Algorithmic Statistical Process Control: Concepts and an Application

The goal of algorithmic statistical process control is to reduce predictable quality variations using feedback and feedforward techniques and then monitor the complete system to detect and remove unexpected root causes of variation. This methodology seeks to exploit the strengths of both automatic control and statistical process control (SPC), two fields that have developed in relative isolation from one another. Recent experience with the control and monitoring of intrinsic viscosity from a particular General Electric polymerization process has led to a better understanding of how SPC and feedback control can be united into a single system. Building on past work by MacGregor, Box, Astrom, and others, the article covers the application from statistical identification and modeling to implementing feedback control and final SPC monitoring. Operational and technical issues that arose are examined, and a general approach is outlined.