Pideya Learning Academy

Machine Learning for Control Systems Optimization

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
03 Feb - 07 Feb 2025 Live Online 5 Day 3250
03 Mar - 07 Mar 2025 Live Online 5 Day 3250
21 Apr - 25 Apr 2025 Live Online 5 Day 3250
23 Jun - 27 Jun 2025 Live Online 5 Day 3250
14 Jul - 18 Jul 2025 Live Online 5 Day 3250
25 Aug - 29 Aug 2025 Live Online 5 Day 3250
03 Nov - 07 Nov 2025 Live Online 5 Day 3250
22 Dec - 26 Dec 2025 Live Online 5 Day 3250

Course Overview

In the era of Industry 4.0, where digitization and intelligence define industrial competitiveness, the optimization of control systems has evolved from a mechanical challenge to a data-driven science. Traditional control systems, such as PID and model-based architectures, have long served as the backbone of industrial automation. However, they often struggle with real-time process variations, nonlinearities, and unexpected system behaviors. To address these challenges, Machine Learning for Control Systems Optimization is emerging as a transformative approach that enables systems to learn, adapt, and continuously improve performance.
Pideya Learning Academy introduces this advanced training course to equip engineers, automation professionals, and system designers with the knowledge and skills needed to harness the power of ML in industrial control contexts. This training bridges the gap between control theory and machine intelligence, empowering participants to create more adaptive, responsive, and fault-tolerant control environments.
According to McKinsey & Company, industrial organizations that deploy advanced analytics and machine learning have achieved up to 30% improvements in throughput, 20% reductions in energy usage, and 50% enhancements in predictive maintenance accuracy. A 2024 Statista survey further confirms that over 65% of manufacturing and energy sector organizations have either implemented or are actively piloting ML-based control strategies, highlighting the urgency for professionals to develop expertise in this area.
To support this transition, the course delivers a powerful combination of technical depth and industry relevance, enriched with the following key highlights:
A detailed understanding of real-world applications of ML algorithms in closed-loop control systems
Development of hybrid control models combining physical dynamics with data-driven insights
Integration of ML techniques into PID, Model Predictive Control (MPC), and distributed control system (DCS) architectures
Advanced anomaly detection and diagnostic approaches using time-series, multivariate, and state-space datasets
Optimization strategies leveraging reinforcement learning in dynamic control environments
Exposure to industry case studies from oil & gas, power generation, smart manufacturing, and utilities
Strong focus on model interpretability, ethical considerations, and governance in industrial AI deployment
What sets this Pideya Learning Academy course apart is its carefully structured curriculum that introduces ML concepts from the ground up—ensuring accessibility for professionals without prior experience in data science or AI. From understanding basic supervised and unsupervised learning to building advanced predictive models tailored to control loops, each module is designed to deepen participants’ capabilities progressively.
Participants will also explore how to construct hybrid models that incorporate both physics-based and ML-based components for superior accuracy and responsiveness. Emphasis is placed on applying these techniques to common control tasks such as setpoint tracking, stability improvement, disturbance rejection, and fault prediction.
In an increasingly competitive landscape where operational efficiency and uptime are critical, this course empowers learners to lead automation modernization projects with confidence. Beyond the algorithms, participants will also engage with forward-looking topics like explainable AI, control system auditability, and the role of intelligent agents in future industrial ecosystems.
Through this holistic and forward-thinking training program, Pideya Learning Academy reinforces its mission to empower professionals with next-generation technical skills that enable smarter, safer, and more sustainable control system performance.

Key Takeaways:

  • A detailed understanding of real-world applications of ML algorithms in closed-loop control systems
  • Development of hybrid control models combining physical dynamics with data-driven insights
  • Integration of ML techniques into PID, Model Predictive Control (MPC), and distributed control system (DCS) architectures
  • Advanced anomaly detection and diagnostic approaches using time-series, multivariate, and state-space datasets
  • Optimization strategies leveraging reinforcement learning in dynamic control environments
  • Exposure to industry case studies from oil & gas, power generation, smart manufacturing, and utilities
  • Strong focus on model interpretability, ethical considerations, and governance in industrial AI deployment
  • A detailed understanding of real-world applications of ML algorithms in closed-loop control systems
  • Development of hybrid control models combining physical dynamics with data-driven insights
  • Integration of ML techniques into PID, Model Predictive Control (MPC), and distributed control system (DCS) architectures
  • Advanced anomaly detection and diagnostic approaches using time-series, multivariate, and state-space datasets
  • Optimization strategies leveraging reinforcement learning in dynamic control environments
  • Exposure to industry case studies from oil & gas, power generation, smart manufacturing, and utilities
  • Strong focus on model interpretability, ethical considerations, and governance in industrial AI deployment

