SlideShare a Scribd company logo
Advanced Process Control and Continuous Processing in
Pharmaceutical Manufacturing: What Can We Learn from
Other Industries
Paul Brodbeck/Control Associates Inc.
 What is Process Control?
 How?
 Why?
 Benefits?
 Why Advanced Process Control?
 Advanced Controls
◦ MPC
◦ Kalman Filter
◦ Neural Networks
◦ LP Optimization
 Controlling process variable to a desired SP.
◦ Reactor Temperature
◦ Heat Exchanger Flow Rate
◦ Boiler Pressure
◦ OTC Tablet (API) Concentration.
◦ Dryer Moisture Content
◦ House Temperature
◦ Car Speed
◦ Distillation Column Production Rate
 Controller
 First Feed Back Controller – Humans
 Closed Loop Control – Level, Press, Flow, API Concentration (%)
 Vary output – Valve, Pump, Agitator, Fan
 WHY?
 Manual vs. Automatic
 Easy
 Quality – Temperature Variability
 Temperature Cycling
◦ Poor Quality
◦ Inefficient
◦ Wear and Tear on Heater and Parts
 Auto change SP at day/night Cost Savings
 Control Improves Quality & Reduces Costs
 WHY?
 Manual vs. Automatic
 Quality – Constant Speed
 Speed Cycling
◦ Poor QualityInefficient
◦ Wear and Tear on Car and Parts
 Get there faster!
◦ Set Speed closer to speed limit
◦ Less Risk/Less Speeding Tickets
 Control Improves Quality & Reduces Costs
 WHY?
 Manual vs. Automatic
 Production
 Yields
 Profit
 Reduces Costs
◦ Labor
◦ Energy
 Safer
 Lower Risk
 Improves Quality
 Reduces Costs
 Increases Production
 Reduce Variability!
◦ Almost at end in itself.
 Edward Deming – Quality Program Founder
 Japan Post WWWII Better Quality
◦ Autos, Semi-Conductors, Steel…
 1980’s American Manufacturing Poor Quality
 Statistical Process Control Introduced into US
 Get Process under Control (Statistically)
◦ Control Charts
 Reduce Variability
 Increase Quality
Variable
Parameters
Variable
Quality
Controlled
Parameters
Fixed
Quality
 Improve Quality
 Increase Yields
 Increase Production
 Reduce off-spec
 Reduce Bad Batches
 Reduce Energy Costs
 Reduce Production Costs
 Improve Safety
 Reduce Risk
 Increase Profitability
 Optimal Control
 Better Control
 Control
 Poor Control
 Manual Control
Basic
PID
Advanced
PID
Advanced
Control
No
Control
Optimal
Control
Optimization
Control
Tuning Constants:
1. Proportional (P)
2. Integral (I)
3. Derivative (D)
Applications
 Car Cruise Control
 Home Heating/AC,
 Distillation Columns
 Chemical Reactors
 Bioreactors
 Crystallization
 Chromatography
Industries
 Chemical
 Pharmaceutical
 Petroleum
 Automotive
 Robots
 Aerospace
 Boilers
 Missile Guidance
Applications
 Distillation Columns
 Robotics
 Drones
 Aerospace
 Robots
 Missile Guidance
 Stock Market,
 Operations Research
 Economics
 Scheduling
Industries
 Chemical
 Pharmaceutical
 Petroleum
 Automotive
 Robots
 Aerospace
 Boilers
 Missile Guidance
 1. Model Predictive Control (MPC)
◦ Distillation Columns, Robotics, Drones, Aerospace…
 2. Kalman Filter
◦ Robots, Aerospace, Missile Guidance…
 3. Neural Networks (NN)
◦ Pattern Recognition, Stock Market, Genetics…
 4. Linear Programming (LP) Optimization
◦ Operations Research, Economics, Scheduling
 Machine Learning
◦ Computer Science & Statistics
◦ Real World Problem Prediction/Optimization
 Search Engines
 Stock Market Prediction
 Pattern Recognition (OCR)
 Robotics
 Recommender Systems
 DNA Sequencing
 Chemometrics
 Numerical Methods
 Least Squares
 Statistics
 Modeling
 Analytics
 Linear Programming
 Optimization
 MPC
 Neural Networks
 MVA Tools
 MLR
 PCA
 PLS
 Kalman Filter
 Multivariate SPC
 Optimal Control
 Slow Processes
 Large Dead Times
 Multiple Loops (50x25)
 Complex Dynamics
 Strongly Correlated Loops
Multi-Loop PID Multi-Loop MPC
          
