A New S-2 Control Chart Using Multiple Dependent State Repetitive Sampling

The combined application of multiple dependent state sampling and the repetitive group sampling (RGS) is an efficient sampling scheme for industrial process monitoring as it combines the advantages of both the sampling schemes. In this paper, a new variance control chart has been proposed, when the interesting quality characteristic follows the normal distribution using the combination of these two efficient sampling schemes called multiple dependent state repetitive sampling. The control chart coefficients and parameters have been estimated through simulation for the in-control process by considering the target in-control average run lengths under different process settings. The efficiency of the proposed chart has been determined by computing the out-of-control ARL for different shift levels. The advantages of the proposed monitoring scheme have been discussed and compared with the existing RGS scheme and the single sampling scheme. A simulated example and a real industrial data have been included to demonstrate the application of the proposed monitoring scheme. It has been observed that the proposed chart is a valuable addition to the toolkit of the quality monitoring personnel.11Ysciescopu

A Multivariate Homogeneously Weighted Moving Average Control Chart

This paper presents a multivariate homogeneously weighted moving average (MHWMA) control chart for monitoring a process mean vector. The MHWMA control chart statistic gives a specific weight to the current observation, and the remaining weight is evenly distributed among the previous observations. We present the design procedure and compare the average run length (ARL) performance of the proposed chart with multivariate Chi-square, multivariate EWMA, and multivariate cumulative sum control charts. The ARL comparison indicates superior performance of the MHWMA chart over its competitors, particularly for the detection of small shifts in the process mean vector. Examples are also provided to show the application of the proposed chart. - 2013 IEEE.Scopu

A Nonparametric HEWMA-p Control Chart for Variance in Monitoring Processes

Control charts are considered as powerful tools in detecting any shift in a process. Usually, the Shewhart control chart is used when data follows the symmetrical property of a normal distribution. In practice, the data from the industry may follow a non-symmetrical distribution or an unknown distribution. The average run length (ARL) is a significant measure to assess the performance of the control chart. The ARL may mislead when the statistic is computed from an asymmetric distribution. To handle this issue, in this paper, an ARL-unbiased hybrid exponentially weighted moving average proportion (HEWMA-p) chart is proposed for monitoring the process variance for a non-normal distribution or an unknown distribution. The efficiency of the proposed chart is compared with the existing chart in terms of ARLs. The proposed chart is more efficient than the existing chart in terms of ARLs. A real example is given for the illustration of the proposed chart in the industry.11Ysciescopu

Contributions to improve the power, efficiency and scope of control-chart methods : a thesis submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy in Statistics at Massey University, Albany, New Zealand

