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Process Optimization

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Process Optimization

Challenge

No matter how you measure productivity,
You can always do it better

Whatever the industry, maximizing productivity is always on the agenda. Fully productive time is often measured by OEE (Overall Equipment Effectiveness), a holy KPI for a lot of industrial companies.

Many factors – be it the quality of raw materials, the state of equipment, process parameters, operator skills or ambient conditions – affect the overall performance of a process and the plant.

Traditional methods such as Lean, Six Sigma and TPM (Total Productivity Maintenance) have proven their value to identify production inefficiencies, but fail to capture the real-time inter-relationships between all those factors.

Time to say hello to AI, the perfect supplement to traditional approaches for process engineers to optimize production.

APPROACH

Make AI part of your toolbox

AI-based optimization does not start with collecting data. Our initial focus is always on understanding the process. Every operation is unique and it’s important to get a full overview of all the production parameters across every step of the process. Needless to say, internal process engineers' involvement is vital.

Connecting machines and gathering real-time data on the production parameters identified gets you one step closer. Machine learning techniques can now be used to identify correlations between all the operational variables and gain insight into the root causes of subpar performance, poor quality and other process inefficiencies.

With an understanding of why process inefficiencies arise, you can move on to the next phase and avoid them.

This can lead to one-off process or machine adjustments to fix the problem, or the deployment of systems providing operators with real-time advice on how to regulate production parameters to get the desired output.

Benefits

The benefits of AI-driven process optimization.

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Quicker decisions and real-time insights

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Higher profits
hour

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Increased throughput and yield

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Optimal setpoints for control variables

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Less waste and fewer quality issues

Process Optimization

Success stories

Forecast Maximum Electricity Production Capacity
Helping a combined cycle power plant providing grid stability services to the grid operator with forecasting the maximum production capacity that can be fed into the grid at any given time. Accurate predictions of the cooling performance needed for electricity production and the early detection of leaks in the steam cycle play an important role in this.
Preventing Production Deviations
Helping a large pharmaceutical company to thoroughly monitor and analyze product deviations. Using NLP to build a root cause suggestions application that significantly reduced the time to find causes of deviations and prevents them from re-occurring.
Quality & Downtime
Anticipating on disruptive quality issues during various stages in the hot strip mill of a large international steel manufacturer, reducing quality issues and downtime. AI translates evolving physical properties of steel strips into real-time alerts operators can act upon.
Yield Optimization
A large chemical concern used analytics to increase the yield of their most cash generative and oldest production recipes. AI helped finetuning that process to achieve yield objectives while maintaining quality.
Asset Health & Performance Optimization
Helping the global leader in air cooled condensers monitoring asset health and forecasting asset performance. Early detection of equipment failures and possible root causes lead to improved maintenance scheduling and lower maitenance costs. Genetic algorithms prescribe optimal parameters for maximing the performance of the system during all circumstances.
Maximize Process Efficiency with Golden Batch Analysis
Detect the features that influence the production time within the different phases of a polymerization batch process (Golden Batch Features). Anticipating bottlenecks through real-time monitoring of golden batch features allows for better scheduling and higher throughput.

Questions?

Let's Talk.

Want to use AI to optimize your processes?

REFERENCES

The Grain Success Stories.

These clients have chosen to embrace process optimization with The Grain.

WHY US

Combining Industrial Intelligence and Data Science.

The way we combine industrial intelligence with our data science skills is what makes us unique: our starting point is your process, not the data. We know how assets work and our domain experts work with you to understand the specifics of your operations. Our data scientists use those insights to translate your business challenge into an analytical use case and ensure the right data and algorithms are used. We build models from scratch or configure our accelerator kits with pre-built model components to meet your specific needs – whichever will give you the best results.

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