22 2
1 1 1 1 1 1
1 1
y u u
n n nP M M
y set u u
j j j j j j j j
i j i j i j
J w y k i y k i w u k i w u k i u
     
                  
y: Controlled variable
u: Actuator
△u: Predicted adjustment
manipulated
variable
deviations
Controlled variable
deviations
controller adjustments
Singh, R., Ierapetritou, M., Ramachandran, R. (2013). European
Journal of Pharmaceutics and Biopharmaceutics,
http://dx.doi.org/10.1016/j.ejpb.2013.02.019.
Tuning parameters
1. Output weights (wy
j)
2. Rate weights ( )
3.Input weight ( )
4. Prediction horizon
5. Control horizon
u
jw
u
jw
Actuator Control variable
Actuat
or
Control variable
Filtered NIR signal CV
(API composition)
Actuato
r Ratio
SP
NIR signal
3
1
2
 Statistically Optimal Estimator
 Numerous Applications
◦ De facto Standard Robotics
◦ Aerospace
◦ Missile Guidance
◦ Economics
◦ Signal Processing
 State Prediction based on:
◦ Noisy Data
◦ Physical Model (Error increases w/ Time)
 Takes a statistical average of:
◦ Measured Variable
◦ Model
 Acts Recursively to continuously predict most
probable state.
 First used by NASA to predict location of rockets
◦ Uncertain GPS Signal
◦ Physical Model error increases with time
 Use measurement signal to correct errors with
model.
 Use model to validate measured values.
dF(x)/dx = f(x)*(1-f(x))
 E-mail Spam
 Internet Browser
 Recommender systems
 Pattern Recognition
◦ Bar coders
◦ Facial identification
◦ Robotics
 Pharma
◦ Soft Sensors
◦ Non-Linear Control
 Non-Linear Data Modeling
 Combination of Linear Regressions
 Build up a series of linear models
(regressions) to create a non-linear model
0
2
4
6
8
10
12
14
1 2 3 4 5 6 7 8 9 10 11
Fit
Raw Data
0
100
200
300
400
500
600
700
1 3 5 7 9 11 13 15 17 19 21 23 25
0
100
200
300
400
500
600
700
1 3 5 7 9 11 13 15 17 19 21 23 25
1
2
3
BUILD
MODEL
PREDICT
VALUE !
 Linear Programming
 A mathematical/computer optimization
technique – Simplex Method
 Solve a system of linear equations
 Can be used to find the minimum and
maximum states of process control
 Can be made subject to multiple constraints
 Pusher Function
 Maximize Flowrate subject to constraints
 Introduction of Technology
◦ PAT
◦ Continuous Manufacturing
 Introduce Advanced Controls
◦ MPC
◦ Kalman Filter
◦ Neural Net
◦ LP Optimization
◦ MultiVariable SPC

More Related Content

Viewers also liked

CHOOSING TECHNOLOGY
CHOOSING TECHNOLOGYCHOOSING TECHNOLOGY
10 Gute Gruende - NetApp DevOps
10 Gute Gruende - NetApp DevOps10 Gute Gruende - NetApp DevOps
10 Gute Gruende - NetApp DevOps
NetApp_Germany
 
Batch Distillation
Batch DistillationBatch Distillation
Batch Distillation
Gerard B. Hawkins
 
Presentation Technology New
Presentation Technology NewPresentation Technology New
Presentation Technology New
nares.piyaneti
 
Water distillation unit quartz
Water distillation unit   quartzWater distillation unit   quartz
Water distillation unit quartz
Acmas Technologies Pvt. Ltd.
 