Listed in 2019 Dean's List of Exceptional ThesesDetection of outliers and other anomalies in multivariate datasets is a particularly difficult problem which spans across a range of systems, such as quality control in factories, microarrays or proteomic analyses, identification of features in image analysis, identifying unauthorized access in network traffic patterns, and detection of changes in ecosystems. Multivariate control charts (MCC) are popular and sophisticated statistical process control (SPC) methods for monitoring characteristics of interest and detecting changes in a multivariate process. These methods are divided into memory-less and memory-type charts which are used to monitor large and small-to-moderate shifts in the process, respectively. For example, the multivariate χ2 is a memory-less control chart that uses only the most current process information and disregards any previous observations; it is typically used where any shifts in the process mean are expected to be relatively large. To increase the sensitivity of the multivariate process control tool for the detection of small-to-moderate shifts in the process mean vector, different multivariate memory-type tools that use information from both the current and previous process observations have been proposed. These tools have proven very useful for multivariate independent normal or "nearly" normal distributed processes. Like most univariate control-chart methods, when the process parameters (i.e., the process mean vector or covariance parameters, or both) are unknown, then MCC methods are based on estimated parameters, and their implementation occurs in two phases. In Phase I (retrospective phase), a historical reference sample is studied to establish the characteristics of the in-control state and evaluate the stability of the process. Once the in-control reference sample has been deemed to be stable, the process parameters are estimated from Phase I, and control chart limits are obtained for use in Phase II. The Phase II aspect initiates ongoing regular monitoring of the process. If successive observed values obtained at the beginning of Phase II fall within specified desired in-control limits, the process is considered to be in control. In contrast, any observed values during Phase II which fall outside the specified control limits indicate that the process may be out of control, and remedial responses are then required. Although conventional MCC are well developed from a statistical point of view, they can be difficult to apply in modern, data-rich contexts. This serious drawback comes from the fact that classical MCC plotting statistics requires the inversion of the covariance matrix, which is typically assumed to be known. In practice, the covariance matrix is seldom known and often empirically estimated, using a sample covariance matrix from historical data. While the empirical estimate of the covariance matrix may be an unbiased and consistent estimator for a low-dimensional data matrix with an adequate prior sample size, it performs inconsistently in high-dimensional settings. In particular, the empirical estimate of the covariance matrix can lead to in ated false-alarm rates and decreased sensitivity of the chart to detect changes in the process. Also, the statistical properties of traditional MCC tools are accurate only if the assumption of multivariate normality is satisfied. However, in many cases, the underlying system is not multivariate normal, and as a result, the traditional charts can be adversely affected. The necessity of this assumption generally restricts the application of traditional control charts to monitoring industrial processes. Most MCC applications also typically focus on monitoring either the process mean vector or the process variability, and they require that the process mean vector be stable, and that the process variability be independent of the process mean. However, in many real-life processes, the process variability is dependent on the mean, and the mean is not necessarily constant. In such cases, it is more appropriate to monitor the coefficient of variation (CV). The univariate CV is the ratio of the standard deviation to the mean of a random variable. As a relative dispersion measure to the mean, it is useful for comparing the variability of populations having very different process means. More recently, MCC methods have been adapted for monitoring the multivariate coefficient of variation (CV). However, to date, studies of multivariate CV control charts have focused on power - the detection of out-of-control parameters in Phase II, while no study has investigated their in-control performance in Phase I. The Phase I data set can contain unusual observations, which are problematic as they can in uence the parameter estimates, resulting in Phase II control charts with reduced power. Relevant Phase I analysis will guide practitioners with the choice of appropriate multivariate CV estimation procedures when the Phase I data contain contaminated samples. In this thesis, we investigated the performance of the most widely adopted memory-type MCC methods: the multivariate cumulative sum (MCUSUM) and the multivariate exponentially weighted moving average (MEWMA) charts, for monitoring shifts in a process mean vector when the process parameters are unknown and estimated from Phase I (chapters 2 and 3). We demonstrate that using a shrinkage estimate of the covariance matrix improves the run-length performance of these methods, particularly when only a small Phase I sample size is available. In chapter 4, we investigate the Phase I performance of a variety of multivariate CV charts, considering both diffuse symmetric and localized CV disturbance scenarios, and using probability to signal (PTS) as a performance measure. We present a new memory-type control chart for monitoring the mean vector of a multivariate normally distributed process, namely, the multivariate homogeneously weighted moving average (MHWMA) control chart (chapter 5). We present the design procedure and compare the run length performance of the proposed MHWMA chart for the detection of small shifts in the process mean vector with a variety of other existing MCC methods. We also present a dissimilarity-based distribution-free control chart for monitoring changes in the centroid of a multivariate ecological community (chapter 6). The proposed chart may be used, for example, to discover when an impact may have occurred in a monitored ecosystem, and is based on a change-point method that does not require prior knowledge of the ecosystem's behaviour before the monitoring begins. A novel permutation procedure is employed to obtain the control-chart limits of the proposed charting test-statistic to obtain a suitable distance-based model of the target ecological community through time. Finally, we propose enhancements to some classical univariate control chart tools for monitoring small shifts in the process mean, for those scenarios where the process variable is observed along with a correlated auxiliary variable (chapters 7 through 9). We provide the design structure of the charts and examine their performance in terms of their run length properties. We compare the run length performance of the proposed charts with several existing charts for detecting a small shift in the process mean. We offer suggestions on the applications of the proposed charts (in chapters 7 and 8), for cases where the exact measurement of the process variable of interest or the auxiliary variable is diffcult or expensive to obtain, but where the rank ordering of its units can be obtained at a negligible cost. Thus, this thesis, in general, will aid practitioners in applying a wider variety of enhanced and novel control chart tools for more powerful and effcient monitoring of multivariate process. In particular, we develop and test alternative methods for estimating covariance matrices of some useful control-charts' tools (chapters 2 and 3), give recommendations on the choice of an appropriate multivariate CV chart in Phase I (chapter 4), present an efficient method for monitoring small shifts in the process mean vector (chapter 5), expand MCC analyses to cope with non-normally distributed datasets (chapter 6) and contribute to methods that allow efficient use of an auxiliary variable that is observed and correlated with the process variable of interest (chapters 7 through 9)

An attribute oriented induction based methodology to aid in predictive maintenance: anomaly detection, root cause analysis and remaining useful life

