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.

A control module is adapted to control technical equipment by processing batch-run data from the technical equipment. The control module operates according to parameters that are obtained by a parameter module. The module receives a reference plurality of multi-variate reference time series with data values from sources that are related to the equipment. There are time series with measurement values and time series with data that describes particular manufacturing operations during a batch-run time interval. The module splits the time interval into phases by determining transitions between the particular manufacturing operations, and divides the time series into particular phase-specific partial series. For each phase separately, and for the phase-specific partial series in combination, the module differentiates phase-specific time series into relevant partial time series or non-relevant partial time series and set the parameters accordingly.

A method and industrial automation system for controlling performance of batch process includes obtaining operational data and Key Performance Indicators (KPI's) for a batch process. The operational data is provided with an absolute timestamp such that absolute timestamp associated with operational data and KPI's is converted to time duration relative to predefined event. The obtained operational data and KPI's, and reference set of operational data and KPI's are aligned based on time duration relative to a predefined event. The method comprises comparing aligned operational data and the KPI's with the reference set of KPI's and operational data. Based on comparison, one or more reference batches are determined. The method comprises identifying one reference batch based on predefined criteria. Thereby, the method involves controlling performance of batch process by providing modified setpoints based on identified reference batch.

One embodiment provides a method, including: obtaining historical information for equipment having at least one control, wherein the historical information indicates a setting for the at least one control during operation of the equipment and identifies operating performance of the equipment corresponding to the indicated setting; receiving a goal for the equipment, wherein the goal is related to a desired operating performance of the equipment; identifying, a plurality of sets of contiguous good reference segments, wherein a contiguous set of good reference segments comprises a plurality of operating time segments where the desired operating performance goal was achieved for a predetermined of time; identifying, a subset of sets comprising reference segments that are achievable from a current operating state of the equipment; selecting, a reference segment that is attainable based upon exogenous factors related to an operating environment of the equipment; and providing a recommendation to an operator of the equipment.

A control module is adapted to control technical equipment by processing batch-run data from the technical equipment. The control module operates according to parameters that are obtained by a parameter module. The module receives a reference plurality of multi-variate reference time series with data values from sources that are related to the equipment. There are time series with measurement values and time series with data that describes particular manufacturing operations during a batch-run time interval. The module splits the time interval into phases by determining transitions between the particular manufacturing operations, and divides the time series into particular phase-specific partial series. For each phase separately, and for the phase-specific partial series in combination, the module differentiates phase-specific time series into relevant partial time series or non-relevant partial time series and set the parameters accordingly.

A monitoring system for an industrial operation having one or more machines, the monitoring system operates to obtain operational information comprising performance operating parameters and uses the operational information to create an operational baseline and reference thresholds and monitors real-time operational data to determine if an operating parameter exceeds a reference threshold.

A monitoring system for an industrial operation having one or more machines, the monitoring system operates to obtain operational information comprising performance operating parameters and uses the operational information to create an operational baseline and reference thresholds and monitors real-time operational data to determine if an operating parameter exceeds a reference threshold.

An object is to provide a control system of a machine tool which can efficiently return the set state of parameters for CNC to a previous set state. A storage unit which stores parameter change history data and parameter attribute data and a change history organization unit which uses the parameter change history data and the parameter attribute data to organize parameters for each of change history attributes and which thereby generates a change history attribute unit list are included. Moreover, a change history display unit which displays the change history attribute unit list, a Undo/Redo target selection unit which specifies arbitrary parameters in the change history attribute unit list obtained by organizing the parameters for each of the change history attributes and a parameter setting return processing unit which performs return processing for returning to the parameters specified in the Undo/Redo target selection unit are included.

One embodiment provides a method, including: obtaining historical information for equipment having at least one control, wherein the historical information indicates a setting for the at least one control during operation of the equipment and identifies operating performance of the equipment corresponding to the indicated setting; receiving a goal for the equipment, wherein the goal is related to a desired operating performance of the equipment; identifying, a plurality of sets of contiguous good reference segments, wherein a contiguous set of good reference segments comprises a plurality of operating time segments where the desired operating performance goal was achieved for a predetermined of time; identifying, a subset of sets comprising reference segments that are achievable from a current operating state of the equipment; selecting, a reference segment that is attainable based upon exogenous factors related to an operating environment of the equipment; and providing a recommendation to an operator of the equipment.

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.