Artificial Intelligence For Industial Applications

Use of Artificial Intelligence In Industry
The Uses of Artificial Intelligence in Industry for

Energy savings and Process improvements
Prepared for Institute of Engineers Seminar

July 1997
Gerard McNulty C.Eng.F.I.E.I

Systems Optimisation Ltd
Systems Optimizations Ltd

E-Mail: gmcnulty@iol.ie
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Table of Contents
INTELLIGENT INDUSTRIAL SYSTEMS 3
BENEFITS OF ARTIFICIAL INTELLIGENCE 4
EXAMPLES OF ARTIFICIAL INTELLIGENCE IN INDUSTRY 5
USING ARTIFICIAL INTELLIGENCE TO IMPROVE BUSINESS PERFORMANCE 6
USING ARTIFICIAL INTELLIGENCE TO BECOME A WORLD CLASS MANUFACTURE 7
THE PRINCIPLES OF ARTIFICIAL INTELLIGENCE NEURAL NETWORKS 8
ARTIFICIAL INTELLIGENCE TECHNIQUES 9
DATA MINING IN INDUSTRY 10
DATA MINING TECHNIQUES 13
NEURAL NETWORKS 14
A THREE LAYER NEURAL NETWORK 14
COMBINING THE TECHNIQUES 15
EXAMPLE OF COMBINING THE TECHNIQUES: 15
INTELLIGENT SENSORS 16
SOFT SENSORS 17
INTELLIGENT SOFT SENSORS - EXAMPLES 18
SUPERVISORY CONTROL 19
ADVANCED CONTROL 20
SUMMARY OF THE BENEFITS OF USING NEURAL NETWORKS FOR 21
ADVANCED CONTROL APPLICATIONS 21
MONITORING AND DIAGNOSTIC ANALYSIS 22
OPTIMISATION USING GENETIC ALGORITHMS 23
GENETIC ALGORITHMS TO THE RESCUE 24
SCHEDULING USING ARTIFICIAL INTELLIGENCE 25
PROCESS MODELLING AND SIMULATION 26
KNOWLEDGE BASED SYSTEMS 27

LEARNING FROM DATA: 28

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Intelligent Industrial Systems

Artificial Intelligence is a general term used to describe various forms of
advanced computational and control techniques. These techniques utilise
special analysis processes, the basis of which is the neural network, that
mimic the natural reasoning method of the Human Brain.
Because neural networks analyse data more wisely then conventional

techniques, they can provide insights into problem domains previously not
possible to obtained or required vast computational power to do so. The net
result is improved process performance by intelligent control and optimisation,
increase sensor reliability through self validation, improved understanding of a
particular are of interest using data mining to discover the contributions of
various attributes to an outcome of interest - such as for example finished
product quality.
One benefit of using artificial intelligence includes better decision making and
hence increases company profits. Since your success is depending upon you
company’s accumulative intellectual ability compared to the competition,
artificial intelligence can provide you with the production edge, the quality
edge, the marketing edge and the ability to make the right decisions at the
right time.
Artificial Intelligence gives companies the power to “Prevent” problems not just
fix them, to “Analysis” data not just depend on experience, to focus on the
“Process” not the just the product, to provide for “Intelligent” localised process
control and optimisation not just process monitoring, to provide overall
company direction by “Intelligent Data Analysis” not just seat of pants
management. It’s the technology that we’ve all been waiting for-like
spreadsheets were to the accountant 10 years ago. What would they do
without spreadsheets today! - It’s unthinkable, isn’t it.
The falling cost of data has encouraged all of to collect more data then we can
analyse. Imagine if you could extract hidden patterns from this data or extract
valuable knowledge from it. Using these new techniques, you won’t need a
small band of statisticians to do it.
The use of Artificial Intelligent techniques in Industry will provide a new era in
process improvements that will result in a big reductions in process variability
and hence product quality improvements. To improve a process is to improve
a product. Improving process variability will reduce reject rates, cut costs, and
increase market share - the key to a successful business.

