Advanced Process Control (APC) is an interdisciplinary technology used to solve process control problems with multiple variables. It is connected to the distributed control system (DCS) and used in various industries to improve manufacturing performance and reduce waste.
Advanced Process Control (APC) is the application of a broad range of disciplines and technologies to refine process control or address a specific problem associated with a process. Interdisciplinary in nature, APC draws knowledge in its application from statistics, decision theory, engineering, signal processing, and artificial intelligence. Most often it is exploited to solve process control problems that have multiple variables or problems that are unrelated to the control process. To achieve the intended objectives, an APC technology is usually connected to the distributed control system (DCS) which controls the process. Because of its inherent tendencies to solve problems that have multiple variables, advanced process control is used in a variety of industries.
Typically in process control, a distributed control system is used to control a process in both a factory and a laboratory. Distributed control system means that the system components are distributed throughout the entire process, each with different degrees of function. An advanced process control instrument is typically connected to the distributed control system via established communication protocols or a software interface. During this communication exchange, the APC will keep track of all information sent to the DCS regulatory controls to isolate a problem or calculate the different variables that manifest themselves in a problem. Standard APCs used include statistical process control units, feedback units, and predictive control units, among others, depending on the objective of the tester.
Within a wide range of industries and process functions, advanced process control is implemented on a regular basis to facilitate manufacturing. Industries that manufacture chemicals or refine various raw materials leverage APCs to address problems that tend to have multiple variables. Other industries, such as semiconductor manufacturers, will use APCs to solve complex process control problems associated with multiple starting points in the manufacturing process. Additionally, industries such as mining have implemented APCs to further refine process control alongside the established process control technology already in use in the industry.
Overall, the goal of advanced process control is to improve the performance of control over the processes that contribute to manufacturing. Exercising consistent control over that process not only helps facilitate the manufacturing process, but also helps make manufacturing outcomes more predictable. Manufacturing process optimization also helps eliminate waste that occurs when processes have to be redone. Eliminating this waste further reduces the overall cost of the manufacturing process.
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