Predictive Maintenance is the maintenance methodology that provides the best performance to industrial organisations in terms of time, equipment effectiveness and economic savings. Thanks to the recent advances in technology, capturing process data from machines and sensors attached to them is no longer a challenging task, and can be used to perform complex analyses to help with maintenance requirements. On the other hand, knowledge of domain experts can be combined with information extracted from the machines’ assets to provide a better understanding of the underlying phenomena. This thesis proposes a methodology to assess the different requirements in relation to Predictive Maintenance. These are (i) Anomaly Detection (AD), (ii) Root Cause Analysis (RCA) and (iii) estimation of Remaining Useful Life (RUL). Multiple machine learning techniques and algorithms can be found in the literature to carry out the calculation of these requirements. In this thesis, the Attribute Oriented Induction (AOI) algorithm has been adopted and adapted to the Predictive Maintenance methodology needs. AOI has the capability of performing RCA, but also possibility to be used as an AD system. With the purpose of performing Predictive Maintenance, a variant, Repetitive Weighted Attribute Oriented Induction (ReWAOI ), has been proposed. ReWAOI has the ability to combine information extracted from the machine with the knowledge of experts in the field to describe its behaviour, and derive the Predictive Maintenance requirements. Through the use of ReWAOI, one-dimensional quantification function from multidimensional data can be obtained. This function is correlated with the evolution of the machine’s wear over time, and thus, the estimation of AD and RUL has been accomplished. In addition, the ReWAOI helps in the description of failure root causes. The proposed contributions of the thesis have been validated in different scenarios, both emulated but also real industrial case studies.Enpresei errendimendu hoberena eskaintzen dien mantentze metodologia Mantentze Prediktiboa da, denbora, ekipamenduen eraginkortasun, eta ekonomia alorretan. Azken urteetan eman diren teknologia aurrerapenei esker, makina eta sensoreetatiko datuen eskuraketa jada ez da erronka, eta manentenimendurako errekerimenduak betetzen laguntzeko analisi konplexuak egiteko erabili daitezke. Bestalde, alorreko jakintsuen ezagutza makinetatik eskuratzen den informazioarekin bateratu daiteke, gertakarien gaineko ulermena hobea izan dadin. Tesi honetan metodologia berri bat proposatzen da, Mantentze Prediktiboarekin lotura duten errekerimenduak betearazten dituena. Ondorengoak dira: (i) Anomalien Detekzioa (AD), (ii) Erro-Kausaren Analisia (RCA), eta (iii) Gainontzeko Bizitza Erabilgarriaren (RUL) estimazioa. Errekerimendu hauen kalkulua burutzeko, ikasketa automatikoko hainbat algoritmo aurkitu daitezke literaturan. Tesi honetan Attribute Oriented Induction (AOI) algoritmoa erabili eta egokitu da Mantentze Prediktiboaren beharretara. AOI-k RCA estimatzeko ahalmena dauka, baina AD kalkulatzeko erabilia izan daiteke baita ere. Mantentze Prediktiboa aplikatzeko helburuarekin, AOI-rentzat aldaera bat proposatu da: Repetitive Weighted Attribute Oriented Induction (ReWAOI ). ReWAOI-k alorreko jakintsuen ezagutza eta makinetatik eskuratutako informazioa bateratzeko ahalmena dauka, makinen portaera deskribatu ahal izateko, eta horrela, Mantentze Prediktiboaren errekerimenduak betetzeko. ReWAOI-ren erabileraren ondorioz, dimentsio bakarreko kuantifikazio funtzioa eskuratu daiteke hainbat dimentsiotako datuetatik. Funztio hau denboran zehar makinak duen higadurarekin erlazionatuta dago, eta beraz, AD eta RUL-aren estimazioak burutu daitezke. Horretaz gain, ReWAOI-k hutsegiteen erro-kausaren deskribapenak eskaintzeko ahalmena dauka. Tesian proposatutako kontribuzioak hainbat erabilpen kasutan balioztatu dira, batzuk emulatuak, eta beste batzuk industria alorreko kasu errealak izanik.El Mantenimiento Predictivo es la metodología de mantenimiento que mejor rendimiento aporta a las organizaciones industriales en cuestiones de tiempo, eficiencia del equipamiento, y rendimiento económico. Gracias a los recientes avances en tecnología, la captura de datos de proceso de máquinas y sensores ya no es un reto, y puede utilizarse para realizar complejos análisis que ayuden con el cumplimiento de los requerimientos de mantenimiento. Por otro lado, el conocimiento de expertos de dominio puede ser combinado con la información extraída de las máquinas para otorgar una mejor comprensión de los fenómenos ocurridos. Esta tesis propone una metodología que cumple con diferentes requerimientos establecidos para el Mantenimiento Predictivo. Estos son (i) la Detección de Anomalías (AD), el Análisis de la Causa-Raíz (RCA) y (iii) la estimación de la Vida Útil Remanente. Pueden encontrarse múltiples técnicas y algoritmos de aprendizaje automático en la literatura para llevar a cabo el cálculo de estos requerimientos. En esta tesis, el algoritmo Attribute Oriented Induction (AOI) ha sido seleccionado y adaptado a las necesidades que establece el Mantenimiento Predictivo. AOI tiene la capacidad de estimar el RCA, pero puede usarse, también, para el cálculo de la AD. Con el propósito de aplicar Mantenimiento Predictivo, se ha propuesto una variante del algoritmo, denominada Repetitive Weighted Attribute Oriented Induction (ReWAOI ). ReWAOI tiene la capacidad de combinar información extraída de la máquina y conocimiento de expertos de área para describir su comportamiento, y así, poder cumplir con los requerimientos del Mantenimiento Predictivo. Mediante el uso de ReWAOI, se puede obtener una función de cuantificación unidimensional, a partir de datos multidimensionales. Esta función está correlacionada con la evolución de la máquina en el tiempo, y por lo tanto, la estimación de AD y RUL puede ser realizada. Además, ReWAOI facilita la descripción de las causas-raíz de los fallos producidos. Las contribuciones propuestas en esta tesis han sido validadas en distintos escenarios, tanto en casos de uso industriales emulados como reales