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Benefits of Artificial Intelligence

These are some of the benefits that can be obtained by using artificial
intelligence and advanced computational techniques in your business
♦ Increase Yield through data mining of the factors that effect output and
cause production bottlenecks
♦ Reduce energy usage through process optimisation of set points and

operational schedules along with intelligent control to produce stable and
responsive operation of processes and systems
♦ Reduced environmental impact by better understanding of process

parameters that contribute to emissions excursions
♦ Increase plant reliability through better understanding of the factors that

effect plant utilisation and the mean time between failures
♦ Reduce manpower requirements by intelligent controls
♦ Increase plant safety by ability of plant control system to learn from

experience and from intelligent operational practices
♦ Improved product quality through better understanding of factors that

effect quality along with their individual contributions to quality.
♦ Understand the factors effecting that effect machine downtime

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Examples of Artificial Intelligence in Industry

Artificial Intelligence or AI is not just for the PhD’s of this life; it’s a technology
that everyone can utilise to his or her benefits. Below are a few examples of
the type of industries that are using AI to remain on top. Remember that 70 of
the Fortune top 100 companies use AI. Here are some examples:
« Power station optimisation using genetic algorithms
« “Self Turning PID Loops to improve control system performance
« Expert system to model and validate process data
« Improve control of a refrigeration plant to optimise COP
« Steam System Optimisation ( Boilers and Turbines ) to reduce running

cost
« Prediction of product quality using neural networks in glass manufacture
« Furnace scheduling using expert systems to minimise energy costs
« Data Mining to reduce utility plant running costs on energy
« Process simulation to identify opportunities for improvements in energy

costs
« Data Mining to improve insight into process operation in chip

manufacture
« Optimisation routine to establish the most economical mix of ingredients

in glass manufacture
« Optimise Air Compressor installation to reduce electrical running costs

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Using artificial Intelligence to Improve Business Performance
Behavioural Traditional Artificial Intelligence

Style Approach Approach
Problems Fixing Preventing
Problem Solving Expert Based Based on data/systems
Analysis Experience Data
Focus Product Process
Behaviour Reactive Proactive
Reasoning Experience Based Statistically Based
Outlook Short Term Long Term
Decision Making Intuition Data Based
Direction Seat of pants Benchmarking /Metrics
Control Centralised Localised with AI
Improvements Dumb Automation Continuous Optimisation

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Using Artificial Intelligence to become a World Class

Manufacture
Your company survival is depending upon continuously growing your
business. We all know that growth in business means growth in sales of your
products. Growth in product sales is largely determined by your Customer
satisfaction. Customer satisfaction is governed by your product quality, price,
and delivery times. Quality, price and delivery are not just controlled by
chance but by the ability of your process to produce a high quality product,
free from defects, at the lowest possible cost and cycle times. Only a process
that is free from variations will be free from defects etc.
Artificial Intelligence will help your company reduce process variations and
hence educe defects, reduce operational costs and cycle times by learning
from experience. It will help to identify potential problems and provide
intelligent control and meaningful management information when you need it.
Simply put the quality of our products and services are a reflection of how
capable our processes really are. To measure product quality is to measure
process quality. Process quality is depending upon the control we have over
it.
Artificial Intelligence allows us to work smarter, not harder. This translates into
making fewer mistakes in all that we do, from the way we manufacture our
products to the way we organise our delivery. As we “data mine” and discover
and eliminate harmful sources of variation, our quality goes up and our
defects rates go down, we keep customers and grow our business.
The table below shows a relative means of benchmarking different

organisations, processes, and systems based on defects per unit where a unit
is any task, product, or physical entity. An invoice, a product made by a
machine etc.
Process Capability Defect per million Opportunity
2 308,500 ( Worst Eastern)

3 66,800 (Average Eastern)
4 6,200 ( Average Western )
5 2300 ( Good Western )
6 3.4 ( World Class )

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The Principles of Artificial Intelligence Neural Networks
If you hate statistics, then neural networks may be for you. When process
engineers are faced with complex multi-variable problems they have a number
of options:
« Use rules of thumb and manual intervention - but expect that a large
errors can result
« Wade through a mass of statistical and non-linear programming

techniques - if you remember how to do them and hope that the process
interactions you're trying to figure out are all linearly related to one
another and there only a few parameters that really matter.
« Try Neural Networks
A neural network takes its design from the current understanding of how the
nervous system of living things works. It learns, it can remember and it can
adjust, to new situations unlike the present “dumb” control systems around
today.

