Enhancing Operational Efficiency with Advanced Analytics

Woman viewing data on computer monitors.

September 13, 2024

The manufacturing field is ultra-competitive, so maximizing efficiency while ensuring consistent quality is vital for success. For a major client in the agricultural sector, Interstates recently delivered a comprehensive analytics solution that not only streamlined their batch processes but also laid the foundation for continuous improvement. Our team helped the client gain critical insights into their production cycles through strategic data integration and advanced analytics, enabling them to identify bottlenecks and optimize recipe parameters for better results.

Unlocking Data for Better Decision-Making

dashboard showing the batch and phase data through the Pi Vision historian.
Dashboard comparing the client's batch data (top) and phase data (bottom) of their plant through the historian Pi Vision.

One of the primary objectives of this project was to centralize and organize batch data from various production areas. According to Nick Malott, Analytics Architect at Interstates, "We provided a solution that increased visibility into batch and phase information by integrating that data alongside existing process data. This integration allowed the client to compare cycle times across different production recipes, making it easier to pinpoint inefficiencies and improve overall operational performance."

The analytics solution focused on setting up a Data Staging Server, optimizing SQL queries, and integrating data from FactoryTalk Batch and FactoryTalk Historian systems. By transitioning the client's batch process to a dynamic, "live" streaming model and synchronizing data streams, Interstates enabled real-time insights without disrupting the client's critical production systems.

Real-Time Insights Driving Operational Excellence

Dashboard showing the batch execution history to show when an area ran production
Dashboard that shows the batch execution history of several tanks in an area to identify when the area was running production.

The key benefit of the centralized batch data system is that it can be safely queried without affecting ongoing production. "Our approach to indexing and organizing the data allows for efficient query processing across all batch operations, giving the client the flexibility to analyze data in real-time," says Malott. This setup ensures that batch data is not only accessible but also ready for deeper analysis, enabling the client to drive meaningful improvements in production.

One of the standout features of this solution is the potential for future developments like a Golden Batch Dashboard. By comparing batch cycle times and recipe parameters, the client can replicate the conditions that produce optimal results—what is commonly referred to as a "golden batch." Malott explains, "Golden Batch Dashboards empower our clients to fine-tune their production systems, leading to optimized parameters for improved key performance indicators such as production speed, throughput, yield, and minimized downtime."

Promising Results

Simplified architecture diagram for a data staging server set up.
This diagram shows how the Data Staging Server is set up. The server lets us look at different batch databases while keeping our main production systems safe from heavy data queries. One important task the server does is combine batch data with process data over time. This makes it easier to access and analyze all the information together.

While the project is still in its early stages, the initial results have been encouraging. The client has expressed satisfaction with the speed and efficiency of the implementation. "Our team quickly identified the bottlenecks in providing batch data to the application services and delivered a solution that safeguards and efficiently organizes this data for future solutions," Malott says.

This comprehensive analytics solution provides immediate value in identifying and addressing production inefficiencies and sets the stage for more advanced analytics capabilities in the future. As the client continues to leverage this system, they will be well-positioned to maintain consistent product quality while optimizing their daily operations. In an industry where every second counts, Interstates' commitment to delivering robust, scalable solutions has once again proven vital in helping our clients achieve their production goals.