MS2 Process Analysis System

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.

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.