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Artificial Intelligence Techniques
« Data Mining for process and product improvements and management

information systems
« Intelligent sensors
« Soft Sensors
« Supervisory Control
« Advanced Control
« Monitoring and Diagnostic Analysis
« Optimisation
« Scheduling
« Process Modelling and Simulation
« Knowledge Based systems for product improvements and management

information systems

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Data Mining in Industry

The falling costs of data storage and processing power have encouraged
large and small organisations world-wide to accumulate vast quantities of
data. Data files are records of the behaviour or performance of machines,
processes, human resources, the environment, etc. Accumulating data files
has been perceived as gathering information, when in reality it can represent
information overload or clutter unless relationships and patterns in the data
can be derived. As such, data files can be viewed as reservoirs of knowledge
that can be “mined” to discover relationships, patterns and rules. The
objective of learning from data is to extract such knowledge from data files.
Learning from data falls into two categories - symbolic and connectionist
learning. Symbolic learning can generate rules and patterns from data files,
while connectionist learning generates networks of processing units from the
same data. By definition, symbolic learning generates results that are
understandable to the human user.
Connectionist learning builds numeric computer models from data, with typical
members of this latter category being Neural Networks. While the accuracy of
connectionist models can often be good, they suffer from a lack of
understandability - a 'black box’ solution, whereas the pattern rules and
decision trees can offer both accuracy and clarity.
There are two modes of learning - supervised and unsupervised learning.

Unsupervised learning can be used to discover any clustering or patterns in
data without specifying an outcome data field of interest using statistical
techniques that are limited in their power. Supervised learning is used to
generate rules and patterns linking a selected data field to other designated
data fields.
Learning from data can be considered an alternative knowledge engineering

strategy if the data represents records of expert decision making.
Alternatively, learning from performance data can derive new patterns and
relationships that improve our understanding of a certain process and
therefore enable us to make better decisions in the future.
Data models (rules and patterns) derived from historical data can be used to
predict the outcome of future events. This is called classification if the
outcome of interest is a discrete category such as 'good' or 'bad' in predicting
say glass product quality, while it is called prediction if the outcome of interest
is a numeric quantity such as 'price' when predicting the movement of the
value of stocks.
Hence, the overall objective is to derive decision trees, patterns rules and
neural networks from your data files. This will give you the ability to do more
“Prediction” and “Prevention” of process problems rather then the traditional
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“Detect” and “React.” Data mining aim is to establish the significant input
variables and than determine how they affect the output capability of the
process. For example, we can produce from such data a graphical decision
tree to profile any data field in relation to other data fields.
From this decision tree, we can produce pattern rules - for discrete outcomes
such as product quality were the contribution of various input variables or
attributes are determined - for example.
( if temp > 300 degc and % lead < 40% and product = “A” then quality =“C”(
prob 0.7 )
Data Mining may extract many such pattern rules from a data file. It may only
take a handful of deduced rules to provide invaluable information about you
process

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Data Mining in a Brewery
The Raw Data set used:

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Data Mining Techniques
Rule Induction
Analyse data using probabilistic rule induction. This is a statistical technique to

produce a generalised decision tree from a data set. A decision tree can be
generated by repeatedly splitting the given data set according to different
attributes until terminal points (leafs) are reached based on statistical
evidence of best split possible within certain confidence limits.
Decision Tree
The parameters or attributes that most effect an area of interest is at the top of
the tree.

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Neural Networks
« Neural Networks model a process by first using an example set of data
were the expected output is known for a given set of inputs. The network
weights are adjusted first randomly then many times until the network
produces the output required for the inputs.
« Then once trained it can be used to predict future outputs for new inputs
at high accuracy.
« Neural Networks provide high degree accuracy at the expense of

understandability - the black box solution.
A three Layer Neural Network

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Combining the techniques

The power of data mining, the modelling and prediction accuracy of neural
networks and the optimisation power of genetic algorithms can all be used to
provide an insight in process plant operations that were not easily obtainable
before.
Using data mining, industrial systems and processes can be “ Mined” to