Design and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation ColumnsDesign and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation Columns
Gerard B. Hawkins
 
L05 treat20150305
L05 treat20150305L05 treat20150305
L05 treat20150305
Sujitra Kanyavilat
 
Laboratory Distillation
Laboratory DistillationLaboratory Distillation
Laboratory Distillation
Gerard B. Hawkins
 
Divided Wall Distillation Column
Divided Wall Distillation Column  Divided Wall Distillation Column
Divided Wall Distillation Column
Prateek Mishra
 
Smart Process Distillation Application Improves Recovery And Saves Energy
Smart Process Distillation Application Improves Recovery And Saves EnergySmart Process Distillation Application Improves Recovery And Saves Energy
Smart Process Distillation Application Improves Recovery And Saves Energy
Jim Cahill
 
15 organic chemistry
15 organic chemistry15 organic chemistry
15 organic chemistry
Neung Satang
 
Control of Continuous Distillation Columns
Control of Continuous Distillation ColumnsControl of Continuous Distillation Columns
Control of Continuous Distillation Columns
Gerard B. Hawkins
 
Desalination and water reuse technologies
Desalination and water reuse technologiesDesalination and water reuse technologies
Desalination and water reuse technologies
Abengoa
 
Distillation column manufacturer (cyclic distillation) efficiency distillatio...
Distillation column manufacturer (cyclic distillation) efficiency distillatio...Distillation column manufacturer (cyclic distillation) efficiency distillatio...
Distillation column manufacturer (cyclic distillation) efficiency distillatio...
Maleta cyclic distillation LLC
 
Maintenance of distillation column asmita
Maintenance of distillation column asmitaMaintenance of distillation column asmita
Maintenance of distillation column asmita
Asmita Mishra
 
Manufacturing planning and self inspection in pharmaceutical industries
Manufacturing planning and self inspection in pharmaceutical industriesManufacturing planning and self inspection in pharmaceutical industries
Manufacturing planning and self inspection in pharmaceutical industries
Sumita Sahoo
 
Distillation
DistillationDistillation
Distillation
Meet2395
 
Practical Advanced Process Control for Engineers and Technicians
Practical Advanced Process Control for Engineers and TechniciansPractical Advanced Process Control for Engineers and Technicians
Practical Advanced Process Control for Engineers and Technicians
Living Online
 
New Techniques of wastewater Management
New Techniques  of wastewater ManagementNew Techniques  of wastewater Management
New Techniques of wastewater Management
Prashant Ojha
 

Viewers also liked (20)

GEA
GEAGEA
GEA
 
CHOOSING TECHNOLOGY
CHOOSING TECHNOLOGYCHOOSING TECHNOLOGY
CHOOSING TECHNOLOGY
 
10 Gute Gruende - NetApp DevOps
10 Gute Gruende - NetApp DevOps10 Gute Gruende - NetApp DevOps
10 Gute Gruende - NetApp DevOps
 
Batch Distillation
Batch DistillationBatch Distillation
Batch Distillation
 
Presentation Technology New
Presentation Technology NewPresentation Technology New
Presentation Technology New
 
Water distillation unit quartz
Water distillation unit   quartzWater distillation unit   quartz
Water distillation unit quartz
 
Design and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation ColumnsDesign and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation Columns
 
L05 treat20150305
L05 treat20150305L05 treat20150305
L05 treat20150305
 
Laboratory Distillation
Laboratory DistillationLaboratory Distillation
Laboratory Distillation
 
Divided Wall Distillation Column
Divided Wall Distillation Column  Divided Wall Distillation Column
Divided Wall Distillation Column
 
Smart Process Distillation Application Improves Recovery And Saves Energy
Smart Process Distillation Application Improves Recovery And Saves EnergySmart Process Distillation Application Improves Recovery And Saves Energy
Smart Process Distillation Application Improves Recovery And Saves Energy
 
15 organic chemistry
15 organic chemistry15 organic chemistry
15 organic chemistry
 
Control of Continuous Distillation Columns
Control of Continuous Distillation ColumnsControl of Continuous Distillation Columns
Control of Continuous Distillation Columns
 
Desalination and water reuse technologies
Desalination and water reuse technologiesDesalination and water reuse technologies
Desalination and water reuse technologies
 
Distillation column manufacturer (cyclic distillation) efficiency distillatio...
Distillation column manufacturer (cyclic distillation) efficiency distillatio...Distillation column manufacturer (cyclic distillation) efficiency distillatio...
Distillation column manufacturer (cyclic distillation) efficiency distillatio...
 
