Machine Learning based Industrial Automation Project -- 2

The primary aim is to develop an AI solution, incorporating predictive modeling for cement producers, to enhance asset performance and reduce maintenance costs. The AI-based Optimizer solution empowers plant managers and teams to make informed decisions based on trends, fostering better goal definition, adherence to best practices, and identification of opportunities through data-driven evidence. Framework: The project will commence with a comprehensive study of the existing process workflow, effectively monitoring and improving ongoing operations. Key Performance Indicators (KPIs) like Productivity, Equipment Reliability, System Utilization, Mean Time Between Failures, and Stoppage Frequency will evaluate plant performance. Identifying Potential Failures and Proactive Measures: The dashboard's proactive approach enables early identification of potential failures and their interdependencies. Armed with this information, operators can take proactive measures to prevent downtime and optimize overall system performance. Utilizing Neural Network for Main Machinery Failure Prediction and Optimization: The proposed model will leverage Neural Networks, integrating past inspection findings and auxiliary machinery availability data to predict and optimize main machinery failures. Employing pattern recognition, clustering, function approximation, time series analysis, prediction, and validation techniques will ensure accurate predictions. Dashboard Visualization: The dashboard will effectively visualize the interdependencies of equipment in the central Cement Mill section using Principal Component Analysis (PCA). Historical equipment data presented through time series graphs will help identify patterns and trends. Additionally, correlations between equipment performances based on past data will be displayed. Visualizing Causal Effects and Failure Probabilities: The dashboard will demonstrate how the performance of one equipment influences others, identifying critical dependencies and vulnerable points in the system. Moreover, it will display failure probabilities at different process stages, utilizing predictive analytics to assess the likelihood of equipment failures. Key Performance Indicators (KPIs) Reinforcement: The evaluation process will reiterate the definitions of essential KPIs, including Productivity Factor (PF), Utilization Factor (UF), Reliability Factor (RF), and Incident Stoppage Frequency (ISF). These metrics will provide valuable insights for continuous improvement.