Training-free data-driven method for input-output modeling of complex process

A twin roll casting system includes a pair of counter-rotating casting rolls, a casting roll controller is configured to receive a plant input comprising at least one process control setpoint for the casting rolls. A cast strip sensor measures at least one parameter of the cast strip. A feedback controller receives measurement signals from the cast strip sensor. The feedback controller is a data-driven model including a database of state-input pairs; and executes the following steps at each time step: measure a state-input similarity between a new state observation and samples, assign a weight to each consequent output of samples based on the measured state input similarity, and sum the weighted outputs and predict an output of a new state observation. The feedback controller is configured to provide the control setpoint to the casting roll controller based on the predicted output of the new state observation.