A computer system and computer-implemented method are described for controlling and monitoring a process to produce a chemical, pharmaceutical or biotechnological product. The method includes providing a database that stores sets of process parameters to control and monitor a plurality of processes performed in order to produce products, receiving a set of characterizing process parameters that characterize the process, identifying a first set process parameters from the stored sets of process parameters, and controlling and monitoring the process using a successful trajectory that includes a time-based profile of measurements.

One embodiment includes a method for simulating an operational effect of one or more changes in a CIP process. The method includes providing a graphical user interface configured to receive inputs from a user, receiving at least one proposed adjustment to one CIP phase of the CIP process, and generating a simulated CIP process based on a first set of CIP data and the at least one proposed adjustment to generate simulated CIP data based on the simulated CIP process. The simulated CIP data is displayed on the display. The simulated CIP data includes at least one of the amount or the total cost of each consumable used to generate the simulated CIP data. A total cost of the simulated CIP process is calculated, where the total cost of the simulated CIP process incorporates the proposed adjustment.

This disclosure provides an apparatus and method for interactive batch operations system enabling operation excellence and competency transition. The method includes collecting data related to a batch process from different departments within a batch processing facility into a common data repository; transforming the collected data based on provided intelligence; exploiting the transformed data in the common data repository; determining a best possible alternative for continued operation of the batch process based on the exploited data; providing a visualization of the best possible alternative of the batch process using a digital twin; and operating the batch process using the determined best possible alternative on a physical twin corresponding to the digital twin.

Methods and apparatus to define stages for multi-variate batch control analytics are disclosed. An example method includes determining, with the processor, a current stage in a current batch process based on a current value of a batch stage parameter. The current value of the batch stage parameter determined based on process control data associated with process parameters in the current batch process. The current stage determined independent of batch events defined by at least one of a start or an end of procedures, unit procedures, operations, or phases in a batch recipe. The example method further includes applying, with the processor, a model to the current batch process, the model corresponding to the current stage.