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn:
How to identify opportunities for ML integration within industrial control systems
Key concepts in supervised, unsupervised, and reinforcement learning relevant to process control
Methods for training and validating ML models using control-relevant datasets
Implementation techniques for hybrid ML-physical models in control loops
Advanced optimization strategies using predictive models and feedback algorithms
Fault detection, diagnostics, and anomaly classification using ML approaches
Best practices for deploying scalable ML models in live control environments

Personal Benefits

Broadened expertise in cutting-edge control system technologies
Enhanced decision-making through data-informed control models
Increased career advancement potential in AI and automation roles
Confidence in applying machine learning principles to real-world control challenges
Access to a valuable network of AI-in-control professionals through Pideya Learning Academy

Organisational Benefits

Improved operational reliability through predictive and adaptive control systems
Reduced downtime and maintenance costs by enabling early fault detection
Enhanced energy efficiency and throughput optimization across industrial processes
Strategic capability building in AI/ML for next-generation process innovation
Accelerated digital transformation in control system modernization initiatives

Who Should Attend

Control Systems Engineers and Process Engineers
Automation and Instrumentation Specialists
AI/ML Engineers working in industrial domains
Plant Operations Managers and Technical Supervisors
R&D Professionals and Systems Integrators
Digital Transformation and Innovation Leaders
Course

Course Outline

Module 1: Fundamentals of Control Systems and ML
Basics of feedback and feedforward control Overview of closed-loop and open-loop systems Introduction to machine learning in control systems Understanding process dynamics and system behavior Data acquisition from control environments ML model selection principles for control applications Differences between rule-based and data-driven controls
Module 2: Supervised Learning for Control Optimization
Linear regression in system response modeling Decision trees and support vector machines for process classification Time-series forecasting using ARIMA and LSTM Model evaluation metrics: MSE, RMSE, R² Overfitting and underfitting control in small datasets Feature engineering in control datasets Real-world implementation examples
Module 3: Unsupervised Learning in Process Analysis
Clustering methods (K-Means, DBSCAN) for system behavior analysis Dimensionality reduction with PCA and t-SNE Detecting sensor drift and system deviations Visualizing high-dimensional control system data Autoencoders for anomaly detection Case study: Quality variance clustering Integrating unsupervised insights into control decisions
Module 4: Reinforcement Learning in Dynamic Control
Basics of Markov Decision Processes (MDPs) Value functions and policy optimization Model-free vs. model-based RL in control Q-Learning and Deep Q Networks (DQNs) Reward shaping for control environments Safety constraints in RL agents Benchmarking RL for industrial controllers
Module 5: Hybrid Modeling: Physics-Based and ML Integration
Introduction to grey-box modeling Combining first-principles with neural networks Parameter estimation in hybrid systems Real-time simulation of hybrid models Interpretability and transparency in hybrid control models Model update and re-training strategies Deployment considerations and system integration
Module 6: Model Predictive Control (MPC) Enhanced with ML
Fundamentals of MPC and its mathematical structure Predictive modeling using ML for setpoint tracking State-space representation and online updates Optimization solvers in MPC frameworks Constraint handling in predictive environments Integration of ML-predicted disturbances Case applications in power and chemical plants
Module 7: Fault Detection and Anomaly Diagnosis
Definitions and taxonomy of faults in control systems Pattern recognition for early-stage fault detection Sensor health monitoring using ML Statistical process control with ML augmentation Classification algorithms for fault categorization Time-series anomaly scoring and alerts Validation using confusion matrix and ROC-AUC
Module 8: Real-Time Deployment and System Integration
Requirements for deploying ML in industrial control Architecture: Edge vs. Cloud-based inference Model latency and control loop timing considerations System integration using APIs and OPC-UA ML model retraining pipelines Scalability and version control Compliance with regulatory standards
Module 9: Ethical AI and Governance in Control Applications
Transparency in AI-assisted decision-making Data privacy and cybersecurity in control systems Bias and fairness in algorithmic control Documentation and model auditability Establishing governance frameworks Ethical implications in automated industrial decisions Risk management for AI-based controllers
Module 10: Industrial Case Studies and Sector-Specific Applications
Smart grid control using AI models Predictive maintenance in oil & gas compressors ML-optimized HVAC systems in manufacturing Water treatment control using unsupervised models Robotics and adaptive control in assembly lines Renewable energy forecasting in wind farms Integrated AI-control systems in smart factories

Have Any Question?

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