Golden Batch Analytics Solution

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Interstates partnered with a leading agricultural client to implement a comprehensive golden batch analytics solution. By centralizing and optimizing batch data from multiple production areas, the project aimed to identify optimal process parameters and replicate “golden batch” conditions, driving enhanced production efficiency and quality.

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Achieving Real Results

Centralized and optimized batch data for real-time analysis.

Improved operational efficiency by identifying and replicating golden batch conditions.

Enhanced data accessibility, enabling more informed decision-making.

Minimized production system impact with a dedicated staging server.

Challenges

  1. Data Centralization Across Systems: Aggregating data from multiple FactoryTalk Batch databases and ensuring time synchronization across streams was complex and potentially difficult.
  2. Real-Time Data Flow: The client needed us to transition their batch systems to a “live” configuration while maintaining production stability.
  3. Efficient Data Management: Implementing a solution that balanced analytics needs with non-disruptive production performance was crucial.
  4. Scalability for Future Enhancements: Interstates had to be careful to design a system architecture that supports advanced analytical tools and considers future project phases.

Solution

Interstates addressed these challenges by implementing a Data Staging Server to aggregate and centralize batch data from various sources throughout the client’s facility. This repositorywas optimized for SQL queries and integratedwith Pi Asset Framework for advanced analytics.Time synchronization was achieved using an NTP server, ensuring that batch data could be analyzed accurately and in real-time. By transitioning the batch system to a dynamic, "live" model, Interstates enabled continuous data flow and analysis without compromising the client's production or output.

Return on Investment

Although the project is still in its early stages, the initial outcomes have been positive. The client expressed satisfaction with the effectiveness of the solution and how quickly Interstates completed the complex work. Interstates’ approach provided immediate value in centralizing and optimizing the client’s batch data, enabling real-time analysis and laying the groundwork for future enhancements.

Through this golden batch analytics project, we:

  • Centralized batch data for easier and more efficient querying.
  • Improved visibility into batch and phase cycle times for identifying bottlenecks.
  • Enhanced the plant’s operational efficiency by correlating recipe parameters with optimal phase times.
  • Prepared the client for future advanced analytics, including Golden Batch Dashboards.

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