PREDICTING EARLY WARNINGS OF AN OPERATING MODE OF EQUIPMENT IN INDUSTRY PLANTS

Currently solutions for early detection of failures in manufacturing utilize predefined threshold levels of the process variables associated with equipment in manufacturing unit/industry plants. The pre-defined threshold and levels thereof are compared with the real values obtained from the manufacturing unit to check behavior of process variables (also referred as 'process parameters') and thus are prone to error. The present disclosure provides systems and method for predicting early warning of operating mode of equipment operating in industry plants which is based on transforming conditions on process parameters into conditions on corresponding fuzzy indices based on their thresholds. The fuzzy indices (concordance index, discordance index) of individual conditions are combined into a composite fuzzy index (composite index or degree of credibility) that describes the failure scenario in the process parameter space. A fuzzy logic-based detection is useful for detecting a failure mode early and providing alerts to operators for necessary action.