obtaining important rules and patterns hidden in the data.
Neural Networks can be set to work to model the process and provide
predictions on process outcomes for different input values.
Genetic Optimisation techniques can use the information learned in the data
mining exercise to optimise an aspect of the process such as energy usage ,
cost of production or production rates
The patterns rules extracted during the data mining exercise can also be used
to develop an knowledge based system so that plant operators etc. can use
these rules to obtain an indication of the likely effects of process plant
modifications on performance.
Example of combining the techniques:
It is required to determine to design a system based on artificial intelligence

techniques that would enable a plastic manufacture to optimise the production
of a component while minimising rejects rate and operational costs. He has
several machines to choose from all with different running costs and nominal
production capacities.
The manufacture has collected historical data on the plant including process
data, quality data, energy, and other costs data.
This data is first transformed and then “mined” several times to determine
what factors effect different areas of Interest and to determine if any pattern
rules exist. This provides a better understanding of say the factors that effect
quality, running costs and output. Using these cost function is established to
include into a genetic algorithms to optimise plant running. A model of the
plant is built up using a NN system to show how the output may vary if a
process parameter is varied. The manufacture how has the tools to optimise
his production and minimise cost.

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Intelligent Sensors
Intelligent Sensors are different then ordinary sensors in that they have in -
built computers that can “ condition “ the data they receive to provide more
accurate sensor readings, hence provide for better process control. The
advantages of intelligent sensors are:
« They can linearise , average and smooth readings from the sensing
element
« They can correct and compensate for changes in other variables such as
pressure and temperature
« Store information in relation to services and calibrations etc.
« Carry out internal checks
The benefits of using “ Intelligent Sensors “ in your process include:
« Reduce process variability
« Finer control of processes
« Improved product quality
« Reduce running cost due to finer control
« Reduce downtime due to process failure caused by inaccurate sensor

measurements
« Validate sensor networks for faulty sensors.

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Soft Sensors
Soft Sensors use neural network modelling techniques to infer values that
cannot be measured directly or is uneconomical to measure by conventional
means.
Soft Sensor Example
A pharmaceutical Manufacture used such as system to provide an indication

of emission levels based on process parameters. This was done by mining
process past data and emission levels and producing a neural network that
predicted to 98% accuracy emission levels based on existing plant
parameters. So good was the predictions of the predictions that the EPA
accepted this method over expensive field testing and provided better
availability.
Soft Sensor Example
You can’t measure paper quality directly. There is usually insufficient

knowledge to develop theoretical models and simple linear regression can not
handle the non-linearity of the paper making processes
A neural network soft sensor was developed by data mining of past process
performance to determine what constituted good quality.

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Intelligent Soft Sensors - Examples

Chemicals:
« Predictive emission monitoring

« Ph Prediction in chemical manufacture
« Flowability of powder
« Colour
« Moisture
« Bubble Size
Food and Pharmaceuticals
« Odour
« Flavour
« Fermentation Rate
« Bubble size
Pulp and Paper

« Moisture
« Colour
« Viscosity
Industrial Utilities

« Ph
« BOD
« COD
« Conductivity

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Supervisory Control
Artificial Intelligence can be used to provide supervisory type control in an
open loop configuration to a production process or manufacturing system.
Using advanced reasoning and based on neural networks combined with

statistical analysis such systems can help operations in a variety of ways such
as:
« Detect key features in process trends
« Recognising patterns over time
« Filter out important information
« Manage information flow to operators
The net benefits of such systems include:
Help operators resolve production problems such as:
« Debottlenecking production operations
« Ensuring good production logistics
« Managing of resources such as personnel and energy

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Advanced Control
Artificial Intelligence can be used to provide intelligent real time control of
complex production processes using artificial neural networks that can learn
from previous data or on-line data:
Process data can be either achieved historical data or on-line data that has
been gathered into training sets. Over time, the training set accumulates
experience about the behaviour of the process during both normal and
abnormal operation. The resulting training set can, over time build a neural set
model that can identify dynamic, non - linear relationships in the data set,
hence identify process interactions that the process specialist can find it
difficult to describe analytically or with a set of rules.
The net result is a system that can:
« Detect non-linear relationships in process operations
« Detect shifts in process performances
« Determine the significance of individual inputs
« Derive probability estimates and other statistics about process

performance
« Validate Process Sensors
« Validate the performance of machinery
« Fault Classification