Maintenance of distillation column asmita
Maintenance of distillation column asmitaMaintenance of distillation column asmita
Maintenance of distillation column asmita
 
Manufacturing planning and self inspection in pharmaceutical industries
Manufacturing planning and self inspection in pharmaceutical industriesManufacturing planning and self inspection in pharmaceutical industries
Manufacturing planning and self inspection in pharmaceutical industries
 
Distillation
DistillationDistillation
Distillation
 
Practical Advanced Process Control for Engineers and Technicians
Practical Advanced Process Control for Engineers and TechniciansPractical Advanced Process Control for Engineers and Technicians
Practical Advanced Process Control for Engineers and Technicians
 
New Techniques of wastewater Management
New Techniques  of wastewater ManagementNew Techniques  of wastewater Management
New Techniques of wastewater Management
 

Similar to AAPS Advanced Controls Uploaded 2

ISA FPID Presentation Final 3
ISA FPID Presentation Final 3ISA FPID Presentation Final 3
ISA FPID Presentation Final 3Paul Brodbeck
 
A2IoT OBDII Case Study
A2IoT OBDII Case StudyA2IoT OBDII Case Study
A2IoT OBDII Case Study
Anand Deshpande
 
OPAL-RT ePHASORsim Webinar
OPAL-RT ePHASORsim WebinarOPAL-RT ePHASORsim Webinar
OPAL-RT ePHASORsim Webinar
OPAL-RT TECHNOLOGIES
 
Final Year Project Presentation
Final Year Project PresentationFinal Year Project Presentation
Final Year Project Presentationfarhan_naseer_1
 
ERC_EGUE_FINAL_Aug 12_PJB
ERC_EGUE_FINAL_Aug 12_PJBERC_EGUE_FINAL_Aug 12_PJB
ERC_EGUE_FINAL_Aug 12_PJBPaul Brodbeck
 
RS_AIChE presentation 2013
RS_AIChE presentation 2013RS_AIChE presentation 2013
RS_AIChE presentation 2013Paul Brodbeck
 
Improving continuous process operation using data analytics delta v applicati...
Improving continuous process operation using data analytics delta v applicati...Improving continuous process operation using data analytics delta v applicati...
Improving continuous process operation using data analytics delta v applicati...
Emerson Exchange
 
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
Amazon Web Services
 
Advances In Digital Automation Within Refining
Advances In Digital Automation Within RefiningAdvances In Digital Automation Within Refining
Advances In Digital Automation Within Refining
Jim Cahill
 
Speed Control of PMDCM Based GA and DS Techniques
Speed Control of PMDCM Based GA and DS TechniquesSpeed Control of PMDCM Based GA and DS Techniques
Speed Control of PMDCM Based GA and DS Techniques
International Journal of Power Electronics and Drive Systems
 
How to develop pm tasks for a machine
How to develop pm tasks for a machineHow to develop pm tasks for a machine
How to develop pm tasks for a machine
Jim Taylor, ASQ-CRE, CPE, CPMM
 
Ijmet 10 01_034
Ijmet 10 01_034Ijmet 10 01_034
Ijmet 10 01_034
IAEME Publication
 
At4201308314
At4201308314At4201308314
At4201308314
IJERA Editor
 
Track 4 session 3 - st dev con 2016 - pedestrian dead reckoning
Track 4   session 3 - st dev con 2016 - pedestrian dead reckoningTrack 4   session 3 - st dev con 2016 - pedestrian dead reckoning
Track 4 session 3 - st dev con 2016 - pedestrian dead reckoning
ST_World
 
