AI Setpoint Advisor — OptiPlant AI

Portal:Process Intelligence/Setpoint Advisor

Pending

Applied (24h)

AP: 25 | HITL: 15

Avg Confidence

86.7%

Realized Benefit (24h)

4,280 kWh

0.42% defect ↓

Model Health

v3.8.2

nominal

Conf ≥80%

HIGHPENDINGPaint Shop — E-Coat Bath 01

5.805.72pH

pH Setpoint — ns=2;s=PA.PaintShop.ECoat01.SP_pH

-3.2% defect rate (film build uniformity), -1.8% chemical consumption

~$4,200/month

92%

Confidence

HIGHPENDINGPaint Shop — Cure Oven 01 Zone 1

165.0162.5°C

Zone 1 Temp SP — ns=2;s=PA.PaintShop.CureOven01.Zone1_SP

-2.4% natural gas consumption, no measurable cure-quality impact

~$8,100/month

88%

Confidence

HIGHPENDINGUtilities — Chiller 01

6.57.2°C

Supply Temp SP — ns=2;s=PA.Utilities.Chiller01.SP_SupplyTemp

-4.1% electrical load on chiller 01, COP improvement +0.18

~$6,400/month

94%

Confidence

MEDAPPLIEDUtilities — Compressed Air Header

7.26.8bar

Header Pressure SP — ns=2;s=PA.Utilities.CompAir01.SP_Pressure

-3.6% compressor kW

~$5,200/month

90%

Confidence

Applied 14:23:47

by Autopilot

RT: 42 ms

MEDPENDINGPaint Shop — E-Coat Bath 02

31.230.5°C

Bath Temp SP — ns=2;s=PA.PaintShop.ECoat02.SP_Temperature

-1.9% tank heating energy, no quality impact predicted

86%

Confidence

MEDPENDINGPaint Shop — Spray Booth 03

5862%RH

Humidity SP — ns=2;s=PA.PaintShop.Booth03.SP_Humidity

-1.4% rework rate on clearcoat (dust/orange peel)

83%

Confidence

MEDDEFERREDPaint Shop — Phosphate Bath

54.053.2°C

Bath Temp SP — ns=2;s=PA.PaintShop.Phosphate01.SP_BathTemp

-0.8% heating energy, marginal

84%

Confidence

Until 22:00

"Hold until shift change"

LOWPENDINGBody Shop — Weld Cell 02

9.89.6kA

Weld Current (sched 14) — ns=2;s=PA.BodyShop.WeldCell02.SP_Current

-2.1% electrode wear, no strength impact

81%

Confidence

LOWPENDINGBattery Line — Coating 02 Dryer Zone 1

118115°C

Dryer Temp SP — ns=2;s=PA.Battery.Coating02.DryerZone1_SP

-1.2% dryer energy, within coating-spec thickness band

85%

Confidence

MEDAPPLIEDBattery Line — Formation 03

0.330.38C

Charge C-Rate — ns=2;s=PA.Battery.Formation03.SP_ChargeRate

+4.1% formation throughput, no scrap increase observed

87%

Confidence

Applied 14:08:22

by J. Novak (HITL)

RT: 38 ms

HIGHPENDINGWWTP — Aeration Basin

2.41.8mg/L

DO Setpoint — ns=2;s=PA.Utilities.WWTP01.SP_DO

-7.2% blower kW, effluent ammonia margin still 1.4 mg/L above permit

~$3,100/month

91%

Confidence

Autopilot Status

STANDBY

Recommendations will be queued for your approval. Autopilot standing by.

Guardrails

Max ±5% SP deviation per adjustment

Max 3 adjustments per unit per hour

No writes during shift handover (06:00–06:30, 14:00–14:30, 22:00–22:30)

Safety-critical tags excluded (8 tags)

Rollback if PV outside 3σ within 10 min post-write

Confidence ≥ 80% required

Recent Autopilot Activity

14:23:47CompAir Header 7.2 → 6.8 barOK

14:18:12Chiller 02 Approach SP 3.0 → 2.8 KOK

14:12:30E-Coat Bath 01 Voltage 285 → 282 VOK

13:58:44Spray Booth 01 AirFlow 12400 → 12800 m³/hOK

13:42:15Boiler Feed Water Temp 62 → 64 °COK