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Summary of the benefits of using Neural Networks for

Advanced Control Applications
« Neuro-fuzzy solutions can easily be implemented for control of non-

linear systems; performance levels comparable with those obtained by
means of classic solutions can be reached even with a poor knowledge
of the system transfer function.
« Intrinsic characteristics of neural networks are particularly attractive in

those cases where a mathematical model of the plant behaviour is not
available or when modifications of the system transfer, functions are
expected during the system lifetime.
« Neural network controllers can easily implement fuzzy controls with

advantages when dealing with non-linear or poorly defined problems;
their computing power seems to match demanding situations related to
complex real-time problems.
« Robustness of neural controls can be verified against system parameter

variations, which may be a critical factor for some applications.
« One of the most sophisticated uses of neural networks in process

engineering is set point optimisation. Neural network models can be
used in combination with neural optimisation techniques to advise on
best control settings to, for example reduce energy usage, increase
product yield (reduce SEC).

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Monitoring and diagnostic Analysis

A few years ago an automatic control system with a graphical interface was
sufficient to give you a competitive edge. These systems control the process
within particular parameters but lacked intelligence to turn the vast quantity of
process data collected into useful operator information that can iron out
process variation and minimise costly disruptions thus providing for consistent
process performance and product quality. Diagnostics involves identifying one
or more causes to a problem out of a large number of possibilities.
Intelligent Diagnostics can help you make the right decisions by analysing
production and process data the very only neural networks can. They provide
intelligent decision support the way your SCADA and MMI cannot.
Intelligent Diagnostic systems can provide the following benefits over

the more conventional type approaches:
Current Situation Improvement Possible With Benefits

Intelligent Diagnostics
Simple Alarms Filter and Correlate alarms Focused attention of
that separate cause from operators , fewer errors
effect
Manually executed On - line support for execution More consistent operations
of operating procedures
Programmed setpoint Setpoint changes based on Higher yield and
changes line diagnosis of process se productivity
Traditional, Off line On-Line SPC coupled with Improved product quality
statistical process control fault diagnosis

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Optimisation using Genetic Algorithms
Traditional Optimisation approaches
Software applications fall into two categories; analysis and synthesis. Analysis
applications are represented by the traditional input / output model of data
processing whereby input data is processed procedurally or heuristically to
generate the output data. Synthesis applications involve the reverse process
of deriving the input data required to generate certain desired outputs. This is
a difficult task since there are, in most cases, no formulae or rules to derive
inputs from outputs. This is further complicated by constraints imposed on the
acceptable values of input data. Optimisation is the process of deriving values
of input data that satisfy constraints and which results in the desired output
data. It can be a very difficult task especially in areas were the attributes are
many and the data set incomplete.
Optimisation problems can be solved by iterative trial and error whereby

different combinations of input values are tried in an attempt to arrive at the
desired output value. However, as the number of possible combinations
grows, it can become impractical to try all combinations to arrive at a solution
in a reasonable time. The problem becomes one of searching a massive
space of solutions looking for the optimal solution.
For example in the problem of optimising the order with which to manufacture
12 products there are (over 40,000,000) possible sequences to consider.
Rules of thumb can be used to narrow down the combinations worth
considering. However, in most cases, good rules are either not available or it
is difficult to capture the rule based trial and error strategy of experts.
Numerical optimisation techniques have been used to solve optimisation

problems and are now available in most advanced spreadsheet programs.
These techniques have the following limitations:
« They lend themselves to optimising independent numeric inputs from

which a desired output is calculated. They are less capable of optimising
problems involving sequencing or scheduling.
« They are "exploitation" and not "exploration" techniques. This means

that given a reasonable starting solution (a set of input values), the
numeric optimisation will converge to a near optimal solution. However,
they are not capable of exploring areas of space where good solutions
exist. This is because numeric optimisation techniques can often get
trapped in local optimal solutions.
« They are not suitable if the outcome cannot be explicitly calculated. For
example, when the outcome is a subjective assessment by an expert or
an observed performance.
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Genetic Algorithms to the rescue

