TwinThread releases Perfect Batch to improve batch manufacturing efficiency
Industrial artificial intelligence provider TwinThread has launched Perfect Batch, a manufacturing analytics solution designed to optimize batch production and improve process consistency.
According to TwinThread, Perfect Batch uses artificial intelligence to analyze historical production data and identify optimal batch profiles, allowing manufacturers to standardize and replicate their highest performing “golden batches.” The system is designed to move operations teams from reactive troubleshooting to proactive process optimization within weeks.
The platform integrates with existing batch execution systems and rapidly builds digital models from past production data. These models dynamically establish process limits and control parameters based on actual performance rather than static, manually defined settings.
TwinThread states that Perfect Batch enables manufacturers to uncover hidden capacity by identifying inefficiencies such as bottlenecks and lost production time. The system also provides automated alerts and diagnostics, allowing operations teams to focus on resolving issues rather than conducting manual investigations.
An optional real-time workflow engine, Thread Builder, extends the platform’s capabilities by enabling automated responses to process anomalies. This includes performing diagnostics and triggering corrective actions without manual intervention.
Perfect Batch is designed for use in regulated industries, offering automated material tracking, quality and yield monitoring, and audit-ready production histories to support compliance requirements.
The solution continuously evaluates five key performance areas: utilization, cycle time, quality, process control, and yield. TwinThread says this approach helps reduce investigation time, minimize waste, and accelerate continuous improvement initiatives.
“By completely automating the discovery of hidden capacity and enabling proactive optimization, we are giving manufacturers the power to eliminate inconsistencies and maximize financial performance of their existing assets,” said Erik Udstuen, co-founder and CEO of TwinThread.
Available in both simple and complex batch configurations, Perfect Batch is designed to scale across manufacturing environments. The platform also provides a centralized view of batch performance across facilities, enabling operations, engineering, and supply chain teams to align on improvement priorities and optimize resource deployment.