Process optimization is the discipline of adjusting a process so as to make the best or most effective use of some specified set of parameters without violating some constraint. Common goals are minimizing cost and maximizing throughput and/or efficiency. Process optimization is one of the major quantitative tools in industrial decision making.
When optimizing a process, the goal is to maximize one or more of the process specifications, while keeping all others within their constraints. This can be done by using a process mining tool, discovering the critical activities and bottlenecks, and acting only on them.
Areas
Fundamentally, there are three parameters that can be adjusted to affect optimal performance. They are:
Equipment optimization
The first step is to verify that the existing equipment is being used to its fullest advantage by examining operating data to identify equipment bottlenecks.
Operating procedures
Operating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant manually.
Control optimization
In a typical processing plant, such as a chemical plant or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow.
If the control loop is not properly designed and tuned, the process runs below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely. For each control loop to run optimally, identification of sensor, valve, and tuning problems is important. It has been well documented that over 35% of control loops typically have problems.[citation needed]
The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.
Control theory is a field of control engineering and applied mathematics that deals with the control of dynamical systems in engineered processes and machines. The objective is to develop a model or algorithm governing the application of system inputs to drive the system to a desired state, while minimizing any delay, overshoot, or steady-state error and ensuring a level of control stability; often with the aim to achieve a degree of optimality.
Mathematical optimization or mathematical programming is the selection of a best element, with regard to some criterion, from some set of available alternatives. It is generally divided into two subfields: discrete optimization and continuous optimization. Optimization problems arise in all quantitative disciplines from computer science and engineering to operations research and economics, and the development of solution methods has been of interest in mathematics for centuries.
Reinforcement learning (RL) is an interdisciplinary area of machine learning and optimal control concerned with how an intelligent agent ought to take actions in a dynamic environment in order to maximize the cumulative reward. Reinforcement learning is one of three basic machine learning paradigms, alongside supervised learning and unsupervised learning.
The theory of constraints (TOC) is a management paradigm that views any manageable system as being limited in achieving more of its goals by a very small number of constraints. There is always at least one constraint, and TOC uses a focusing process to identify the constraint and restructure the rest of the organization around it. TOC adopts the common idiom "a chain is no stronger than its weakest link". That means that organizations and processes are vulnerable because the weakest person or part can always damage or break them, or at least adversely affect the outcome.
In computer science, program optimization, code optimization, or software optimization is the process of modifying a software system to make some aspect of it work more efficiently or use fewer resources. In general, a computer program may be optimized so that it executes more rapidly, or to make it capable of operating with less memory storage or other resources, or draw less power.
Performance tuning is the improvement of system performance. Typically in computer systems, the motivation for such activity is called a performance problem, which can be either real or anticipated. Most systems will respond to increased load with some degree of decreasing performance. A system's ability to accept higher load is called scalability, and modifying a system to handle a higher load is synonymous to performance tuning.
In computer science and mathematical optimization, a metaheuristic is a higher-level procedure or heuristic designed to find, generate, tune, or select a heuristic that may provide a sufficiently good solution to an optimization problem or a machine learning problem, especially with incomplete or imperfect information or limited computation capacity. Metaheuristics sample a subset of solutions which is otherwise too large to be completely enumerated or otherwise explored. Metaheuristics may make relatively few assumptions about the optimization problem being solved and so may be usable for a variety of problems.
Model predictive control (MPC) is an advanced method of process control that is used to control a process while satisfying a set of constraints. It has been in use in the process industries in chemical plants and oil refineries since the 1980s. In recent years it has also been used in power system balancing models and in power electronics. Model predictive controllers rely on dynamic models of the process, most often linear empirical models obtained by system identification. The main advantage of MPC is the fact that it allows the current timeslot to be optimized, while keeping future timeslots in account. This is achieved by optimizing a finite time-horizon, but only implementing the current timeslot and then optimizing again, repeatedly, thus differing from a linear–quadratic regulator (LQR). Also MPC has the ability to anticipate future events and can take control actions accordingly. PID controllers do not have this predictive ability. MPC is nearly universally implemented as a digital control, although there is research into achieving faster response times with specially designed analog circuitry.
