Computer System for Processing Industrial Information for Controlling the Production of Multi-Assortment Polymeric Films

The results of the development of a computer system for processing big data and expert knowledge of multi-assortment production of polymeric films have been presented. The computer system is an effective tool that helps operators to make decisions on the polymeric film production control in a routine mode and in the event of a defect. It is adjusted to the characteristics of polymeric film production and allows making advices on the choice of controlling actions at the main stages of production, ensuring the specified quality of the polymeric film (in the routine mode) and entering quality indices into the regulatory restrictions (in the event of a film defect). The system integrates production data obtained from various sources (a SCADA system, a video monitoring system, a thickness gauge, etc.). The information ware of the system includes a bank of data and knowledge on polymeric film production characteristics. Mathematical models are used to calculate quality indices of intermediates (extrudate) and products (polymeric film) that are not monitored in production. Data mining methods are used to compress, cluster complete sets of measured and calculated data, and predict consumer characteristics of the film. Interfaces of managerial production staff are used to visualize the results of industrial information processing (trends in production parameters, 3D graphs of the dependencies of quality indices on controlling actions, areas for quality indices, advices on control). The results of testing the system according to the data of the productions of rigid polymeric films for pharmaceutical and food packaging on the extrusion-calendering lines of factories in Russia and Germany have confirmed the system operability. The effectiveness of the system application is due to increased efficiency of decision-making on control and ensuring resource saving in production by improving the quality of the polymeric film and reducing non-returnable waste (defective film).