Genetic Algorithms (GA) are techniques for solving optimisation problems
inspired by the theory of evolution and biogenetics. These algorithms are
excellent at exploring large spaces for optimal or near optimal solutions. The
basics of a genetic algorithm are:
« Representing possible solutions to problems as a string of parameters

(numbers). This string is called a chromosome and the parameters
within it are called genes.
« Randomly creating a number (generation) of these chromosomes.
« Calculating the effectiveness of each chromosome as a solution to the

problem then ranking the chromosomes in order of effectiveness (fitness
to survive).
« Repeating steps 3 to 4 for a number of cycles (generations).
The randomness of the above process allows the effective exploration of the
space of solutions. While the selection of effective solutions (chromosomes)
and the mixing of their genes allows the accumulation of good features from
partially good solutions. Therefore, genetic algorithms can explore large
domains and converge on good solutions relatively quickly. GA's also give a
powerful trade off between the time taken to reach a solution and the quality
of the solution. Typically, it is desirable to achieve a "good" solution in a short
time as opposed to an optimal solution that may require infinite time.
Genetic Algorithms can out-perform traditional mathematical approaches by

finding better more accurate solutions in fastest times, and without a team of
statisticians and computer scientists that may be required to solve some of the
typical optimisation problems found in many industries today.
Typical Optimisation problems in Industry:
« Optimise production
« Minimise energy
« Minimise waste
« Minimise Labour

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Scheduling using Artificial Intelligence

The object of scheduling is to order activities in time taking into account
constraints that are imposed on the system.
Scheduling using Artificial Intelligence can be a very powerful tool and it finds
applications in many industrial areas such as:
« Production Scheduling
« Material Logistics
« Resource Management
« Activity Reviews
« Process Re-Engineering
Scheduling software based on artificial intelligence can represent dynamic

events and respond based on real time information to process needs.
Examples of scheduling problems that have been managed with AI include:
« Scheduling production of many different brands of product based on

distribution requirements
« Managing electrical demand by scheduling plant running order

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Process Modelling and Simulation

Process Modelling and Simulation can provide many benefits over trial and
error real time operations which can both be costly and even dangerous.
Process modelling is possible using mathematical simulations of plant if the

process dynamics are fully understood and the equations that define the input
and output variables are know and are well defined. However, many
processes are very complex and difficult if not impossible to obtain reasonable
mathematical representation of the process dynamics.
Neural networks can model a process using previous history data of the
process, which in essence represents the past behaviour of the process.
Hence neural networks can model the actual response of a process not just
the theoretical response – which may be based on nominal design data.
Artificial Intelligence provides the answer by analysing previous process data

using neural networks; it is possible to “ Predict “ the process behaviour for a
given set of conditions.
Combining data mining, neural networks, process optimisation and diagnostic

procedures can result in a powerful “ Intelligent system “ that can provide a
company with the competitive edge.
Hence, process modelling can be used in many industrial processes to:
« Perform “ what if “ analysis to determine the impact of proposed process

changes in a particular process
« Determine the optimum mix of utility plant to minimise energy costs
« Optimise yields in processes
« Provide alternatives to full scale experiments to determine effects of

particular process changes
« Provide means of determine safety issues relating to process

modifications.
« Determine environmental impact of process changes
« Help in process re-engineering issues

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Knowledge Based systems

Knowledge Based Systems (KBS) have emerged over the last five years as
the most practical implementation of Artificial Intelligence. Practical because
they have been used to deliver business solutions on standard hardware
platforms. A strict definition of a Knowledge Based System is:
A computer program that:
« Contains human knowledge
« Is able to give advice by inferring from this knowledge
« Can justify the advice given
« The knowledge can be maintained independently of the program
Experts apply knowledge to solve problems. Generally speaking there are two
types of knowledge; declarative and procedural knowledge. Declarative
knowledge consists of facts, concepts, and relationships in a particular
domain. Procedural knowledge is information regarding the application of the
declarative knowledge in problem solving.
Knowledge can be also classified into surface and deep knowledge. Surface
knowledge combines declarative and procedural knowledge into problem-
solving heuristics (rules of thumb) enabling an expert to solve common
problems in a domain without formal analysis from first principles. These
heuristic rules are normally learned by experience without an understanding of
the underlying reasons. On the other hand, deep knowledge consists of
fundamental knowledge of a domain, including definitions, axioms, general
laws, principles, and causal relationships.
The objective of deep Knowledge Based Systems is to model complex

domains which humans find difficult to understand. These Knowledge Based
Systems will assist the experts in making decisions and add to their
knowledge.
Systems based on surface knowledge are intended to capture the problem

solving and decision-making skills of a human expert, in order to automate
this expertise.

