Hybrid AI and LLM-Enabled Agent-Based Real-Time Decision Support Architecture for Industrial Batch Processes: A Clean-in-Place Case Study

A hybrid AI and LLM-enabled architecture is presented for real-time decision support in industrial batch processes, where supervision still relies heavily on human operators and ad hoc SCADA logic. Unlike algorithmic contributions proposing novel AI methods, this work addresses the practical integration and deployment challenges arising when applying existing AI techniques to safety-critical industrial environments with legacy PLC/SCADA infrastructure and real-time constraints. The framework combines deterministic rule-based agents, fuzzy and statistical enrichment, and large language models (LLMs) to support monitoring, diagnostic interpretation, preventive maintenance planning, and operator interaction with minimal manual intervention. High-frequency sensor streams are collected into rolling buffers per active process instance; deterministic agents compute enriched variables, discrete supervisory states, and rule-based alarms, while an LLM-driven analytics agent answers free-form operator queries over the same enriched datasets through a conversational interface. The architecture is instantiated and deployed in the Clean-in-Place (CIP) system of an industrial beverage plant and evaluated following a case study design aimed at demonstrating architectural feasibility and diagnostic behavior under realistic operating regimes rather than statistical generalization. Three representative multi-stage CIP executions—purposively selected from 24 runs monitored during a six-month deployment—span nominal baseline, preventive-warning, and diagnostic-alert conditions. The study quantifies stage-specification compliance, state-to-specification consistency, and temporal stability of supervisory states, and performs spot-check audits of numerical consistency between language-based summaries and enriched logs. Results in the evaluated CIP deployment show high time within specification in sanitizing stages (100% compliance across the evaluated runs), coherent and mostly stable supervisory states in variable alkaline conditions (state-specification consistency Γs≥0.98), and data-grounded conversational diagnostics in real time (median numerical error below 3% in audited samples), without altering the existing CIP control logic. These findings suggest that the architecture can be transferred to other industrial cleaning and batch operations by reconfiguring process-specific rules and ontologies, though empirical validation in other process types remains future work. The contribution lies in demonstrating how to bridge the gap between AI theory and industrial practice through careful system architecture, data transformation pipelines, and integration patterns that enable reliable AI-enhanced decision support in production environments, offering a practical path toward AI-assisted process supervision with explainable conversational interfaces that support preventive maintenance decision-making and equipment health monitoring.