A Digital Twin For Process Operations
Imagine how much better your process would perform if every Process Operator had your Most Experienced, Best-Ever, Expert Operator always at his side. Well now you can and with the Expert’s continuous help your Process Operation will be improved reducing operating costs, emissions and energy usage and delivering higher yields, more consistent product and a safer process.
Improve Operation and Meet Emissions Targets
The costs of energy use, especially indirect environmental costs, are becoming dominant in many industries. These factors are often nonlinear as emissions permits impose soft constraints on operation. This new landscape of costs and constraints shifts ideal operation from the original process design and requires adaptation and changed process operation to continue efficient operations.
Modern Operator Alarm Improvement and Rationalization
Better operator alarms make money for your plant by reducing operational variability, which delivers a reduction in operating costs and, in cases where throughput is increased, to a reduction in the unit costs of production. Conversely, poor operator alarms cost you money every single day by allowing unnecessary variability.
Is there still a Role for Six Sigma? Improving Six Sigma to Expand its Relevance
Challenges facing implementation of six sigma and lean manufacturing processes include a focus on gut-driven rather than data-driven projects and getting full management buy-in. This is a failure of the analytic tools used in the process. As they focus in detail on the relationship of a small number of variables, project selection is often done intuitively, pre-screening and judging the data and improvement possibilities.
Operating Envelopes for Batch, Semi-batch, Grade Transitions, Cyclic Operation, Startup, and other Time Dependent Processes
Operating envelopes are fairly straightforward to understand in the context of fully-developed, steady-state processes, but often the processes we’re dealing with aren’t that simple. Time dependent variation in batch, semi-batch, product transitions and many other complications require multiple operating envelopes with movement between them, or even fully time-varying envelopes.
Enhancing the value of Digital Twins with GPC
Digital Twins are showing great promise for the processing industries. The applications of Digital Twins span disciplines of operation, including process control, predictive maintenance, optimization, virtual testing, process improvement, and more. But these benefits come from bringing more and more diverse data sources together, and engineers already struggle to make use of the smaller datasets they use today!
Build an Abnormal Event Detection Model
Abnormal events like mechanical faults and unexpected disturbances cause process variation leading to degraded quality and even lost production time due to the actions of safety systems resulting in trips. By giving the operator advanced warning of these developing situations, it can provide crucial extra time to react and keep the system running, improving the time on line as well as providing quality and safety benefits.
Operational Process Improvement: You already have the Data
You already have the data for enormous potential in improving plant operation through making operational changes to capture, repeat, and improve best historic operation. Understanding your process behavior is key to unlocking benefits such as higher throughput, better product, lowest costs, less waste, and more uptime.