A generative neural network model for the quality prediction of work in progress products

Abstract One of the key challenges in manufacturing processes is improving the accuracy of quality monitoring and prediction. This paper proposes a generative neural network model for automatically predicting work-in-progress product quality. Our approach combines an unsupervised feature-extraction step with a supervised learning method. An autoencoding neural network is trained using raw manufacturing process data to extract rich information from production line recordings. Then, the extracted features are reformed as time-series and are fed into a multi-layer perceptron for predicting product quality. Finally, the outputs are decoded into a forecast quality measure. We evaluate the performance of the generative model on a case study from a powder metallurgy process. Our experimental results suggest that our method can precisely capture the defective products.

[1]  Jay Lee,et al.  Quality prediction modeling for multistage manufacturing based on classification and association rule mining , 2017 .

[2]  Min-Hsiung Hung,et al.  A processing quality prognostics scheme for plasma sputtering in TFT-LCD manufacturing , 2006 .

[3]  Amir Arifin,et al.  Material processing of hydroxyapatite and titanium alloy (HA/Ti) composite as implant materials using powder metallurgy: A review , 2014 .

[4]  Thomas P. Ryan,et al.  Statistical methods for quality improvement , 1989 .

[5]  Martin Fodslette Møller,et al.  A scaled conjugate gradient algorithm for fast supervised learning , 1993, Neural Networks.

[6]  Yoshua Bengio,et al.  Learning long-term dependencies with gradient descent is difficult , 1994, IEEE Trans. Neural Networks.

[7]  Gisela Guthausen,et al.  Process control with compact NMR , 2016 .

[8]  Liping Zhao,et al.  A dynamic quality control approach by improving dominant factors based on improved principal component analysis , 2015 .

[9]  William H. Woodall,et al.  Statistical monitoring of nonlinear product and process quality profiles , 2007, Qual. Reliab. Eng. Int..

[10]  Yuehjen E. Shao,et al.  Mixture control chart patterns recognition using independent component analysis and support vector machine , 2011, Neurocomputing.

[11]  Thomas Rbement,et al.  Fundamentals of quality control and improvement , 1993 .

[12]  Radu Grosu,et al.  An Automated Auto-encoder Correlation-based Health-Monitoring and Prognostic Method for Machine Bearings , 2017, ArXiv.

[13]  Huijun Gao,et al.  Data-Driven Process Monitoring Based on Modified Orthogonal Projections to Latent Structures , 2016, IEEE Transactions on Control Systems Technology.

[14]  A. R. Crathorne,et al.  Economic Control of Quality of Manufactured Product. , 1933 .

[15]  Radu Grosu,et al.  A novel Bayesian network-based fault prognostic method for semiconductor manufacturing process , 2017, 2017 IEEE International Conference on Industrial Technology (ICIT).

[16]  Sofiane Achiche,et al.  Online prediction of pulp brightness using fuzzy logic models , 2007, Eng. Appl. Artif. Intell..

[17]  Ying Zheng,et al.  Data-based fault-tolerant control of the semiconductor manufacturing process based on K-nearest neighbor nonparametric regression , 2012, Proceedings of the 10th World Congress on Intelligent Control and Automation.

[18]  Jimmy Ba,et al.  Adam: A Method for Stochastic Optimization , 2014, ICLR.

[19]  Mustapha Ouladsine,et al.  Prediction of the Wafer quality with respect to the production equipments data , 2015 .

[20]  Yoram Singer,et al.  Adaptive Subgradient Methods for Online Learning and Stochastic Optimization , 2011, J. Mach. Learn. Res..

[21]  S. Devahastin,et al.  Application of wavelet transform coupled with artificial neural network for predicting physicochemical properties of osmotically dehydrated pumpkin , 2009 .

[22]  Quoc V. Le,et al.  Semi-supervised Sequence Learning , 2015, NIPS.

[23]  Miao Zhang,et al.  Improved fruit fly optimization algorithm optimized wavelet neural network for statistical data modeling for industrial polypropylene melt index prediction , 2015 .

[24]  Jay Lee,et al.  A Cyber-Physical Systems architecture for Industry 4.0-based manufacturing systems , 2015 .

[25]  Ahmet Özdemir,et al.  WARPAGE PREDICTION IN PLASTIC INJECTION MOLDED PART USING ARTIFICIAL NEURAL NETWORK , 2013 .

[26]  Jay Lee,et al.  Service Innovation and Smart Analytics for Industry 4.0 and Big Data Environment , 2014 .

[27]  Burairah Hussin,et al.  A Data Mining Approach for Developing Quality Prediction Model in Multi-Stage Manufacturing , 2013 .

[28]  Hichem Snoussi,et al.  A fast and robust convolutional neural network-based defect detection model in product quality control , 2017, The International Journal of Advanced Manufacturing Technology.

