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AI agent for process development scientists

Continuous Manufacturing Run Monitoring Agent

Steady state is confirmed with evidence and drift is corrected before quality is affected

MonitoringRisk managementScience and research
See how it worksGet access
Continuous Manufacturing Run Monitoring Agent: what goes in, what the agent does and what you get

What it does

In continuous manufacturing, declaring steady state too early can hide drift for hours. This agent reads the process signals and tests for steady state using statistical rules for each signal, and watches for drift in residence time distribution, quality attributes and feed rates. It proposes adjustments, such as a small feeder change, when a signal moves outside its band. After each adjustment it rechecks whether the signal returned. It keeps a log of each decision. The scientist approves any change to the run plan. Edge case: a quality attribute stays steady but a feed rate slowly creeps, so the agent flags the creep before the attribute moves.

How it works

Follow the arrows from top to bottom. The orange dashed arrow is the loop: when a check fails, the agent goes back and tries again.

Start and resultWhat it doesA check on its own workWaits for your OKGoes back and retries
Yes, continueApprovedYes, continueNoNo 1 STARTS WHEN Run starts or signals update 2 USES A TOOL Read process signals and in-line quality data 3 DOES Test each signal for steady state 4 CHECKS THE RESULT Have all signals stayed inside limits for the holdperiod? If not: keep the run in transient state and continue tomonitor. Back to step 3. 5 DOES Check for drift in feed rates and residence time 6 DOES Propose an adjustment for any drifting signal 7 YOU APPROVE Scientist approves any change to the run plan 8 USES A TOOL Read signals after the adjustment 9 CHECKS THE RESULT Did the signal return inside limits within theexpected time? If not: propose a larger or different adjustment andflag for review. Back to step 5. 10 DOES Log decisions and times 11 RESULT Run log with steady state record
Read the steps as a list
  1. Run starts or signals update
  2. Read process signals and in-line quality data
  3. Test each signal for steady state
  4. Have all signals stayed inside limits for the hold period?If not: keep the run in transient state and continue to monitor. Back to step 3.
  5. Check for drift in feed rates and residence time
  6. Propose an adjustment for any drifting signal
  7. Scientist approves any change to the run planThe agent waits here for your OK.
  8. Read signals after the adjustment
  9. Did the signal return inside limits within the expected time?If not: propose a larger or different adjustment and flag for review. Back to step 5.
  10. Log decisions and times
  11. Run log with steady state record

How it decides

Steady state is confirmed only when all signals stay within their limits for the required hold period. Drift is flagged on trend, not only on limits.

  • Confirm steady state after the signals hold for the set hold period
  • Flag drift when a slope is outside its allowed range for 3 readings
  • Make one adjustment at a time
  • Stop collecting product when quality leaves its limits

Make it yours

Every agent is a starting point. You choose these settings for your own situation.

  • Hold period for steady state
  • Signal limits
  • Drift slope limit
  • Check interval (default 5 minutes)

What keeps you in control

It always asks you first

  • Changes to the run plan
  • Decisions to divert product

Hard limits

  • Never changes setpoints itself
  • Never marks steady state without the hold period

It stops when

  • Done: run completes in steady state
  • Stop: quality attributes leave their limits

Set it up

We guide you through the set-up, step by step

Members get the full set-up guide for this agent. No technical skills needed: you copy, paste and upload.

10 minto set it up in your AI
5 AIsChatGPT, Claude, Copilot, Gemini, Grok
  • One set of instructions to paste into your AI, with the clicks for ChatGPT, Claude, Microsoft 365 Copilot, Gemini and Grok
  • The agent then walks you through connecting your own data, one source at a time
  • A downloadable copy with the flow chart, the rules and the full guide
Get access to this agent

An example run

What happensDuring run 12 the agent saw feed rate A drift from 10.0 to 9.7 kg per hour over 40 minutes while the quality attribute stayed in range. The steady state check failed against the 1 percent limit. It proposed a 0.2 kg feeder adjustment. The scientist approved it. After 15 minutes the rate returned to 9.99 and the agent logged steady state starting at 10:20.

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