Manufacturing · AI and Advanced Analytics

Golden Batch and Correlation Analytics

Two connected dashboards turn operational PI data into golden batch comparisons and clear evidence of the variables driving process performance.

ClientGlobal manufacturing organisation

LocationGlobal

DisciplineAI and Advanced Analytics

Core dashboards

Real time

Process visibility

Batch

Performance comparison

Scalable

Analytics foundation

Project profile

Outcome-led engineering

Two connected dashboards turn operational PI data into golden batch comparisons and clear evidence of the variables driving process performance.

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Project objective

The project turns raw PI System data into insight that operators, engineers and leaders can use to understand process variation. A Golden Batch Comparison Dashboard shows how current and completed batches compare with the preferred operating profile, while a Correlation Coefficients Dashboard highlights the variables most closely associated with performance changes.

Execution approach

Réalta worked with process engineers to identify critical PI tags, define batches and agree golden batch criteria. The team built pipelines for extraction, alignment and correlation calculation, then refined bespoke visuals with subject-matter experts and confirmed the outputs against known process behaviour.

Following deployment, operators and engineers received training. The architecture also supports future variables, alerts and predictive analytics.

Business impact

The dashboards give production teams a more consistent way to spot drift, compare execution and investigate the drivers of variability. The solution supports tighter process control, improved reliability and greater transparency while creating a foundation for future AI use cases.

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