IBATCH interactive batch operations system enabling operational excellence and competency transition

An apparatus comprising:

• a memory;
• and
• a processor operably coupled to the memory, the processor configured to:
• collect data related to a physical batch process running on physical equipment within a batch processing facility, the data collected from different departments within the batch processing facility into a common data repository;
• build a knowledge repository over time from the collected data, the knowledge repository built at least in part using a self-learning algorithm;
• transform the collected data in the common data repository using the knowledge repository;
• exploit the transformed data in the common data repository;
• determine a best possible alternative for continued operation of the physical batch process using a digital twin that uses the exploited data to simulate the physical batch process in order to visualize a number of possible alternatives for continued operation of the physical batch process, where the best possible alternative is either re-routing a current product or monitoring the batch without altering the physical batch process in case an issue is naturally resolved;
• provide a visualization of the best possible alternative of the physical batch process using the digital twin;
• and
• operate the physical batch process using the determined best possible alternative on the physical equipment within the batch processing facility.

A non-transitory computer readable medium containing instructions that, when executed by at least one processing device, cause the at least one processing device to:

• collect data related to a physical batch process running on physical equipment within a batch processing facility, the data collected from different departments within a batch processing facility into a common data repository;
• build a knowledge repository over time from the collected data, the knowledge repository built at least in part using a self-learning algorithm;
• transform the collected data in the common data repository using the knowledge repository;
• exploit the transformed data in the common data repository;
• determine a best possible alternative for continued operation of the physical batch process using a digital twin that uses the exploited data to simulate the physical batch process in order to visualize a number of possible alternatives for continued operation of the physical batch process;
• provide a visualization of the best possible alternative of the physical batch process using the digital twin;
• and
• operate the physical batch process using the determined best possible alternative on the physical equipment within the batch processing facility.