Umetrics Suite Blog

Get more control of your production processes: Introducing SIMCA 15 and SIMCA-online 15

November 21, 2017

In a previous blog post we discussed how SIMCA-online can help you make complex data simple and ensure that you get maximum value from your data.

In this blog post we will introduce a number of benefits of the newly released versions of SIMCA 15 and SIMCA-online 15. To mention just a few things, you get a much improved ability to model and control complete processes, including processes with a very high complexity. You also get a much better connection between SIMCA and SIMCA-online so that information can flow in both ways.

Simca15-Simca-online 15 improve ability to model and control processes

A quick look: New features in SIMCA 15 and SIMCA-online 15

With the new versions you can do the following:

  • Transfer data seamlessly between SIMCA 15 and SIMCA-online 15
  • Model and monitor complex batch processes, including sub-batches and reworks
  • Handle continuous production processes with changing speed by use of dynamic lagging
  • Prepare SIMCA-online configurations already in SIMCA
  • Self-service advanced analytics monitoring models directly in SIMCA-online
  • Get e-mail notifications when process upsets occur
  • Support for batch production that lacks context such as batch start and stop time
  • Monitor data and information from the process without advanced analytics (SPC charts)
  • Get a production overview on the go with a thin client (web client)

Now let’s have a closer look at the new features that will improve the control of your production processes:

Transfer data seamlessly between SIMCA 15 and SIMCA-online 15

With the new versions SIMCA 15 and SIMCA-online 15 you get a more seamless integration between SIMCA and SIMCA-online, which will give you a streamlined workflow and faster model updating. You can create a model in SIMCA and transfer it – with a partly pre-populated SIMCA-online configuration – seamlessly to SIMCA-online, and you can also transfer a model from SIMCA-online to SIMCA for model maintenance. SIMCA project files are version managed on the SIMCA-online server.

Model and monitor complex batch processes, including sub-batches and reworks

A new feature inside SIMCA 15 and SIMCA-online 15 is phase iteration support, which means that you have an improved ability to model and monitor complex batch processes that include process steps, or phases, that are repeated several times in the same batch. For instance phase reworks or when a batch is split into sub-batches for parallel or serial processing.

For example, SIMCA and SIMCA-online can now handle situations where you have a rework cycle at process failures, where batches are looped back into a rework cycle or second iteration.

SIMCA 15 Batches enter a rework cycle after quality check

Batches enter a rework cycle after a quality check.

In some processes, batches are split into sub-batches which are processed separately – in parallel or in series. SIMCA and SIMCA-online can now handle these situations with phase iteration support.

batches divided into sub-batches - simca15

Batches divided into sub-batches and processed in parallel or in series.

Handle continuous production processes with changing speed by use of dynamic lagging

Continuous processes can have various speed. The previous versions of SIMCA support classical lagging, which is of relevance when the process speed is the same throughout the entire production. With SIMCA 15 you get support for dynamic lagging, which is relevant if the process speed varies. You also get a better visualization with respect to time. In the control charts, you will for example be able to see time gaps easier, which is illustrated in the image below.

visualization of time gaps in statistical process control (SPC) charts

Visualization of time gaps in statistical process control (SPC) charts.

Prepare SIMCA-online configurations already in SIMCA

Another new feature is that you can prepare SIMCA projects for SIMCA-online configuration already in SIMCA. You can for example set warning limits, alarms, and trigger levels already when building the multivariate model inside SIMCA. All information will be stored in the SIMCA project file (the USP file) and will be transferred directly to SIMCA-online for real-time usage.

Self-service advanced analytics monitoring models directly in SIMCA-online

Initial monitoring models can now be created directly in SIMCA-online to get a first idea of your process. SIMCA-online will automatically create an initial monitoring model based on your process data.

SIMCA-online monitoring model

Monitoring model created directly in SIMCA-online.

Get e-mail notifications when process upsets occur

SIMCA 15 and SIMCA-online 15 include an e-mail notification system. The notification system will send e-mail based alarms in risk situations, for example when there are upsets in the production process or when there are other issues that may impact your production, such as server problems or when the monitoring model has for some reason stopped executing.

Support for batch production that lacks context such as batch start and stop time

Sometimes the batch process lacks a batch context or it is difficult to get hold of one. Now SIMCA-online will be possible to use, even without that information, since these contexts can be created or recreated within SIMCA-online in the all new batch context generator. This will allow advanced analytics to be deployed on any type of batch process that has current or historical data available in real-time.

Monitor data and information from the process without advanced analytics (SPC charts)

It is now possible to monitor your process also without an advanced data analytics model. This will allow the user to see how a preset number of variables vary over time. This will help the user to find the root-cause for issues in variables that are not directly associated with a specific model.

Get a production overview on the go with a thin client (web client)

There is a brand new web client for SIMCA-online which will simplify future upgrades of the SIMCA-online system as well as reduce the maintenance cost for the system. With a web browser, anyone with access rights can now connect from any device to the SIMCA-online server.

simca15 production-overview-thin-client

Production overview in the thin client.

Try out the new features

Do you want to have a first taste of SIMCA 15 and SIMCA-online 15? Try out the new features and get a better understanding with a free trial.

Get a Free Trial of SIMCA

 

Topics: SIMCA, Umetrics News

Marie Wensley

Written by Marie Wensley

Marketing Manager at Sartorius Stedim Data Analytics

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