Factory Harmonizer
Why choose soft sensors?
Understanding every aspect of your production process is key to staying ahead. Soft sensors enable you to:
- Gain Real-Time Insights: Get continuous visibility into your production parameters, allowing for immediate adjustments and optimizations.
- Reduce Costs: Minimize the need for expensive testing and reduce unnecessary consumption with the gained information.
- Improve Process Efficiency: Optimize your production process by accurately estimating key variables, leading to improved quality, reduced waste, and lower energy consumption.
How soft sensors work
Soft sensors are built by combining process knowledge with advanced data analytics. Here’s how we do it:
We start by gathering historical process data from various sources, such as Distributed Control Systems (DCS), Manufacturing Execution Systems (MES), and laboratory data.
Collected data is cleaned, normalized, and filtered to remove any noise or inconsistencies, ensuring high-quality inputs for model development.
Using machine learning algorithms, we create models that predict the values of difficult-to-measure variables based on the available data. These models are rigorously tested to ensure accuracy and reliability.
Once the models are refined, they undergo thorough validation to ensure they perform as expected in real-world conditions. After validation, the models are deployed into your production environment, where they continuously provide real-time estimates.
Overcoming Common Challenges
While the benefits of soft sensors are clear, successful implementation requires careful planning and execution. At SimAnalytics, we address the challenges of soft sensor design by:
- Ensuring Data Quality: We perform a comprehensive Data Health Check before deployment to ensure only relevant and high-quality data is used in the models.
- Customizing Models: Each soft sensor is tailored to your specific process needs, ensuring that the models provide the most accurate and useful insights. We ensure a good dialogue with your process experts throughout the development process.
- Seamless Integration: Our soft sensors use our advanced Factory Harmonizer Data Platform to smoothly integrate with your existing systems. This also enables updates without disturbances to your production.