The Golden Batch for Manufacturers
Process Digital Twins help manufacturers meet the challenges of fast-changing consumer demand, regulatory requirements and looming generation knowledge gap. Process Digital Twins create models of ‘the best way’ to run a process in a given environment – often referred to as ‘the golden batch’. By identifying the most optimal process to manufacture a given product, plant operators can ensure they are consistently delivering against quality, cost and volume objectives.
Most customers have continuous improvement teams driving initiatives to improve product quality, reduce manufacturing process variation and costs.
And while 90% of manufacturers are already investing or planning to invest in predictive capabilities in the next five years, and 75% are investing in machine learning, Process Digital Twins are very early in their application compared to Network and Asset twins. This is due in part to the high variability of manufacturing processes (equipment, scale, environment, complexity and poor data quality).
Through our CSense Operations Performance Management solutions, GE Digital has already delivered Process Digital Twins in multiple industries, including Mining, Food & Beverage, Oil & Gas and Power Generation, and Water & Wastewater industries.
Competitive Power Ventures (CPV) uses Operations Performance Management (OPM) software to drive significant operational production gains. CPV increased use of the gas turbine’s peak fire service by 10x without impacting its maintenance interval and has improved the accuracy of Day Ahead capacity predictions by 2%. Manual Excel-based processes have been replaced with AI/ Machine Learning algorithms, enabling CPV to compile weather data and plant status to more accurately predict the hourly capacity and heat rate of their plants.
OPM software creates Process Digital Twins of processes and assets to help team members more accurately predict day-ahead and intraday plant capacity and heat rate. This helps CPV to make the most profitable use of that capacity through improved commitment preparation, fuel nomination and dispatch planning.