Abstract: State of the art systems used for industrial plant monitoring have the disadvantage that they fail to correctly assess reason for dip in performance of the plant and in turn trigger appropriate corrective measures. The disclosure herein generally relates to industrial plant monitoring, and, more particularly, to a system and method for development and deployment of self-organizing cyber-physical systems for manufacturing industries. The system monitors and collects data with respect to various parameters, from the industrial plant. If any performance dip is detected, the system determines corresponding cause, and also triggers one or more corrective actions to improve performance of the plant and different plant components to a desired performance level.

Abstract: In an industrial plant, various equipment are used to handle processing of raw materials. Considering complexities involved in the processes and the equipment, constant monitoring is required to obtain desired results. The disclosure herein generally relates to industrial process and equipment monitoring, and, more particularly, to data analysis for Just In Time (JIT) characterization of raw materials in any process industry. The system collects real-time plant data among other inputs, and performs characterization of raw materials being used in the plant. The characterization involves categorizing the raw materials into different classes. The class information is further used to predict performance of the industrial plant, and in turn to generate recommendations for optimization of the industrial plant.

Abstract: This disclosure relates to a method and system for adaptive learning of physics-based models, data-driven models and hybrid models used in an industrial manufacturing plant. A model-based optimization and advisory device (MOAD) is configured for monitoring performance of data-driven and physics-based models of industrial process units in real-time, computing model quality index for models, triggering adaptive learning of these models and in case of drift in predictions, diagnosing the reasons for drift in predictions. Suggesting re-tuning, re-building, and recreating of the models to achieve highest prediction quality, and automatic deployment of latest models.

Abstract: A system and method for performing data-based optimization of performance indicators of process and manufacturing plants. The system consists of modules for collecting and merging data from industrial processing units, pre-processing the data to remove outliers and missingness. Further, the system generates customized outputs from data and identifies important variables that affect a given process performance indicator. The system also builds predictive models for key performance indicators comprising the important features and determines operating points for optimizing the key performance indicators with minimum user intervention. In particular, the system receives inputs from users on the key performance indicators to be optimized and notifies the users of outputs from various steps in the analysis that help the users to effectively manage the analysis and take appropriate operational decisions.

Abstract: A system and method for performing data-based optimization of performance indicators of process and manufacturing plants. The system consists of modules for collecting and merging data from industrial processing units, pre-processing the data to remove outliers and missingness. Further, the system generates customized outputs from data and identifies important variables that affect a given process performance indicator. The system also builds predictive models for key performance indicators comprising the important features and determines operating points for optimizing the key performance indicators with minimum user intervention. In particular, the system receives inputs from users on the key performance indicators to be optimized and notifies the users of outputs from various steps in the analysis that help the users to effectively manage the analysis and take appropriate operational decisions.

Abstract: This disclosure relates generally to data preprocessing, and more particularly to implementing data pre-processing through outlier analysis and multivariate imputation process. In one embodiment, the method includes performing iterations for processing integrated data associated with a manufacturing process. Each iteration comprises removing outliers from the integrated data using a multi-level outlier model to obtain a filtered data. The filtered data is categorized into multiple categories to identify missing data based on a frequency of occurrence of various parameters. Missing data is selectively imputed based on the multiple categories to obtain imputed data which is clustered into various data clusters based on a predefined criteria. After every iteration, it is determined whether the imputed data associated with a current iteration is clustered into the same data clusters as associated with a previous iteration.