On Line Process and Regulator Control (Detailed Version)

Venkatesan Gopalachary

Abstract

Modern manufacturing practices and advancement in process control technology are accompanied and faces two problem, namely, (i) to provide quality goods and services and (ii) to contend with limited resources. Statistical modelling methods can provide broad and effective means to address this problem. Process control practitioners, in the Statistical Process Control (SPC) and the Automatic Process Control (APC) areas have endeavoured to integrate SPC and APC for more than half a century. This paper on 'on-line' integrated statistical process and regulator control uses existing process control literature and research results in stochastic process control theory and synthesises in a concise and effective model building manner, an inductive-deductive approach to integrate SPC and APC at their interface. This paper explains an integrated statistical process and regulator product quality control methodology through the use of basic mathematical and statistical models which is later extended to 'on-line' computer-based regulator control using generic mathematical and stochastic models. There seems to exist a wide gap in the existing methodologies which show a constructive and practical method for 'on-line' process and quality control. To this end, this paper makes efforts by the integration of SPC and APC tools and techniques for 'on-line' computer regulator process control to minimise variance of the outgoing product quality. It has been proven and detailed literature research shows that time series modelling methods are useful (i) to characterise and (ii) to forecast time dependent processes in which data are gathered according to some time order, and account for the time related correlation that is present in recorded values. It is possible to automate model building by incorporating sophisticated statistical control procedures and feedback control rules for decision making with the use of modern high-speed computers. Use of computers is order of the day and as almost all modern processes are computer monitored, direct-digital controlled (DDC) with the modern SCADA and DCS. Keywords: SPC, APC, Integration, dynamic, Stochastic, discrete, feedback control stability.

On Line Process and Regulator Control (Detailed Version)

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