Best Web-Based Advanced Process Control (APC) Systems of 2025

Epicor Connected Process Control provides a simple-to-use software solution that allows you to configure digital work instructions and enforce process control. It also ensures that operations are error-proof. Connect IoT devices to collect 100% time studies and process data, images and images at the task level. Real-time visibility and quality control on a new level! eFlex can handle any number of product variations or thousands of parts, whether you are a component-based or model-based manufacturer. Work instructions can be linked to Bill of Materials, ensuring that products are built correctly every time, even if changes are made during the process. Work instructions that are part a system that is advanced will automatically react to model and component variations and only display the right work instructions for what's currently being built at station.

Producers like yourself possess the expertise required to maneuver through the intricate hurdles of remaining competitive in today’s market landscape. This is applicable across a wide range of sectors, including pharmaceuticals, consumer goods, food and beverage, mining, and chemicals. Therefore, embracing the latest technological innovations is essential for advancing your ongoing digital transformation efforts. Throughout your organization, from the control room to executive meetings, users of process systems consistently grapple with the challenge of optimizing productivity while managing budget limitations and resource availability, all while tackling shifting operational risks. By addressing these challenges head-on, you can unlock significant productivity enhancements across your facility with the PlantPAx distributed control system (DCS). The features of this system can greatly influence the lifespan of your plant operations, ensuring that integrated and scalable systems enhance productivity, boost profitability, and minimize operational risks. Ultimately, investing in such advanced systems can lead to a more resilient and efficient production environment.

The DeltaV S-series Electronic Marshalling utilizing CHARMs allows for flexible placement of field cabling, independent of the type of signal or control methodology employed. The DeltaV™ Distributed Control System (DCS) is designed to streamline automation processes, which reduces operational challenges and mitigates project risks effectively. This advanced collection of products and services enhances plant efficiency through intuitive control solutions that are straightforward to manage and service. Importantly, the DeltaV DCS is adaptable, easily scaling to fit your specific requirements without introducing additional complexity. Furthermore, the seamless integration capabilities of the DeltaV system encompass various functions including batch processing, advanced control, change management, engineering tools, diagnostics, and much more, ensuring a comprehensive solution for your operational needs. Ultimately, this flexibility and integration pave the way for improved productivity and reliability in industrial environments.

Navigating the complexities of industrial processes presents a significant challenge for businesses striving to be both responsive to market demands and economically viable. To meet these challenges, manufacturers are required to refine their production techniques in order to offer an expanded range of higher-value items while also accommodating shorter production runs. It is essential for them to enhance output, optimize operational efficiency, and elevate product quality to the fullest extent permitted by their existing equipment. Achieving this necessitates maximizing equipment uptime and facilitating smoother transitions while minimizing waste. Furthermore, there is an increasing expectation from the public for manufacturers to lessen their environmental footprint and adhere to strict emissions regulations. Rockwell Automation Pavilion8® Model Predictive Control (MPC) technology serves as an advanced intelligence layer that integrates with automation systems, continuously steering the plant toward achieving a multitude of business goals—including cost savings, reduced emissions, consistent quality, and increased production—while operating in real time. This innovative approach not only enhances operational effectiveness but also aligns with sustainability initiatives, positioning manufacturers for success in an evolving marketplace.

A closed-loop universal multivariable optimizer is designed to enhance both the performance and quality of Model Predictive Control (MPC) systems. This optimizer utilizes data from Excel files sourced from Dynamic Matrix Control (DMC) by Aspen Tech, Robust Model Predictive Control Technology (RMPCT) from Honeywell, or Predict Pro from Emerson to develop and refine accurate models for various multivariable-controller variable (MV-CV) pairs. This innovative optimization technology eliminates the need for step tests typically required by Aspen Tech and Honeywell, operating entirely within the time domain while remaining user-friendly, compact, and efficient. Given that Model Predictive Controls (MPC) can encompass tens or even hundreds of dynamic models, the possibility of incorrect models is a significant concern. The presence of inaccurate dynamic models in MPCs leads to bias, which is identified as model prediction error, manifesting as discrepancies between predicted signals and actual measurements from sensors. COLUMBO serves as a powerful tool to enhance the accuracy of Model Predictive Control (MPC) models, effectively utilizing either open-loop or fully closed-loop data to ensure optimal performance. By addressing the potential for errors in dynamic models, COLUMBO aims to significantly improve overall control system effectiveness.

The System 800xA is more than just a Distributed Control System (DCS); it serves as an Electrical Control System, a Safety system, and a platform for collaboration, designed to enhance engineering efficiency, operator performance, and asset utilization. With its integrated electrical control capabilities, the ABB Ability System 800xA allows for comprehensive management of the entire electrical system, spanning from high-voltage switchgear to low-voltage motor control systems. Whether used in conjunction with the 800xA DCS or independently, this system is an optimal choice for managing electrical controls. By utilizing intelligent devices, users can significantly reduce the amount of hardwired cabling required for switchgear, regardless of the standard protocols in place. The digital communication's high reliability not only enhances the flow of information from devices but also allows for the elimination of additional electrical measurement instruments, thereby streamlining operations and improving overall system efficiency. Ultimately, the ABB Ability System 800xA stands out as a versatile and effective solution in modern electrical control management.

Guidewheel's AI platform will help you get more out of existing assets, reduce costs, and make your team win. The fastest way to improve factory operation. Track downtime accurately and identify root causes for improved efficiency and utilization. Forecast throughput accurately and track planned production vs. actual. Monitor OEE in real-time and see your trend over time. Track cycles, cycle times, and performance against goals. Monitor energy consumption and look for ways to reduce costs and consumption. Find out about maintenance issues before they become a problem. Monitor conditions such as temperature, flow, humidty, and pressure. Unlock hidden capacity by revealing and addressing losses such as preventable downtimes, long changeovers and late starts. AI-driven alerts will notify you when performance is deviating from the plan. This allows your team to take corrective actions and stay on track. Delivering on time is the best way to build customer trust.

Enhance precision and sustainability in advanced process control (APC) models by integrating both linear and nonlinear variables through deep learning techniques, thereby expanding their operational capabilities. Achieve improved returns on investment through swift controller implementation, ongoing model refinement, and streamlined workflows that facilitate easier adoption by engineers. Transform the process of model creation with artificial intelligence and simplify controller calibration by using guided wizards that outline both linear and nonlinear optimization goals. Boost controller availability by leveraging cloud technology to access, visualize, and analyze real-time key performance indicators (KPIs). In the dynamic landscape of the global economy, energy and chemical industries are compelled to operate with increased flexibility to respond to market shifts and optimize profit margins. Aspen DMC3 represents an innovative digital solution that aids organizations in realizing a throughput enhancement of 2-5%, a yield increase of 3%, and a 10% decrease in energy usage. Explore the benefits of next-generation advanced process control solutions to stay competitive and efficient in the industry. The integration of these technologies not only addresses immediate operational challenges but also positions companies for long-term success in an increasingly competitive market.