Batch Analysis Application for Outlier Screening and Trend Comparison
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Solution Overview
Problem
Conventional batch management applications lack the ability to facilitate easy comparison of current batch data with prior successful batches and do not provide a mechanism to screen out outlier batches effectively for analysis purposes.
Innovation Solution
A batch analysis application that integrates with a process automation system, allowing users to display real-time data alongside hypothetical ideal batch runs, retrieve historical data for analysis, and visualize trends, enabling operators to identify outliers and compare batch performance across different equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional batch management applications are used, then batch processes can be managed and controlled, but operators cannot easily compare current batch data with prior successful batches
Solution Approach 1:
The system pre-processes and stores historical batch data in a structured format with identified successful batches before comparison is needed. When a new batch is initiated, the system automatically retrieves and displays relevant historical data for comparison, eliminating the need for operators to manually search through archives.
Solution Approach 2:
The system creates simplified, on-demand comparison views that display only the essential differences between current and historical batch data. Rather than requiring operators to access complex database structures, the system generates lightweight comparison reports that can be quickly reviewed and discarded after use.
2Measurement precision
If all historical batch data is used for analysis, then comprehensive data is available, but outlier batches cannot be easily screened out
Solution Approach 1:
The system automatically identifies and extracts outlier batches from the historical data set using statistical analysis of process parameters. Batches that deviate significantly from established norms are flagged and can be excluded from comparison, allowing operators to focus analysis on representative successful batches without manual intervention.
Solution Approach 2:
The system continuously monitors batch performance data and provides feedback on data quality and consistency. When outliers are detected, the system notifies operators and allows them to adjust comparison parameters, creating a feedback loop that improves the precision of batch analysis over time.
3Loss of information
If detailed batch data is displayed, then comprehensive analysis is possible, but the interface becomes overwhelming and difficult to navigate
Solution Approach 1:
The interface divides batch data into logical segments such as process parameters, quality metrics, timing information, and equipment status. Each segment can be independently viewed or expanded, allowing operators to access detailed information when needed while maintaining a clean, organized overview of the most important data.
Solution Approach 2:
The system presents batch comparison data across multiple dimensions including time trends, parameter relationships, and equipment performance. By organizing data in multi-dimensional views rather than simple tables, the system enables comprehensive analysis while maintaining interface clarity through intuitive visual navigation.
Data Source
AI summary
The present invention is directed to a batch system for managing and analyzing batch runs of a batch process in a process cell. The batch system includes a computer readable medium, a plurality of batch management routines and a plurality of batch analysis routines stored on the computer readable medium and adapted to be executed by the at least one processor. The batch management routines are operable to schedule batch runs and create and edit recipes for the batch process. The batch analysis routines include a batch filter routine, a golden batch routine, a cycle time analysis routine, and a report wizard routine.