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Learning From Data:
Organisations are increasingly facing situations where a Knowledge Based

System is required to carry out a certain task where the expert with the
expertise is no longer available or where the expert has limited expertise.
However, organisations may hold a large database of records representing
case history data of previous decision making or data representing the verdict
of history.
Data Mining can be considered as an alternative knowledge learning strategy

when the data in question contains history of past process performance (from
which a model of the process can be formed) or history of past decision
making from which valuable information concerning the decision making
process can be obtained.

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Use of Artificial Intelligence In Industry

The Uses of Artificial Intelligence in Industry for

Prepared for Institute of Engineers Seminar

Gerard McNulty C.Eng.F.I.E.I

Systems Optimizations Ltd

INTELLIGENT INDUSTRIAL SYSTEMS 3

BENEFITS OF ARTIFICIAL INTELLIGENCE 4

EXAMPLES OF ARTIFICIAL INTELLIGENCE IN INDUSTRY 5

USING ARTIFICIAL INTELLIGENCE TO IMPROVE BUSINESS PERFORMANCE 6

USING ARTIFICIAL INTELLIGENCE TO BECOME A WORLD CLASS MANUFACTURE 7

THE PRINCIPLES OF ARTIFICIAL INTELLIGENCE NEURAL NETWORKS 8

ARTIFICIAL INTELLIGENCE TECHNIQUES 9

DATA MINING IN INDUSTRY 10

DATA MINING TECHNIQUES 13

INTELLIGENT SOFT SENSORS - EXAMPLES 18

SUMMARY OF THE BENEFITS OF USING NEURAL NETWORKS FOR 21

ADVANCED CONTROL APPLICATIONS 21

MONITORING AND DIAGNOSTIC ANALYSIS 22

OPTIMISATION USING GENETIC ALGORITHMS 23

GENETIC ALGORITHMS TO THE RESCUE 24

SCHEDULING USING ARTIFICIAL INTELLIGENCE 25

PROCESS MODELLING AND SIMULATION 26

KNOWLEDGE BASED SYSTEMS 27

Systems Optimizations Ltd

Intelligent Industrial Systems

Because neural networks analyse data more wisely then conventional

Systems Optimizations Ltd

Benefits of Artificial Intelligence

♦ Reduce energy usage through process optimisation of set points and

♦ Reduced environmental impact by better understanding of process

♦ Increase plant reliability through better understanding of the factors that

♦ Reduce manpower requirements by intelligent controls

♦ Increase plant safety by ability of plant control system to learn from

♦ Improved product quality through better understanding of factors that

♦ Understand the factors effecting that effect machine downtime

Systems Optimizations Ltd

Examples of Artificial Intelligence in Industry

« Power station optimisation using genetic algorithms

« “Self Turning PID Loops to improve control system performance

« Expert system to model and validate process data

« Improve control of a refrigeration plant to optimise COP

« Steam System Optimisation ( Boilers and Turbines ) to reduce running

« Prediction of product quality using neural networks in glass manufacture

« Furnace scheduling using expert systems to minimise energy costs

« Data Mining to reduce utility plant running costs on energy

« Process simulation to identify opportunities for improvements in energy

« Data Mining to improve insight into process operation in chip

« Optimisation routine to establish the most economical mix of ingredients

« Optimise Air Compressor installation to reduce electrical running costs

Systems Optimizations Ltd

Using artificial Intelligence to Improve Business Performance

Behavioural Traditional Artificial Intelligence

Problems Fixing Preventing

Problem Solving Expert Based Based on data/systems

Analysis Experience Data

Focus Product Process

Behaviour Reactive Proactive

Reasoning Experience Based Statistically Based

Outlook Short Term Long Term

Decision Making Intuition Data Based

Direction Seat of pants Benchmarking /Metrics

Control Centralised Localised with AI