Manufacturing processes, particularly those related to chemicals, such as pharmaceuticals, petrochemicals, organic synthesis and so on, are highly complex. Many variables interact to impact on quality, yield, cost of operation, life of expensive process items and many other business goals. Yet performance improvement has never been more critical to success and survival. Only by understanding the complex variability of the process can this be achieved.

The MS2 Process Analysis System has been developed to provide powerful, advanced techniques to companies of any size; we have provided versions to sites from Small & Medium Enterprises to major refineries. Throughout 2003-5 the initial designs encompassed both batch and continuous modelling, together with some simple statistical process control functions. At the start of 2006, having recognised the potential of multivariate analysis, AJM Consulting was awarded a development grant by Yorkshire Forward, which together with some industrial partner programmes enabled massive progress in functionality.

Today, a wide range of advanced tools is available, including both univariate and multivariate techniques. These are integrated into a single system which has the primary features of ease of use, powerful analysis capabillity designed specifically for chemical and related processes and flexibility in both size and cost. The system is suitable for both continuous and batch production processes.

Techniques such as Parallel Coordinate Visualisation and Principal Component Analysis are augmented by a wide range of data pre-screening methods which can lead to fundamental gains in process understanding being achieved rapidly. Nor are these the only techniques available; development of more advanced algorithms, in association with the Centre for Process Analytics and Control Technology at Newcastle University, further strengthens the system's capability.

A new project - Project Hawk - will take MS2 into real time analysis. With further funding form Yorkshire Forward and the European Union's Regional Development Fund, Hawk will enable detection of faults in real time, allowing rapid action to be taken. The system will identify the "fingerprint" of the process problem, and will facilitate the provision of advice to the operators. Initial data sources will include Emerson's DeltaV, OsiSoft's PI and Wonderware's ActiveFactory.

In only six months, over 20 companies have invested in MS2's data mining technology. See what users are saying:

"There have been some genuine surprises. It is MS2's ability to analyse diverse data sets which will yield significant benefit..."

Aesica Pharmaceuticals (Click here for case study)

"Analysis has yielded valuable information. We are looking forward to further developments including adding customer data"

Fibres Worldwide (Click here for case study)

"PCA has been of particular interest and has given valuable insights in process control strategies and maintenance activities"

Holliday Pigments (Click here for case study)

"The MS2 system integrated the data from our commercial, process control and plant historian systems and provided both an effective visualisation of the problem and an analysis of its cause, enabling us to implement changes which have resulted in increased consistency and quality.

We are now implementing MS2 across the plant.”

Synthomer Ltd (Click here for case study)

For further details of the MS2 Data Mining System, some newsletters describing its development are available:

Newsletter 1 - Understand the Process to Improve Profitability

Newsletter 2 - Number of MS2 Process Analytics Users Continues to Grow

Newsletter 3 - On-Line Analysis

Newsletter 4 - Real-time Diagnostics Project Starts

Training - We are now providing more training courses on MS2 Process Analytics:

• 10th April 2008 (Fully booked) - (click for info)
• 28th May 2008 ( Fully booked)
• 9th July 2008 (Fully booked)
• 9th September 2008 (Places Available)
• Further dates to be announced shortly. Early booking recommended.

Demonstrations - we regularly host demonstration events around the UK:

• Huddersfield, June 24 (click for info)
• NEC, Birmingham, October 28-30 (ChemEng08)

If you would like further details, please contact us on 01472 500306 or email cathy.oswin@ajm.co.uk

This project received funding from Yorkshire Forward (Yorkshire and Humber Regional Development Agency). Project part-financed by the European Union.