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Real-Time Modeling System™
Predict how automation will behave in the future

Predict how automation will behave in the future

Emerson’s Real-Time Modeling System™ allows customers to visualize the facility constraints, accommodate variability, maximize production, and understand the implications of any change in the manufacturing process.

By collecting data from across the organization, our Real-Time Modeling System can consolidate, analyze, and present an accurate model of the entire process. The model produces an optimal scheduling overview and debottlenecking and capacity analyses for process optimization.

 

Create a virtual sandbox for plant experimentation

Create a virtual sandbox for plant experimentation

Our Real-Time Modeling System software is an environment that has the flexibility to model any facility, operation, or process. It uses one platform for both analysis and finite-scheduling utilizing discrete-event simulation.

Develop an always feasible real-time schedule

Develop an always feasible real-time schedule

Using a model created by the Real-Time Modeling System, real-time scheduling automatically schedules future operations based on operations rules by reconciling the real-time status of the manufacturing floor.

Determine the current bottleneck and target improvement

Determine the current bottleneck and target improvement

Utilizing plant data, run what-if analysis to detect bottlenecks that are impacting operational performance. Through iterative improvements and changes in process parameters, recognize significant refinements in throughput, and analyze impact on KPIs.

Track facility performance metrics based on consolidated corporate data sources

Track facility performance metrics based on consolidated corporate data sources

Create datasets from batch historians to be used in the modeling system. Using this data, calculate and manage performance metrics such as OEE scores or golden batches and update these metrics automatically to reflect the most up-to-date data.

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Benefits of Real-Time Modeling

Benefits of Real-Time Modeling

Account for Plant Variability

Variability is a fact of reality and accounted for with RTMS. The models that are created capture the manufacturing and process randomness so that your projects consider all possibilities, not just ideal ones.

Link Models into any Database

Utilizing Integration Framework, RTMS models can easily link to data from any database, from automation systems to enterprise resource planning systems. Data-integrated models reflect reality, not just an approximation.

Automation Conflict Resolution

The core architecture automatically resolves equipment unavailability, scheduling changes, and resource conflicts. The result is less time on resolving issues, more time on analysis, and a reduction in unplanned downtimes

Process Optimization based on Real-Time Data.

Emerson’s Real-Time Modeling System technology creates various outputs based on consolidated data that can be quickly analyzed for better decision making and process optimization.

Real-Time Modeling System Benefits:

Design Validation - validate process design prior to capital expenditure.
Bottleneck Detection - establish a clear and accurate debottlenecking pathway.
Facility Flexibility - future proof facilities for multiple products and higher titers.
New Technologies - understand the effects of new technology on your process.
Detailed Resource Analysis - generate highly detailed models of utilities, labor, and other potential constraints.
Capacity & Cadence - determine feasible facility capacity and cadence (including surge capacity).

Real-Time Scheduling Benefits:

Schedule Adherence - accurately monitor facility goals and personnel efficiency.
White Space Analysis - easily view and plan maintenance activities without disrupting plant operations.
What-if Scenarios - immediately see the impact of strategy changes on schedule and facility performance.
Automatic Schedule Updates - reflect the current status of all recipes to the schedule through integrations framework and update the future schedule.
Peak Utility & Labor Requirements - visualize peak demand for critical utilities, labor, or other potential constraints.
Views for Functional Teams - create and publish views for activities dedicated to different teams or operators.
Operator Allocation - automatically assign operators to tasks based on capability matrix and availability.

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