This article presents two hybrid robust process optimization approaches int
egrating artificial neural networks (ANN) and stochastic optimization forma
lisms-genetic algorithms (GAs) and simultaneous perturbation stochastic app
roximation (SPSA). An ANN-based process model was developed solely from pro
cess input - output data and then its input space comprising design and ope
rating variables was optimized by employing either the GA or the SPSA metho
dology. These methods possess certain advantages over widely used determini
stic gradient-based techniques. The efficacy of ANN-GA and ANN-SPSA formali
sms in the presence of noise-free as well as noisy process data was demonst
rated for a representative system involving a nonisothermal CSTR. The case
study considered a nontrivial optimization objective, which, in addition to
the conventional parameter design also addresses the issue of optimal tole
rance design. Comparison of the results with those from a robust determinis
tic modeling/optimization strategy suggests that the hybrid methodologies c
an be gainfully employed for process optimization.