A chemical plant is an industrial process plant that manufactures chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation and or separation of materials. Chemical plants use specialized equipment, units, and technology in the manufacturing process. Other kinds of plants, such as polymer, pharmaceutical, food, and some beverage production facilities, power plants, oil refineries or other refineries, natural gas processing and biochemical plants, water and wastewater treatment, and pollution control equipment use many technologies that have similarities to chemical plant technology such as fluid systems and chemical reactor systems. Some would consider an oil refinery or a pharmaceutical or polymer manufacturer to be effectively a chemical plant.
In control theory, quantitative feedback theory (QFT), developed by Isaac Horowitz, is a frequency domain technique utilising the Nichols chart (NC) in order to achieve a desired robust design over a specified region of plant uncertainty. Desired time-domain responses are translated into frequency domain tolerances, which lead to bounds on the loop transmission function. The design process is highly transparent, allowing a designer to see what trade-offs are necessary to achieve a desired performance level.
Trajectory optimization is the process of designing a trajectory that minimizes some measure of performance while satisfying a set of constraints. Generally speaking, trajectory optimization is a technique for computing an open-loop solution to an optimal control problem. It is often used for systems where computing the full closed-loop solution is not required, impractical or impossible. If a trajectory optimization problem can be solved at a rate given by the inverse of the Lipschitz constant, then it can be used iteratively to generate a closed-loop solution in the sense of Caratheodory. If only the first step of the trajectory is executed for an infinite-horizon problem, then this is known as Model Predictive Control (MPC).
Scheduling is the process of arranging, controlling and optimizing work and workloads in a production process or manufacturing process. Scheduling is used to allocate plant and machinery resources, plan human resources, plan production processes and purchase materials.
A surrogate model is an engineering method used when an outcome of interest cannot be easily measured or computed, so an approximate mathematical model of the outcome is used instead. Most engineering design problems require experiments and/or simulations to evaluate design objective and constraint functions as a function of design variables. For example, in order to find the optimal airfoil shape for an aircraft wing, an engineer simulates the airflow around the wing for different shape variables. For many real-world problems, however, a single simulation can take many minutes, hours, or even days to complete. As a result, routine tasks such as design optimization, design space exploration, sensitivity analysis and "what-if" analysis become impossible since they require thousands or even millions of simulation evaluations.
In control theory a self-tuning system is capable of optimizing its own internal running parameters in order to maximize or minimize the fulfilment of an objective function; typically the maximization of efficiency or error minimization.
Stochastic control or stochastic optimal control is a sub field of control theory that deals with the existence of uncertainty either in observations or in the noise that drives the evolution of the system. The system designer assumes, in a Bayesian probability-driven fashion, that random noise with known probability distribution affects the evolution and observation of the state variables. Stochastic control aims to design the time path of the controlled variables that performs the desired control task with minimum cost, somehow defined, despite the presence of this noise. The context may be either discrete time or continuous time.
IOSO is a multiobjective, multidimensional nonlinear optimization technology.
SIMUL8 simulation software is a product of the SIMUL8 Corporation used for simulating systems that involve processing of discrete entities at discrete times. This program is a tool for planning, design, optimization and reengineering of real production, manufacturing, logistic or service provision systems. SIMUL8 allows its user to create a computer model, which takes into account real life constraints, capacities, failure rates, shift patterns, and other factors affecting the total performance and efficiency of production. Through this model it is possible to test real scenarios in a virtual environment, for example simulate planned function and load of the system, change parameters affecting system performance, carry out extreme-load tests, verify by experiments the proposed solutions and select the optimal solution. A common feature of problems solved in SIMUL8 is that they are concerned with cost, time and inventory.
Design Automation usually refers to electronic design automation, or Design Automation which is a Product Configurator. Extending Computer-Aided Design (CAD), automated design and Computer-Automated Design (CAutoD) are more concerned with a broader range of applications, such as automotive engineering, civil engineering, composite material design, control engineering, dynamic system identification and optimization, financial systems, industrial equipment, mechatronic systems, steel construction, structural optimisation, and the invention of novel systems.
Theory of constraints (TOC) is an engineering management technique used to evaluate a manageable procedure, identifying the largest constraint (bottleneck) and strategizing to reduce task time and maximise profit. It assists in determining what to change, when to change it, and how to cause the change. The theory was established by Dr. Eliyahu Goldratt through his 1984 bestselling novel The Goal. Since this time, TOC has continued to develop and evolve and is a primary management tool in the engineering industry. When Applying TOC, powerful tools are used to determine the constraint and reduce its effect on the procedure, including:
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