Aiya - Production Optimization

Aiya is a state-of-the-art production optimization solution that enables the customer to achieve desired production outcomes with minimized costs and high degree of confidence

Aiya – Key Functionalities

Predicting the quality of the products

The production personnel need to steer the process and production lines so that the target product quality is met as accurately as possible. Currently this is done by measuring the quality by samples, which is done based on either the past process outcome or the current situation. These measures are used when the future quality is predicted and steered based on the operators’ experience. 

  • Aiya enables predictions based on learning from historical data. This  relates to the understanding of the past and currently used process parameters’ correlation with the achieved product quality. Aiya learns and models the correlation and uses that to guide how the process parameters should be set in order to achieve the desired future quality.
  • Aiya learning is based on AI modelling of how the product quality is determined by operating the process parameters that could be e.g. chemicals, temperature and pressure.
  • Aiya is able to analyze and visualize how the key process parameters will affect the product quality in the future.
  • Aiya is also able to suggest the optimal configuration as requested.

Minimizing the use of chemicals

Taking into account the target quality and the given production configuration Aiya is able to minimize the amount of chemicals needed to achieve production targets.

  • All relevant chemicals and other configuration parameters and their statuses can be seen and modified in the Aiya user interface.
  • The user can easily assess how the process has performed in the past with different configurations and chemical dosages.
  • Modifying e.g. the amount of a chemical per production stage Aiya shows how the change will affect to process outcome in the future.

Simulations to predict performance of different production configurations

Aiya enables users to virtually modify process parameters and run simulations to create different production scenarios.

  • Operators can use this to consider different choices and for making decisions on how the production is run.
  • As creating and running a simulation is quick this capability enables more real-time decision making.
  • The user can freely decide what configurations will be tested or run the production based on the optimal parameter set up suggested by the solution.

Different configuration setups can be stored for future usage.

Advisory tool to guide the daily operations

Engineers and operators can provide instructions to colleagues or contractors for their work. The instructions are created by utilizing Aiya application functionality e.g. for predicting and simulations, and can include any process relevant information.

  • The instructions can contain configuration data relating to certain production scenarios etc.
  • The operative personnel can see the instructions and give feedback on the process back to the engineers / operators.

The verified best performing production configuration can be saved and reused later on.

Aiya – Solution benefits

 

  • Aiya enables achieving targeted product quality and thus meeting the business requirements with high degree of confidence
    • The production optimization has achieved several percentage improvements in meeting the quality objectives, which has significant savings potential per a mill per year in pulp production.
  • Improved ability to predict and control the production processes
    • Improved ability to forecast the need of chemicals and process outcomes.
    • Scenario analysis and simulations to increase the reliability of the process.
    • Support for engineers and operative personnel in their planning work through process transparency.
  • Minimized usage of raw material and chemicals
    • The cost savings achieved are significant as the optimization directly minimizes the use of chemicals and in-directly the use of energy.
  • Improved planning and operative working environment
    • Engineers and operators are provided intuitive and robust tool that they can utilize in their daily work.
    • Improve communication and clarity on process status, production plans and operative tasks.
    • Support for real-time decision making based on continuously updated information about process status.
  • Minimized usage of raw material and chemicals
    • The cost savings achieved are significant as the optimization directly minimizes the use of chemicals and in-directly the use of energy.
  • Improved planning and operative working environment
    • Engineers and operators are provided intuitive and robust tool that they can utilize in their daily work.
    • Improve communication and clarity on process status, production plans and operative tasks.
    • Support for real-time decision making based on continuously updated information about process status.

Aiya – End-user profiles

 

E

Engineers

  • Engineers use Aiya for planning the production and how the process should be operated in order to achieve business targets. They utilize the visible information about
    • Historical process performance
    • Current status of the process in each stage
  • They can run scenario analysis and simulations to test and visualize impact of changes to process parameters. This provides them proof points to steer the process in an optimal manner.
  • Engineers can utilize Aiya’s communication functionality to give instructions to operative personnel.
E

Operators

  • Operators use Aiya continuously as it enables easy-to-access, intuitive and real-time view of the whole production process.
    • With Aiya the operators can be more secure that the process is performing as planned.
    • Due to this they can focus on other operative tasks and still stay informed about the process status.
  • In case of an incident, operators are equipped to take the right corrective actions as the solution provides all necessary functions to choose and validate configuration changes before executing actions.
    • They can e.g. run quick simulations to verify a specific configuration change.
  • Continuous communication tools for engineers and operators secure that right decisions are made and executed in a coordinated and reliable manner.

Aiya – Solution Framework and Architecture

 

Aiya’s solution framework consists of AI / ML technology components, business logic and application functionality modules, and a versatile set of interface services. Modularity is designed throughout the framework, enabling high level of flexibility in selecting the most high-performing AI / ML algorithms for each specific optimization task. This also allows  integrating Aiya with any amount of sensors needed for production optimization. Application functionality can be fine-tuned for different industries and user profiles.

In the picture below the integration is drawn as a reference towards a Pulp & Paper industry technical infrastructure and systems set up.

  • With Aiya solution framework the optimization can be done by every process stage and for the whole production line. The framework enables flexible deployment of the production optimization for different production processes.

  • Aiya’s technical architecture is platform agnostic and the solution can be deployed to different cloud infrastructure and as on-premise solution.

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