Intelligent recommendations for your process.
What is Adaptive Coaching?
A production tool for producing better and more consistent operator decisions. Adaptive Coaching builds on your operator’s expertise through real-time coaching with expert suggestions. The coach’s recommendations are focused on delivering a consistent quality product in safe operating conditions while minimizing energy consumption.
Adaptive Coaching can be integrated into new equipment builds or upgrades to an existing system.
Why is Adaptive Coaching needed?
- Levels up operator expertise and performance between shifts.
- Improves product uniformity.
- Reduces fire risk.
- Lowers energy cost.
What are the key features of Adaptive Coaching?
Improve safety by getting alerted when key settings are trending poorly or are at dangerous levels.
Improvements to quality - more than a line event management system, Adaptive Coaching uses line data to make real-time recommendations.
Improve consistency by leveling the playing field for your operators. All operators across all shifts will benefit from the expert recommendations.
Improve support by automatically collecting and displaying trends and other data useful to troubleshooting.
Where has Adaptive Coaching been used?
Adaptive Coaching was pioneered on an oven used for puffing rice. It integrates operating data from the oven’s PLC with a mass and energy balance. Adaptive Coaching uses this balance to evaluate operating conditions. Recommending operating settings to deliver the best product quality, safety, and energy efficiency.
Adaptive Coaching does not directly control the oven. Instead, it reinforces the operator’s existing technical expertise through intelligent recommendations.
The system is currently in use and producing excellent results. This graph shows the prediction errors from a test with over 28,000 data points. The largest error, just 3%, is well within the expected variability caused by minute changes in measurement technique by the operator.
Where can Adaptive Coaching be used?
Adaptive Coaching can be used in any industry with the following operations:
Puffing & Toasting
Dehydration
Drying
Cooling
Spray Drying
Roasting
Coating
And More!
What can Adaptive Coaching do for you?
Adaptive Coaching can help you optimize the performance of your process with intelligent, data-driven recommendations to your operators.
Optimize
Quality and OEE • Energy • Actions
Enhance
Safety • Communication
What Drives Adaptive Coaching?
Adaptive Coaching is an AI coaching tool that lives at the intersection of expert operational knowledge, applied science and sensor technology, industrial computing power, and skilled modeling. Producing ongoing recommendations to the operator’s workstation enables the production of consistent product, at a low energy cost, and in a safe manner.
As a collaborative effort between ChiAha, Inc. and Process Partners, Adaptive Coaching combines expert engineering knowledge with advanced decision support architecture to provide reliable recommendations to the operator on the production floor.
Who is behind Adaptive Coaching?
A recognized expert in the field, Jim Breslin of Process Partners has supported food companies with technical expertise, process support, and production equipment for more than 43 years. Process Partners has done business with both Fortune 500 companies and small start-up companies all over the globe. A small selection of customers includes WK Kellogg Company, Kellanova, General Mills, Rembrandt Baking, Philip Morris, Post Foods, Undercover Chocolates, Cargill, Kraft Foods and Wabash Valley.
Jim has several U.S. patents to his credit, including No Dry Coating Process for Sugar Coated Food Products, No Dry coating process for Coated Food Products, Method of Processing a Grain Product, Apparatus for Processing a Grain Product, Heat Recovery System, Conditioning Process for Tobacco and or Snuff Compositions.
In addition, Jim is a contributing author to the book “Breakfast Cereals and How They Are Made.” He wrote the chapters on Toasting, Drying, and Coating Dryers for the second and third editions.
Andrew Siprelle, founder of Simulation Dynamics, Inc. (SDI) and ChiAha, has witnessed the manufacturing industry evolve from the perspective of a simulation expert with over 30 years of optimization and modeling experience. He saw how the emergence of automated data collection systems has allowed companies to monitor every detail of their production lines. This shift in data collection practices paved the way for the development of more sophisticated modeling techniques, such as digital twin simulation. Throughout its existence, SDI has capitalized on the increasing availability of data by providing bespoke modeling and simulation expertise to a range of industries, with a focus on the consumer packaged goods industry.
