According to IndustryWeek research published in 2021, 70% of companies want to learn more about analytics, but the big question is how to get started. What if there were software tools that process engineers could use, without the need for a data scientist, and if these tools were also accessible to small businesses?
The example of process loop regulation
A simple form of process controller is the thermostat which maintains the temperature of a room according to a certain set point. It works as a closed loop control device, trying to minimize the difference between the room temperature and the desired one.
THEprocess optimization it is critical in industry and control loops are critical components. For many, they present a challenge, as all processes are different. Out-of-tune loops can impact product quality, material and energy usage, and ultimately increase the risk of recalls. Artificial intelligence and machine learning can be used to improve and optimize control loops and generate big savings and reduce risk.
An advanced analysis software, such as Proficy CSense, can help by examining historical data to model the current profile and recommend new settings accordingly. The model will take into account the variation of parameters, such as viscosity and vapor pressure in a chemical reactor, which affect the heat transfer coefficient and flow pattern. The same tool can be used to monitor the evolution of the process and detect variations that the human eye is unable to detect.
What is Proficy CSense in a nutshell?
Proficy CSense uses a suite of components to determine and understand the causes of process deviations in industrial environments. Process engineers, quality engineers and data scientists can analyze, monitor, predict, simulate, optimize and control key process parameters in real time through Proficy CSense. Proficy CSense incorporates patented algorithms that leverage AI and ML. It is capable of solving a wide range of problems in industrial segments such as mining, metallurgical, food, pharmaceutical, water and wastewater industries.
Proficy CSense includes two sets of features:
- one for process modeling and problem solving,
- the second for online distribution and real-time monitoring.
Data is prepared, visualized and process models can be built based on rules and data. Thanks to these models, it is possible to identify the root causes of process deviations and optimize them.
How does a major food and beverage manufacturer use data to optimize performance?
The initial goal of the project was simply to save on raw materials. With GE Digital's software, this customer connected their machines to get all the data and model the processes to visualize what was happening. He performed an in-depth analysis to understand the correlations and root causes of the problems, discovering what was affecting the processes and how to improve them.
Using our Proficy CSense analytics solution, they were able to stabilize production lines and processes and pinpoint 'profit loops' by identifying areas of the process that were causing problems.
The result was a 20% improvement in OEE, higher quality products and the alignment of processes to their needs.
Conclusion
Investing in solutions like Proficy CSense to optimize processes is not expensive. Our customers can get a quick return on investment at a low cost. To help you get started on your journey, GE Digital offers a free trial of CSense and a free 6-hour advanced analytics consultation with every CSense purchase. We invite you to learn more about these offers and contact us.
6 free hours of advanced industrial analytics consulting with Proficy CSense