Advanced batch analysis and monitoring enhanced by big data analytics technologies

To maximize profit potential in process operations, repeatable, high quality is essential. In chemical and pharmaceutical processing in particular, batch management systems are critical to ensuring reliable quality throughout processes.

ABB Ability™ BatchInsight enables customers to detect anomalies sooner in batch processes. It combines software solutions in a single tool, supported by ABB Advanced Services. ABB Ability™ BatchInsight helps process specialists and control system operators in their time-consuming work by automatically and efficiently conducting batch level analysis for detecting and resolving abnormalities.

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Your challenge

Which batches are faulty? Do you have a quality issue or a cycle time issue? When did the error occur? What are the best practices to ensure quality production? When it comes to ensuring consistent quality in process operations, there are a number of challenges.

Troubleshooting and finding root causes quickly

Monitoring multiple variables with dynamic interactions

Creating real insights from terabytes of collected process data

Identifying slowly creeping plant degradation

Preserving knowledge in times of demographic change

ABB Ability™ BatchInsight is ideal for vertical integration projects because it connects DCS and MES/ERP for domain-specific data consolidation and handling from multiple data sources. It combines web-based batch analysis tools with intelligent visualization (and advanced statistical algorithms) to make root-cause analysis more efficient.

Detect and correct anomalies early in your batch production

Save time and improve operations by conducting batch level analysis automatically and efficiently

Correct anomalies sooner with time-level analysis that recognizes the time of occurrence of the deviation and isolates the process variables that contributed to the process or operating deviation

Automatically gain the insights you need to take effective and timely corrective action

Improve production efficiency

Reduce unplanned downtime

Features

ABB Ability™ BatchInsight consolidates all batch management applications into one easy-to-use tool.

BatchInsight Datahub

Consolidates all collected data into one repository of information

Consolidation and reasoning of multi-
data sources
Pre-processing of bigdata for analysis and monitoring
Management and store of Batch labels, models and KPIs

Batch Analysis

Extends classic process data historians by combining the batch/recipe data
and the process trend data, to provide a
holistic/ comprehensive analysis for batch production

Process variable view
Duration view
Gantt view
Batch Parameter view
Batch equipment utilization view

Batch Modelling

Provides efficient batch modelling lifecycle for hundreds of recipes and product

Data-driven batch model building and verification using multi-variant algorithms
Batch model management system
Root cause analysis using batch model

Batch Monitoring

Creates online
monitoring templates using the model created
in Batch Modelling

Enables monitoring in real-time
Batch cycle time monitor
Single process variable monitor (golden batch monitor)
Multivariate monitor
Integration in DCS HMI

ABB Advanced Services

Advanced services from ABB experts

ABB offers advanced services that provide an expert who helps with data handling and process analysis, and creates a customized monitor
BatchInsight hands-on training and batch modelling based on predefined use cases by the customer

Batch Analysis - Parameter View