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Contributions to the Use of Statistical Methods for Improving Continuous Production
Luleå University of Technology, Department of Business Administration, Technology and Social Sciences, Business Administration and Industrial Engineering. (Quality Technology)
2017 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Complexity of production processes, high computing capabilities, and massive datasets characterize today’s manufacturing environments, such as those of continuous andbatch production industries. Continuous production has spread gradually acrossdifferent industries, covering a significant part of today’s production. Commonconsumer goods such as food, drugs, and cosmetics, and industrial goods such as iron,chemicals, oil, and ore come from continuous processes. To stay competitive intoday’s market requires constant process improvements in terms of both effectivenessand efficiency. Statistical process control (SPC) and design of experiments (DoE)techniques can play an important role in this improvement strategy. SPC attempts toreduce process variation by eliminating assignable causes, while DoE is used toimprove products and processes by systematic experimentation and analysis. However,special issues emerge when applying these methods in continuous process settings.Highly automated and computerized processes provide an exorbitant amount ofserially dependent and cross-correlated data, which may be difficult to analyzesimultaneously. Time series data, transition times, and closed-loop operation areexamples of additional challenges that the analyst faces.The overall objective of this thesis is to contribute to using of statisticalmethods, namely SPC and DoE methods, to improve continuous production.Specifically, this research serves two aims: [1] to explore, identify, and outlinepotential challenges when applying SPC and DoE in continuous processes, and [2] topropose simulation tools and new or adapted methods to overcome the identifiedchallenges.The results are summarized in three appended papers. Through a literaturereview, Paper A outlines SPC and DoE implementation challenges for managers,researchers, and practitioners. For example, problems due to process transitions, themultivariate nature of data, serial correlation, and the presence of engineering processcontrol (EPC) are discussed. Paper B further explores one of the DoE challengesidentified in Paper A. Specifically, Paper B describes issues and potential strategieswhen designing and analyzing experiments in processes operating under closed-loopcontrol. Two simulated examples in the Tennessee Eastman (TE) process simulatorshow the benefits of using DoE techniques to improve and optimize such industrialprocesses. Finally, Paper C provides guidelines, using flow charts, on how to use thecontinuous process simulator, “The revised TE process simulator,” run with adecentralized control strategy as a test bed for developing SPC and DoE methods incontinuous processes. Simulated SPC and DoE examples are also discussed.

Place, publisher, year, edition, pages
Luleå: Luleå University of Technology, 2017. , p. 109
Series
Licentiate thesis / Luleå University of Technology, ISSN 1402-1757
Keywords [en]
Process industry, Continuous process, Statistical process control, Design of experiments, Process improvements, Simulation tool, Engineering process control
National Category
Other Engineering and Technologies
Research subject
Quality Technology and Management
Identifiers
URN: urn:nbn:se:ltu:diva-66256ISBN: 978-91-7583-996-7 (print)ISBN: 978-91-7583-997-4 (electronic)OAI: oai:DiVA.org:ltu-66256DiVA, id: diva2:1152534
Presentation
2017-11-27, A109, Luleå University of Technology, Luleå, 13:00 (English)
Opponent
Supervisors
Funder
Swedish Research Council, 4731241Available from: 2017-10-25 Created: 2017-10-25 Last updated: 2017-11-27Bibliographically approved
List of papers
1. Managerial implications for improvingcontinuous production processes
Open this publication in new window or tab >>Managerial implications for improvingcontinuous production processes
2017 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Data analytics remains essential for process improvement and optimization. Statistical process control and design of experiments are among the most powerful process and product improvement methods available. However, continuous process environments challenge the application of these methods. In this article, we highlight SPC and DoE implementation challenges described in the literature for managers, researchers and practitioners interested in continuous production process improvement. The results may help managers support the implementation of these methods and make researchers and practitioners aware of methodological challenges in continuous process environments.

Keywords
Productivity, Statistical tools, Continuous processes
National Category
Engineering and Technology Reliability and Maintenance
Research subject
Quality Technology and Management
Identifiers
urn:nbn:se:ltu:diva-65568 (URN)
Conference
24th EurOMA Conference, Edinburgh, July 1-5, 2017
Projects
Statistical Methods for Improving Continuous Production
Funder
Swedish Research Council, 4731241
Available from: 2017-09-11 Created: 2017-09-11 Last updated: 2018-03-26Bibliographically approved
2. Exploring the Use of Design of Experiments in Industrial Processes Operating Under Closed-Loop Control
Open this publication in new window or tab >>Exploring the Use of Design of Experiments in Industrial Processes Operating Under Closed-Loop Control
2017 (English)In: Quality and Reliability Engineering International, ISSN 0748-8017, E-ISSN 1099-1638, Vol. 33, no 7, p. 1601-1614Article in journal (Refereed) Published
Abstract [en]

Industrial manufacturing processes often operate under closed-loop control, where automation aims to keep important process variables at their set-points. In process industries such as pulp, paper, chemical and steel plants, it is often hard to find production processes operating in open loop. Instead, closed-loop control systems will actively attempt to minimize the impact of process disturbances. However, we argue that an implicit assumption in most experimental investigations is that the studied system is open loop, allowing the experimental factors to freely affect the important system responses. This scenario is typically not found in process industries. The purpose of this article is therefore to explore issues of experimental design and analysis in processes operating under closed-loop control and to illustrate how Design of Experiments can help in improving and optimizing such processes. The Tennessee Eastman challenge process simulator is used as a test-bed to highlight two experimental scenarios. The first scenario explores the impact of experimental factors that may be considered as disturbances in the closed-loop system. The second scenario exemplifies a screening design using the set-points of controllers as experimental factors. We provide examples of how to analyze the two scenarios

Place, publisher, year, edition, pages
John Wiley & Sons, 2017
National Category
Reliability and Maintenance
Research subject
Quality Technology and Management
Identifiers
urn:nbn:se:ltu:diva-61872 (URN)10.1002/qre.2128 (DOI)000413906100024 ()2-s2.0-85012952363 (Scopus ID)
Note

Validerad;2017;Nivå 2;2017-11-03 (andbra)

Available from: 2017-02-08 Created: 2017-02-08 Last updated: 2018-03-26Bibliographically approved
3. The Revised Tennessee Eastman Process Simulator as Testbed for SPC and DoE Methods
Open this publication in new window or tab >>The Revised Tennessee Eastman Process Simulator as Testbed for SPC and DoE Methods
2018 (English)In: Quality Engineering, ISSN 0898-2112, E-ISSN 1532-4222Article in journal (Refereed) Epub ahead of print
Abstract [en]

Engineering process control and high-dimensional, time-dependent data present great methodological challenges when applying statistical process control (SPC) and design of experiments (DoE) in continuous industrial processes. Process simulators with an ability to mimic these challenges are instrumental in research and education. This article focuses on the revised Tennessee Eastman process simulator providing guidelines to use it as a testbed for SPC and DoE methods. We provide flowcharts that will help new users get started in the Simulink/Matlab framework, and illustrate how to run stochastic simulations for SPC and DoE applications using the Tennessee Eastman process.

Place, publisher, year, edition, pages
Taylor & Francis, 2018
Keywords
Simulation, Tutorial, Statistical process control, Design of experiments, Engineering process control, Closed-loop
National Category
Other Engineering and Technologies Reliability and Maintenance
Research subject
Quality Technology and Management
Identifiers
urn:nbn:se:ltu:diva-66255 (URN)10.1080/08982112.2018.1461905 (DOI)
Projects
Statistical Methods for Improving Continuous Production
Available from: 2017-10-25 Created: 2017-10-25 Last updated: 2018-04-11

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