SIMCA®-online — Real-Time Process Monitoring Software
Apply process understanding to everyday manufacturing decisions
SIMCA®-online real-time process monitoring software gives scientists and engineers more time to investigate emerging problems and respond before process performance or product quality is affected. Part of the Umetrics® Data Analytics Ecosystem, it applies models developed in SIMCA® software to evaluate related process variables together, detect abnormal behavior, and identify what is driving a change.
The business value of real-time process monitoring
Process changes that are only recognized after a run can lead to reactive troubleshooting and more costly investigations. SIMCA®-online software monitors live process behavior against established models, giving earlier visibility into abnormal patterns before they escalate during manufacturing.
Maintaining compliance and consistency across teams and sites can be challenging. SIMCA®-online software brings established process models into live manufacturing, supporting a more standardized view of expected performance across the organization.
Complex process data can be difficult to review manually, especially when many variables need to be monitored at once. Real-time monitoring, alarms, and performance visualization in SIMCA®-online help teams focus on meaningful process changes, reducing unnecessary review and helping experts use their time more effectively.
Delayed awareness of process changes can slow investigations, extend interruptions, and reduce available manufacturing time. SIMCA®-online software helps identify abnormal process behavior while the run is still in progress, giving teams more time to review, escalate, or act before issues become more costly.
Changes in process behavior can affect critical outcomes before they are visible in final quality or yield results. SIMCA®-online software provides earlier visibility into shifts that may affect batch performance, supporting faster action to protect product quality and yield.
Investigations, rework, delays, and lost production time all add cost to manufacturing operations. By supporting earlier detection, faster review, and more consistent monitoring, SIMCA®-online software helps reduce avoidable effort and the cost of process issues.
Answer complex bioprocessing questions with real-time monitoring
Is the process behaving as expected?
Compare live process behavior with established models to understand whether the run is following the expected performance pattern.
Where is the process starting to shift?
Monitor multiple variables together to identify abnormal patterns, trends, or deviations as they develop.
Which variables need attention?
Use alarms, contribution information, and performance visualizations to focus investigation on the variables most associated with a process change.
What is the process likely to do next?
Use deployed models to predict process outcomes or quality attributes before offline sampling results are available.
Which issues should be escalated?
Review live monitoring results in context to distinguish meaningful process changes from normal variation and support timely investigation or action.
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SIMCA®-online software at a glance
Applications across biopharma manufacturing
Explore how SIMCA®-online software can support real-time process monitoring and prediction across biopharmaceutical manufacturing, from cell culture through downstream processing and fill and finish.
Explore key SIMCA®-online software capabilities
Deploy multivariate models developed in SIMCA® software to continuously assess live process behavior. These models provide a reference for monitoring process health, identifying departures from expected performance, and supporting predictive applications.
Monitor multiple process variables and their correlation patterns simultaneously using multivariate control charts and batch-centric views. Dedicated visualizations provide an immediate view of current process behavior and enable comparison with previous batches, supporting faster, data-driven decisions.
Configure alerts and notifications to flag abnormal process behavior as it develops. When a deviation occurs, process control charts, visual summaries, and drill-down functionality help identify contributing variables and support root-cause investigation.
Apply predictive models during processing to forecast critical quality attributes, batch completion, and expected quality outcomes. This provides earlier visibility into how the process is progressing and its likely final performance.
Use in silico optimization to identify potential adjustments to controllable process parameters within the approved design space, supporting more advanced real-time monitoring and control strategies.
See how SIMCA®-online fits into the Umetrics® Data Analytics Ecosystem
SIMCA®-online software supports the Deploy area of the Umetrics® Data Analytics Ecosystem, where teams apply models to monitor and predict process performance in real time. Explore how Deploy connects with Innovate, Build, and Elevate to enable better decision making across development and manufacturing.
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Frequently asked questions
SIMCA®-online software is used for real-time monitoring of live processes, applying multivariate models built in SIMCA® software to detect deviations, predict outcomes, and support process control as batches run.
SIMCA® software is for offline data exploration and model building. SIMCA®-online deploys those models to monitor production processes in real time.
Real-time process monitoring continuously compares live process data against a model of normal operation, flagging deviations as they occur so teams can act before quality is affected.
SIMCA®-online compares live measurements to a multivariate batch model and raises alerts when the process drifts outside expected behavior, enabling early fault detection.