Semi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
Semi Autonomous Hand Launched Rotary Wing Unmanned Air VehiclesSemi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
Semi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
ahmad bassiouny
 
IRJET- Performance Analysis of ACO based PID Controller in AVR System: A ...
IRJET-  	  Performance Analysis of ACO based PID Controller in AVR System: A ...IRJET-  	  Performance Analysis of ACO based PID Controller in AVR System: A ...
IRJET- Performance Analysis of ACO based PID Controller in AVR System: A ...
IRJET Journal
 
Data acquisition and logging system
Data acquisition and logging systemData acquisition and logging system
Data acquisition and logging systemarpita3017
 
OBD II VT200 & VT400 Introduction
OBD II VT200 & VT400 IntroductionOBD II VT200 & VT400 Introduction
OBD II VT200 & VT400 Introduction
ThinkRace Technology
 
OBD GPS Tracker for Car safety and security
OBD GPS Tracker for Car safety and securityOBD GPS Tracker for Car safety and security
OBD GPS Tracker for Car safety and security
happyme20
 
Alcohol monitoring scram iid fuel cell devices 2015
Alcohol monitoring scram iid fuel cell devices 2015Alcohol monitoring scram iid fuel cell devices 2015
Alcohol monitoring scram iid fuel cell devices 2015
Powers Law Firm PA
 

Similar to AAPS Advanced Controls Uploaded 2 (20)

ISA FPID Presentation Final 3
ISA FPID Presentation Final 3ISA FPID Presentation Final 3
ISA FPID Presentation Final 3
 
A2IoT OBDII Case Study
A2IoT OBDII Case StudyA2IoT OBDII Case Study
A2IoT OBDII Case Study
 
OPAL-RT ePHASORsim Webinar
OPAL-RT ePHASORsim WebinarOPAL-RT ePHASORsim Webinar
OPAL-RT ePHASORsim Webinar
 
Final Year Project Presentation
Final Year Project PresentationFinal Year Project Presentation
Final Year Project Presentation
 
ERC_EGUE_FINAL_Aug 12_PJB
ERC_EGUE_FINAL_Aug 12_PJBERC_EGUE_FINAL_Aug 12_PJB
ERC_EGUE_FINAL_Aug 12_PJB
 
RS_AIChE presentation 2013
RS_AIChE presentation 2013RS_AIChE presentation 2013
RS_AIChE presentation 2013
 
Improving continuous process operation using data analytics delta v applicati...
Improving continuous process operation using data analytics delta v applicati...Improving continuous process operation using data analytics delta v applicati...
Improving continuous process operation using data analytics delta v applicati...
 
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
Intelligent Production: Deploying IoT and cloud-based machine learning to opt...
 
Advances In Digital Automation Within Refining
Advances In Digital Automation Within RefiningAdvances In Digital Automation Within Refining
Advances In Digital Automation Within Refining
 
Speed Control of PMDCM Based GA and DS Techniques
Speed Control of PMDCM Based GA and DS TechniquesSpeed Control of PMDCM Based GA and DS Techniques
Speed Control of PMDCM Based GA and DS Techniques
 
How to develop pm tasks for a machine
How to develop pm tasks for a machineHow to develop pm tasks for a machine
How to develop pm tasks for a machine
 
Ijmet 10 01_034
Ijmet 10 01_034Ijmet 10 01_034
Ijmet 10 01_034
 
At4201308314
At4201308314At4201308314
At4201308314
 
Track 4 session 3 - st dev con 2016 - pedestrian dead reckoning
Track 4   session 3 - st dev con 2016 - pedestrian dead reckoningTrack 4   session 3 - st dev con 2016 - pedestrian dead reckoning
Track 4 session 3 - st dev con 2016 - pedestrian dead reckoning
 
Semi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
Semi Autonomous Hand Launched Rotary Wing Unmanned Air VehiclesSemi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
Semi Autonomous Hand Launched Rotary Wing Unmanned Air Vehicles
 
IRJET- Performance Analysis of ACO based PID Controller in AVR System: A ...
IRJET-  	  Performance Analysis of ACO based PID Controller in AVR System: A ...IRJET-  	  Performance Analysis of ACO based PID Controller in AVR System: A ...
IRJET- Performance Analysis of ACO based PID Controller in AVR System: A ...
 
