Process Intelligence

Turn process variability into operational advantage.

Connect machine signals, process parameters, quality, energy and production results in one real-time decision system.

InAnalytics helps manufacturers understand what drives process performance, predict deviations and continuously move operations toward higher efficiency, quality and yield.

Schedule a Process Intelligence Assessment

Process variability hides losses—and opportunities

Industrial processes change continuously.

Machine condition, raw-material properties, recipes, operating parameters, environmental conditions and production sequences all affect the final result.

Traditional monitoring shows what happened. Process Intelligence identifies the relationships behind performance and determines what should be changed.

Use process data to identify:

which parameters have the greatest impact on output and quality,
where energy, materials and production capacity are being lost,
which operating conditions deliver the best results,
when the process begins to move away from its optimal state,
how technical deviations affect cost, yield and profitability.

Algorithms that learn how your process really performs

Process Intelligence models analyze historical and real-time data to determine how process conditions influence production results.

They identify normal operating patterns, detect deviations and forecast the likely outcome of current conditions.

This provides a reliable foundation for operational recommendations, automated control algorithms and continuous process optimization.

Compressor and compressed air network intelligence dashoard

Move every process toward its best operating point

The best operating point is not a fixed parameter.

It changes with product type, recipe, raw material, equipment condition, energy price, production target and environmental conditions.

Process Intelligence continuously answers:

Which parameters are limiting throughput?
What is causing the current loss of efficiency?
Is the process moving toward a quality deviation?
Which operating conditions produce the highest yield?
Which machine or process step is creating the bottleneck?
How much energy and material does each product or batch require?
What parameter change is most likely to improve the result?
What will be the financial impact of the proposed adjustment?

Measure continuously. Detect early.
Optimize every cycle.

Process Intelligence turns every production cycle, batch and operating hour into an opportunity to improve performance.

One decision model. From sensor to process result.

Process Intelligence connects:

temperatures, pressures, flows, speeds, vibration and other process measurements,
machine states, alarms, operating modes and control parameters,
recipes, products, batches and production sequences,
raw-material properties and laboratory results,
throughput, yield, scrap, rework and quality data,
electricity, gas, heat, steam, water and compressed air,
maintenance events and equipment condition,
production costs, material value and financial results.

The result is one analytical model linking every process condition with its operational and financial consequence.

Optimization that respects process reality

The theoretically optimal setting is not always operationally possible.

InAnalytics evaluates recommendations against actual process constraints:

permissible operating ranges,
equipment capacity and technical limits,
process continuity and production sequence,
quality and safety requirements,
available buffers and storage capacity,
product and recipe requirements,
start-up, shutdown and changeover conditions,
production targets and delivery commitments.

Recommendations remain practical, explainable and achievable under real production conditions.

From monitoring to measurable improvement

Traditional process monitoring records values and alarms.

Process Intelligence shows what is changing, why it is changing and what action should be taken next:

detect deviations before they become production losses,
identify the conditions responsible for unstable operation,
find bottlenecks limiting throughput,
predict quality, yield and energy consumption,
compare machines, shifts, products and operating modes,
recommend better process parameters,
simulate changes before implementation,
quantify every loss and improvement financially.

Real Industrial Reference

Industrial application example

Compressed-air system optimization

Combine compressor operation, electrical power, air production, pressure and plant demand in one analytical model.

Process Intelligence can:

calculate actual efficiency in kWh/m³,
compare compressors and operating combinations,
identify inefficient loading and unloading cycles,
detect unstable pressure and control behaviour,
estimate compressed-air losses and leaks,
recommend the most efficient compressor configuration,
calculate the financial cost of inefficient operation.

The same approach can be applied to boilers, furnaces, pumps, cooling systems, production lines and other industrial processes.

Built on real industrial data

Process Intelligence is powered by the InAnalytics Data Platform.

Connect PLC, SCADA, DCS, MES, LIMS, ERP, historians, sensors, meters, laboratory systems, SQL databases, files and external APIs using OPC UA, Modbus, REST, ODBC and other industrial interfaces.

Use PostgreSQL and open analytics tools including Grafana, Power BI, Metabase and Looker Studio. Retain full control of your data, process models, algorithms and deployment.