent of its output to coatings manufacturers who produce architectural paint, coatings for ships, new cars and car repair finishes.


Albert Zwerus, Senior Technical Service Manager at Nuplex: "We manufacture around 100,000 ton of resin annually, making us the world’s largest resin production site. This resin is made in batches."


"We employ about 320 people here and supply mostly coatings producers in Europe, the Middle East and Africa. Our products also find their way into cars made in Asia and South America."


"Originally we were part of AkzoNobel. But we’ve been part of Nuplex Industries since 2004, a New Zealand group which produces resins and other exclusive products worldwide."


"The automotive sector in particular is a d​iscerning industry, demanding resins of the highest purity level and consistent quality. It is challenging to deliver constant quality with batch production, and given that we produce various products in each batch reactor."


Dousma: "A certificate of analysis is attached to each charge, which offers the client a guarantee that the product meets with the specifications."


"We test this both in our Quality Control lab and during production. We check for the amount of solvents, the viscosity, the acidic content and the appearance. The recipe is a standard."


"The quality of the coatings is for the most part determined by the quality of the resins. To meet this, our QA/QC process is exceptionally intensive."


"Car coatings are tested for at least five years in the US state of Florida, to check that they hold their shine and do not deteriorate too rapidly under the influence of sun, rain and wind."

The automotive sector in particular is a d​iscerning industry, demanding resins of the highest purity level and consistent quality.

Albert Zwerus - Senior Technical Servicemanager

Nuplex Resins


Non Conformity and SPC Alarms

Nuplex does not continuously make the same product. There may be days, weeks or even months between the various charges.


Dousma states: "If the parameters of a charge are too close to the specification limits, we risk exceeding these the following time, resulting in the product being rejected. We therefore wish to prevent this by always remaining on the safe side, some distance from the specification limits."


"When an operator reproduces a product, he or she will take into account the analysis data from the previous production batch and make the required adjustments."


"Given that we continuously make 500 different products, from a practical point of view it is impossible to enter the data and update the archive by hand, as well as to later retrieve it for use with SPC, the statistic process control."


"Therefore we limited these activities to the products which in our view require the additional attention. We would collect the data on Excel sheets, which allowed us to make calculations and visualize trends."


"To save time and follow more products, we were seeking an SPC tool which would take care of everything automatically. Researching the market we quickly came across Alis by Asystance," remembers Dousma.


"Alis seemed highly attractive to Nuplex, as it is the standard package for quality management with production companies. Nuplex contacted Asystance in May, and by September Alis went live."


Zwerus: "When an operator starts, he or she can immediately see the results of the previous charges and start the preparations by tracking these."


"Non-conformity and SPC alerts are indicated per day. These alerts warn the operator that production in certain charges may not quite be 'in control'. The product may meet the specifications, but not the static criteria for following the process that Nuplex has implemented."


"In the following charge, the operator can influence the processes to a certain degree, thus ensuring the product parameters are an improved fit with the specification."


"The program also allows for a trend line to be visualized, ensuring you quickly see if specific parameters are dropping when measured over the longer term by aligning a series of batches of the same product."


"Once corrective measures have been instigated we can also observe if these have resulted in the desired effect by following their trends."


Alis also shows us how the operators have reacted to the alerts. In this sense it truly acts as an outstanding Quality Production Dashboard."

When an operator starts, he or she can immediately see the results of the previous charges and start the preparations by tracking these.

Albert Zwerus - Senior Technical Servicemanager

Nuplex Resins


More consistent end product

Dousma sums up the advantages: "We can now offer a more consistent end product. In the event of deviations, operators are able to react much faster."


"We now have an accurate and real-time control system. A problematic product can be accurately followed and safeguarded with SPC."


"The automotive sector also appreciates the fact that there are inbuilt control mechanisms within the process, ensuring that the route is better managed and that you’re able to guarantee the quality of the products even better than before."


"Alis certainly takes a major step forward in this. Our resins' product numbers, batch code and analyses data are all recorded in Alis."


Zwerus: "Alis works via the internet, this gives us the facility to call up the data when away from the office or when visiting a client. If a client has any questions, the data is at our fingertips and we can talk with the kind of confidence that is backed by hard facts."


Dousma emphasizes that Alis is not a process control system: "Process control is performed by Honeywell TDC; a system that also records data such as temperature, pressure and filtering. With Alis we look at the product data and utilize the lab's and the operators' analyses."


"All measured data arrives in a sort of reservoir within Alis," he continues. "This is where we can unleash a whole set of statistical analysis tools on it. These are a standard setup in Alis, to mine additional information on the quality of the production and the products."


"Alis analyses the raw data automatically and will give alerts when specifications are exceeded, or when patterns discovered flag up the process as not being 'under statistical control'."


"It is entirely user friendly and fast. Operators view the data every morning when preparing for the day's production."


"Everybody is deeply impressed by the system’s speed. Without automation it would be impractical to collect and collate the data from so many products, and certainly entirely impossible to analyse it. Now all of this is readily available and it even permits us to retrieve additional information."


We now have an accurate and real-time control system. A problematic product can be accurately followed and safeguarded with SPC.

Peter Dousma, Manager Quality Control Nuplex Resins

Lean Manufacturing

The tools provided by Asystance support its clients' Lean Manufacturing practices, delivering considerably lower operational costs for the client.


Asystance's co-founder Gerben de Haan explains: "The client loses less time when processing data, which increases productivity and reduces the amount of rejected goods. And there is no requirement for the client's organization to manage the package; this is Software as a Service!" 


Dousma acknowledges that this makes Asystance exceptionally competitive: "Weighing up the costs against the benefits, the company certainly delivers an excellent product. We now save a great deal of time as we’re no longer obliged to enter data by hand onto Excel sheets."


"And with the quality monitoring we’re able to monitor the process closely, which improves quality and safeguards our products throughout the line. And that of course is to the advantage of the entire company."

We now save a great deal of time as we’re no longer obliged to enter data by hand onto Excel sheets.

Peter Dousma, Manager Quality Control Nuplex Resins

Watch our online demo

Alis Quality Intelligence Software gives Quality Management a boost.


In this demo we show you how quickly Alis can be set up for your factory, and how it can reduce failure costs by up to 20%.