Data acquisition and logging system
Data acquisition and logging systemData acquisition and logging system
Data acquisition and logging system
 
OBD II VT200 & VT400 Introduction
OBD II VT200 & VT400 IntroductionOBD II VT200 & VT400 Introduction
OBD II VT200 & VT400 Introduction
 
OBD GPS Tracker for Car safety and security
OBD GPS Tracker for Car safety and securityOBD GPS Tracker for Car safety and security
OBD GPS Tracker for Car safety and security
 
Alcohol monitoring scram iid fuel cell devices 2015
Alcohol monitoring scram iid fuel cell devices 2015Alcohol monitoring scram iid fuel cell devices 2015
Alcohol monitoring scram iid fuel cell devices 2015
 

AAPS Advanced Controls Uploaded 2

  • 1. Advanced Process Control and Continuous Processing in Pharmaceutical Manufacturing: What Can We Learn from Other Industries Paul Brodbeck/Control Associates Inc.
  • 2.  What is Process Control?  How?  Why?  Benefits?  Why Advanced Process Control?  Advanced Controls ◦ MPC ◦ Kalman Filter ◦ Neural Networks ◦ LP Optimization
  • 3.  Controlling process variable to a desired SP. ◦ Reactor Temperature ◦ Heat Exchanger Flow Rate ◦ Boiler Pressure ◦ OTC Tablet (API) Concentration. ◦ Dryer Moisture Content ◦ House Temperature ◦ Car Speed ◦ Distillation Column Production Rate  Controller
  • 4.  First Feed Back Controller – Humans  Closed Loop Control – Level, Press, Flow, API Concentration (%)  Vary output – Valve, Pump, Agitator, Fan
  • 5.  WHY?  Manual vs. Automatic  Easy  Quality – Temperature Variability  Temperature Cycling ◦ Poor Quality ◦ Inefficient ◦ Wear and Tear on Heater and Parts  Auto change SP at day/night Cost Savings  Control Improves Quality & Reduces Costs
  • 6.  WHY?  Manual vs. Automatic  Quality – Constant Speed  Speed Cycling ◦ Poor QualityInefficient ◦ Wear and Tear on Car and Parts  Get there faster! ◦ Set Speed closer to speed limit ◦ Less Risk/Less Speeding Tickets  Control Improves Quality & Reduces Costs
  • 7.  WHY?  Manual vs. Automatic  Production  Yields  Profit  Reduces Costs ◦ Labor ◦ Energy  Safer  Lower Risk
  • 8.  Improves Quality  Reduces Costs  Increases Production
  • 9.  Reduce Variability! ◦ Almost at end in itself.  Edward Deming – Quality Program Founder  Japan Post WWWII Better Quality ◦ Autos, Semi-Conductors, Steel…  1980’s American Manufacturing Poor Quality  Statistical Process Control Introduced into US  Get Process under Control (Statistically) ◦ Control Charts  Reduce Variability  Increase Quality
  • 11.
  • 12.  Improve Quality  Increase Yields  Increase Production  Reduce off-spec  Reduce Bad Batches  Reduce Energy Costs  Reduce Production Costs  Improve Safety  Reduce Risk  Increase Profitability
  • 13.  Optimal Control  Better Control  Control  Poor Control  Manual Control
  • 15. Tuning Constants: 1. Proportional (P) 2. Integral (I) 3. Derivative (D)
  • 16. Applications  Car Cruise Control  Home Heating/AC,  Distillation Columns  Chemical Reactors  Bioreactors  Crystallization  Chromatography Industries  Chemical  Pharmaceutical  Petroleum  Automotive  Robots  Aerospace  Boilers  Missile Guidance
  • 17. Applications  Distillation Columns  Robotics  Drones  Aerospace  Robots  Missile Guidance  Stock Market,  Operations Research  Economics  Scheduling Industries  Chemical  Pharmaceutical  Petroleum  Automotive  Robots  Aerospace  Boilers  Missile Guidance
