This thesis investigates how data-driven analytics can be systematically implemented in legacy industrial batch processes to support robust, interpretable, and operationally relevant decision-making.Industrial batch environments are characterised by heterogeneous data structures, variable process trajectories, evolving operating conditions, and limited contextualisation, complicating the direct application of conventional analytical methods.
The work develops an integrated analytical framework combining batch data analytics, machine learning, cost-sensitive learning, and model-agnostic post-hoc analysis.Batch data analytics is used to contextualise and consolidate irregular industrial process data into analytics-ready representations suitable for downstream modelling.Machine learning methods are subsequently applied to perform classification, regression, and degradation modelling across multiple industrial case studies, with emphasis placed on parsimonious and interpretable models rather than unnecessary model complexity.
To extend predictive modelling beyond conventional accuracy-oriented evaluation, cost-sensitive learning is introduced to align model behaviour with operational and economic objectives.The proposed framework demonstrates how predictive confidence and model coverage can be balanced against operational risk and cost constraints, enabling selective and value-aware decision-support strategies.
Beyond predictive optimisation, the thesis introduces a model-agnostic post-hoc analysis framework for examining model behaviour across operational regimes.By embedding interpretability metrics into reduced-dimensional representations and constructing continuous behavioural landscapes through surrogate modelling, regions associated with confidence, systematic error, uncertainty, and interaction-driven behaviour can be identified and analysed.The results demonstrate that predictive performance is not uniformly distributed across the input space, but instead governed by distinct operational regimes with varying levels of reliability and interpretability.
The framework is validated through multiple industrial case studies within alloy production, ceramic manufacturing, and degradation modelling of electrical resistance heating wires.The results show that structured batch contextualisation improves the suitability of industrial data for machine learning, that selective modelling strategies can achieve substantially higher predictive performance within identified operational regions, and that region-aware post-hoc analysis enables diagnostically grounded evaluation of model behaviour under changing industrial conditions.
The thesis contributes a coherent methodological framework for trustworthy industrial analytics in legacy batch environments by integrating structured data contextualisation, interpretable machine learning, value-aware evaluation, and region-aware behavioural analysis into a unified decision-support perspective.