TwinThread Debuts KPI-Driven Production Optimizer

Industrial AI expert TwinThread has announced the release of an automated, KPI-aligned, priority-driven solution to help process manufacturers optimize production runs. Perfect Centerline is the latest addition to TwinThread’s Pre-Built Solutions for Process Optimization. The solution is designed to help reduce/eliminate run-to-run variation and enhance production through automated, AI-driven industrial analysis, parameter oversight and modification, and real-time monitoring of production parameters, aiding anomaly identification and parameter optimization.

TwinThread says its Perfect Centerline solution can help its customers achieve substantial value, with a 50-75% increase in process stability. Image used courtesy of TwinThread

Perfect Centerline

The ability to analyze production run data to obtain the golden standard, or “golden run", is the key to optimizing production and obtaining those all-important KPIs. This is what TwinThread’s Perfect Centerline solution is designed to achieve.

The solution uses industrial AI to scour your complete production history and identify the formulas that drive the optimal production run for each product across multiple runs. Process engineers can select objectives such as maximizing yield and reducing downtime. Customers can also select and modify different variables/parameters (via clear ranges and set points), including mill speed, temperature, moisture, particle size, line pressure, pH, motor current, conductivity, mixer speed, and more. The intuitive user interface provides users with a clear view of parameters and how they compare to their acceptable range. The Perfect Centerline system displays ideal set points for parameters, designated criticality, and optimal operating ranges based on the best-performing parameter values recorded in previous production runs.

Customers can review and apply recommended setpoints (for low to high limits; targets or entire runs). Once set, users can view active runs in a single analysis dashboard to monitor operations. Customers can also use the TwinThread advisor to explore parameters, discover current trends, review anomalies, and diagnose issues before they disrupt operations. Process engineers can go even deeper to review anomaly history, correct parameter settings, and devise solutions to optimize future runs.

TwinThread’s Perfect Centerline solution is built to help customers improve speed-to-value, address run-to-run variation, optimize production runs, and enhance trust between users and TwinThread's team and offerings.

Customers can probe deeper with TwinThread Advisor, enabling engineers to compare real-time historical records and isolate key drivers that boost performance. Image used courtesy of TwinThread

Optimizing Uptime

As part of TwinThread’s Asset Optimization Suite of Pre-Built Solutions, customers can use Uptime Optimization to model downtime probability and review the status of assets and the stability of workflows. This solution provides insights into the optimal conditions for mitigating unwanted downtime, diagnosing potential causes of downtime events, providing advanced warning of such events, identifying process and/or asset anomalies, and prioritizing them to prevent downtime.

TwinThread worked with a manufacturer in the packaging and food industry to improve process stability, increase production, and reduce material losses. The manufacturer used TwinThreads Digital Twin Technology and Uptime Optimization as part of the overall solution framework. The result of this implementation was increased throughput, material conservation, and improved uptime.

Overall, Perfect Centerline is a valuable addition to TwinThread’s industrial AI platform, affording users an inclusive approach to production operations. Engineers can review recommended runs provided by AI, compare them to the best historical production line runs, and then override/validate settings to achieve the best results.