[29]  Douglas C. Montgomery,et al.  Introduction to Statistical Quality Control , 1986 .

[30]  Kuang-Ku Chen,et al.  Integrating support vector machine and genetic algorithm to implement dynamic wafer quality prediction system , 2010, Expert Syst. Appl..

[31]  David Wang,et al.  Robust Data-Driven Modeling Approach for Real-Time Final Product Quality Prediction in Batch Process Operation , 2011, IEEE Transactions on Industrial Informatics.

[32]  Wen-Chin Chen,et al.  A neural network-based approach for dynamic quality prediction in a plastic injection molding process , 2008, Expert Syst. Appl..

[33]  Nitesh V. Chawla,et al.  SMOTE: Synthetic Minority Over-sampling Technique , 2002, J. Artif. Intell. Res..

[34]  Jie Yu,et al.  Online quality prediction of nonlinear and non-Gaussian chemical processes with shifting dynamics using finite mixture model based Gaussian process regression approach , 2012 .

[35]  László Monostori,et al.  ScienceDirect Variety Management in Manufacturing . Proceedings of the 47 th CIRP Conference on Manufacturing Systems Cyber-physical production systems : Roots , expectations and R & D challenges , 2014 .

[36]  Robert X. Gao,et al.  A deep learning-based approach to material removal rate prediction in polishing , 2017 .

[37]  Peng Fei Zhu,et al.  Prediction of Quality Index of Injection-Molded Parts by Using Artificial Neural Networks , 2011 .

[38]  A. J. Collins,et al.  Introduction To Multivariate Analysis , 1981 .

[39]  Tm McGinnity,et al.  Downstream performance prediction for a manufacturing system using neural networks and six-sigma improvement techniques , 2009 .

[40]  Si-Zhao Joe Qin,et al.  Survey on data-driven industrial process monitoring and diagnosis , 2012, Annu. Rev. Control..

[41]  Tullio Tolio,et al.  Design and management of manufacturing systems for production quality , 2014 .

[42]  Yibing Li,et al.  Quality Prediction Model Based on Mechanical Product Gene , 2013 .

[43]  Radu Grosu,et al.  Compositional neural-network modeling of complex analog circuits , 2017, 2017 International Joint Conference on Neural Networks (IJCNN).

[44]  Kaixu Bai,et al.  Integrating multisensor satellite data merging and image reconstruction in support of machine learning for better water quality management. , 2017, Journal of environmental management.

[45]  Lifeng Xi,et al.  A neural network ensemble-based model for on-line monitoring and diagnosis of out-of-control signals in multivariate manufacturing processes , 2009, Expert Syst. Appl..

[46]  Yun Bai,et al.  Manufacturing Quality Prediction Based on Two-Step Feature Learning Approach , 2017, 2017 International Conference on Sensing, Diagnostics, Prognostics, and Control (SDPC).

[47]  Radu Grosu,et al.  Efficient modeling of complex Analog integrated circuits using neural networks , 2016, 2016 12th Conference on Ph.D. Research in Microelectronics and Electronics (PRIME).

[48]  Patrick Charpentier,et al.  Implantation of an on-line quality process monitoring , 2013, Proceedings of 2013 International Conference on Industrial Engineering and Systems Management (IESM).

[49]  Stelios Psarakis,et al.  Multivariate statistical process control charts: an overview , 2007, Qual. Reliab. Eng. Int..

[50]  Prashant Mhaskar,et al.  Data‐driven model predictive quality control of batch processes , 2013 .

[51]  Fernando Nogueira,et al.  Imbalanced-learn: A Python Toolbox to Tackle the Curse of Imbalanced Datasets in Machine Learning , 2016, J. Mach. Learn. Res..

[52]  Klaus-Dieter Thoben,et al.  An approach to monitoring quality in manufacturing using supervised machine learning on product state data , 2013, Journal of Intelligent Manufacturing.

[53]  Alejandro Alvarado-Iniesta,et al.  A Recurrent Neural Network for Warpage Prediction in Injection Molding , 2012 .

[54]  G. A. Pugh Synthetic neural networks for process control , 1989 .

[55]  José Blasco,et al.  Machine Vision-Based Measurement Systems for Fruit and Vegetable Quality Control in Postharvest. , 2017, Advances in biochemical engineering/biotechnology.

[56]  Lei Yang,et al.  Bayesian Belief Network-based approach for diagnostics and prognostics of semiconductor manufacturing systems , 2012 .

[57]  Marc'Aurelio Ranzato,et al.  Sparse Feature Learning for Deep Belief Networks , 2007, NIPS.

[58]  Enrique Del Castillo,et al.  A Bayesian method for robust tolerance control and parameter design , 2006, IIE Transactions.

[59]  Ahmed Ghorbel,et al.  A survey of control-chart pattern-recognition literature (1991-2010) based on a new conceptual classification scheme , 2012, Comput. Ind. Eng..