  • 18.  1. Model Predictive Control (MPC) ◦ Distillation Columns, Robotics, Drones, Aerospace…  2. Kalman Filter ◦ Robots, Aerospace, Missile Guidance…  3. Neural Networks (NN) ◦ Pattern Recognition, Stock Market, Genetics…  4. Linear Programming (LP) Optimization ◦ Operations Research, Economics, Scheduling
  • 19.  Machine Learning ◦ Computer Science & Statistics ◦ Real World Problem Prediction/Optimization  Search Engines  Stock Market Prediction  Pattern Recognition (OCR)  Robotics  Recommender Systems  DNA Sequencing  Chemometrics
  • 20.  Numerical Methods  Least Squares  Statistics  Modeling  Analytics  Linear Programming  Optimization  MPC  Neural Networks  MVA Tools  MLR  PCA  PLS  Kalman Filter  Multivariate SPC
  • 21.  Optimal Control  Slow Processes  Large Dead Times  Multiple Loops (50x25)  Complex Dynamics  Strongly Correlated Loops
  • 22.
  • 24.            22 2 1 1 1 1 1 1 1 1 y u u n n nP M M y set u u j j j j j j j j i j i j i j J w y k i y k i w u k i w u k i u                          y: Controlled variable u: Actuator △u: Predicted adjustment manipulated variable deviations Controlled variable deviations controller adjustments Singh, R., Ierapetritou, M., Ramachandran, R. (2013). European Journal of Pharmaceutics and Biopharmaceutics, http://dx.doi.org/10.1016/j.ejpb.2013.02.019. Tuning parameters 1. Output weights (wy j) 2. Rate weights ( ) 3.Input weight ( ) 4. Prediction horizon 5. Control horizon u jw u jw
  • 25.
  • 26.
  • 27.
  • 29.
  • 30.
  • 31.
  • 33. Filtered NIR signal CV (API composition) Actuato r Ratio SP NIR signal
  • 34. 3 1 2
  • 35.  Statistically Optimal Estimator  Numerous Applications ◦ De facto Standard Robotics ◦ Aerospace ◦ Missile Guidance ◦ Economics ◦ Signal Processing  State Prediction based on: ◦ Noisy Data ◦ Physical Model (Error increases w/ Time)
  • 36.  Takes a statistical average of: ◦ Measured Variable ◦ Model  Acts Recursively to continuously predict most probable state.  First used by NASA to predict location of rockets ◦ Uncertain GPS Signal ◦ Physical Model error increases with time  Use measurement signal to correct errors with model.  Use model to validate measured values.
  • 37.
  • 39.  E-mail Spam  Internet Browser  Recommender systems  Pattern Recognition ◦ Bar coders ◦ Facial identification ◦ Robotics  Pharma ◦ Soft Sensors ◦ Non-Linear Control
  • 40.  Non-Linear Data Modeling  Combination of Linear Regressions  Build up a series of linear models (regressions) to create a non-linear model
  • 41. 0 2 4 6 8 10 12 14 1 2 3 4 5 6 7 8 9 10 11 Fit Raw Data 0 100 200 300 400 500 600 700 1 3 5 7 9 11 13 15 17 19 21 23 25 0 100 200 300 400 500 600 700 1 3 5 7 9 11 13 15 17 19 21 23 25 1 2 3
  • 42.
  • 43.
  • 44.
  • 46.
  • 47.  Linear Programming  A mathematical/computer optimization technique – Simplex Method  Solve a system of linear equations  Can be used to find the minimum and maximum states of process control  Can be made subject to multiple constraints
  • 48.  Pusher Function  Maximize Flowrate subject to constraints
  • 49.
  • 50.  Introduction of Technology ◦ PAT ◦ Continuous Manufacturing  Introduce Advanced Controls ◦ MPC ◦ Kalman Filter ◦ Neural Net ◦ LP Optimization ◦ MultiVariable SPC