Methods, systems, articles of manufacture and apparatus to manage process excursions

1. An apparatus to identify an excursion effect in a process control system, the apparatus comprising:

digital twin comparer circuitry to determine when a product fails to satisfy a tolerance metric of a digital twin;

fingerprint manager circuitry to generate a fingerprint corresponding to a sensor pattern;

classification manager circuitry to classify the fingerprint against a knowledgebase of known process excursion fingerprints;

node interfacer circuitry to:

prevent operational disparity of the process control system by transmitting the classified fingerprint to a number of workstations of the process control system within a threshold amount of time; and

identify a threshold count of transmission confirmations of the classified fingerprint, the threshold count of transmission confirmations corresponding to the number of workstations of the process control system; and

excursion statistics calculator circuitry to invoke a corrective action for respective ones of the number of workstations, the corrective action based on a threshold count of the number of workstations that exhibit the fingerprint.

2. The apparatus as defined in claim 1 , further including sensor characteristics engine circuitry to identify the sensor pattern based on sensor types corresponding to sensor value occurrences preceding a first time, the first time indicative of when the product fails to satisfy the tolerance metric of the digital twin.

3. The apparatus as defined in claim 2 , further including temporal characteristics analyzer circuitry to identify the sensor pattern based on temporal occurrences of sensor values preceding the first time.

4. The apparatus as defined in claim 1 , further including:

sensor characteristics engine circuitry to identify a sensor type pattern corresponding to sensor value occurrences preceding a first time, the first time associated with a failure to satisfy the tolerance metric; and

temporal characteristics engine circuitry to identify a temporal pattern of the sensor value occurrences preceding the first time.

5. The apparatus as defined in claim 1 , wherein the classification manager circuitry is to invoke a preventative maintenance procedure as the corrective action in response to a match of the fingerprint in the knowledgebase.

6. The apparatus as defined in claim 1 , wherein the fingerprint manager circuitry is to add the fingerprint to a fingerprint excursion database when no match of the fingerprint in a knowledge database occurs.

7. A non-transitory computer readable storage medium comprising computer readable instructions to cause processor circuitry to at least:

determine when a product fails to satisfy a tolerance metric of a digital twin;

generate a fingerprint corresponding to a sensor pattern;

classify the fingerprint against a knowledgebase of known process excursion fingerprints;

prevent operational disparity of a process control system by transmitting the classified fingerprint to a number of workstations of the process control system within a threshold amount of time;

identify a threshold count of transmission confirmations of the classified fingerprint, the threshold count of transmission confirmations corresponding to the number of workstations of the process control system; and

invoke a corrective action for respective ones of the number of workstations, the corrective action based on a threshold count of the number of workstations that exhibit the fingerprint.

8. The non-transitory computer readable storage medium as defined in claim 7 , wherein the instructions cause the processor circuitry to identify the sensor pattern based on sensor types corresponding to sensor value occurrences preceding a first time, the first time indicative of when the product fails to satisfy the tolerance metric of the digital twin.

9. The non-transitory computer readable storage medium as defined in claim 8 , wherein the instructions cause the processor circuitry to identify the sensor pattern based on temporal occurrences of sensor values preceding the first time.

10. The non-transitory computer readable storage medium as defined in claim 7 , wherein the instructions cause the processor circuitry to:

identify a sensor type pattern corresponding to sensor value occurrences preceding a first time, the first time associated with a failure to satisfy the tolerance metric; and

identify a temporal pattern of the sensor value occurrences preceding the first time.

11. The non-transitory computer readable storage medium as defined in claim 7 , wherein the instructions cause the processor circuitry to invoke a preventative maintenance procedure as the corrective action in response to a match of the fingerprint in the knowledgebase.

12. The non-transitory computer readable storage medium as defined in claim 7 , wherein the instructions cause the processor circuitry to add the fingerprint to a fingerprint excursion database when no match of the fingerprint in the knowledge database occurs.

13. A computer-implemented method to identify an excursion effect in a process control system, the method comprising:

determining, by executing an instruction with at least one processor, when a product fails to satisfy a tolerance metric of a digital twin;

generating, by executing an instruction with the at least one processor, a fingerprint corresponding to a sensor pattern;

classifying, by executing an instruction with the at least one processor, the fingerprint against a knowledgebase of known process excursion fingerprints;

preventing, by executing an instruction with the at least one processor, operational disparity of the process control system by transmitting the classified fingerprint to a number of workstations of the process control system within a threshold amount of time;

identifying, by executing an instruction with the at least one processor, a threshold count of transmission confirmations of the classified fingerprint, the threshold count of transmission confirmations corresponding to the number of workstations of the process control system; and

invoking, by executing an instruction with the at least one processor, a corrective action for respective ones of the number of workstations, the corrective action based on a threshold count of the number of workstations that exhibit the fingerprint.

14. The method as defined in claim 13 , further including identifying the sensor pattern based on sensor types corresponding to sensor value occurrences preceding a first time, the first time indicative of when the product fails to satisfy the tolerance metric of the digital twin.

15. The method as defined in claim 14 , further including identifying the sensor pattern based on temporal occurrences of sensor values preceding the first time.

16. The method as defined in claim 13 , further including:

identifying a sensor type pattern corresponding to sensor value occurrences preceding a first time, the first time associated with a failure to satisfy the tolerance metric; and

identifying a temporal pattern of the sensor value occurrences preceding the first time.

17. The method as defined in claim 13 , further including invoking a preventative maintenance procedure as the corrective action in response to a match of the fingerprint in the knowledgebase.