A new CUSUM control chart under uncertainty with applications in petroleum and meteorology

Please read abstract in the article.http://www.plosone.orgpm2022Statistic

ISBIS 2016: Meeting on Statistics in Business and Industry

This Book includes the abstracts of the talks presented at the 2016 International Symposium on Business and Industrial Statistics, held at Barcelona, June 8-10, 2016, hosted at the Universitat Politècnica de Catalunya - Barcelona TECH, by the Department of Statistics and Operations Research. The location of the meeting was at ETSEIB Building (Escola Tecnica Superior d'Enginyeria Industrial) at Avda Diagonal 647. The meeting organizers celebrated the continued success of ISBIS and ENBIS society, and the meeting draw together the international community of statisticians, both academics and industry professionals, who share the goal of making statistics the foundation for decision making in business and related applications. The Scientific Program Committee was constituted by: David Banks, Duke University Amílcar Oliveira, DCeT - Universidade Aberta and CEAUL Teresa A. Oliveira, DCeT - Universidade Aberta and CEAUL Nalini Ravishankar, University of Connecticut Xavier Tort Martorell, Universitat Politécnica de Catalunya, Barcelona TECH Martina Vandebroek, KU Leuven Vincenzo Esposito Vinzi, ESSEC Business Schoo

Volumetric Error-Based Condition and Health Monitoring System for Machine-Tools

Résumé Des défaillances ou détériorations imprévues ou non détectées des machines-outils entraînent des pertes de production et de qualité, d'où la nécessité d'une maintenance prescriptive et normative utilisant la surveillance de l'état des machines-outils. Cette recherche présente la méthodologie et les solutions développées pour surveiller l’état de précision des machines-outils à cinq axes en analysant les erreurs volumétriques de la machine-outil. L’erreur volumétrique est définie comme un vecteur d'erreur cartésien représentant l'écart de la position réelle de l'outil par rapport à sa position attendue par rapport au repère de la pièce et projeté dans le repère de base. La méthode SAMBA (Scale and Master Ball Artefact) a été utilisée pour mesurer les erreurs volumétriques de la machine-outil expérimentale à cinq axes. Les erreurs volumétriques acquises contenant les états normaux et défectueux de la machine-outil constituent la base de données pour cette recherche. De plus, des pseudo-fautes et les fautes graduelles et soudaines simulées ont également été utilisées. Les caractéristiques du vecteur d'erreurs volumétriques extraites par des mesures de similarité de vecteur sont utilisées comme entrée pour le graphique de contrôle basé sur les moyennes mobiles pondérées exponentiellement, où le changement anormal du vecteur unique d'erreurs volumétriques peut être détecté. Pour surveiller de manière exhaustive l’état de précision de la machine-outil, une matrice de mesures de similarité vectorielle combinée contenant toutes les caractéristiques d’erreurs volumétriques acquises a été proposée et traitée par le graphique de contrôle de la moyenne mobile pondérée exponentiellement. Pour les mêmes défauts, les deux traitements de données ci-dessus peuvent tous détecter automatiquement le temps exact d’apparition du défaut. Sur la base d'une logique de surveillance complète des erreurs volumétriques, une analyse fractale des coordonnées d'erreur volumétrique a également été explorée. Les résultats des tests révèlent qu’il s’agit d’un outil efficace pour représenter la fonctionnalité des erreurs volumétriques. Pour comprendre le processus de changement de l'état de la machine-outil, les erreurs volumétriques historiques acquises ont été traitées par analyse en composantes principales et par K-moyennes. D'une part, les méthodes proposées séparent les états normaux et défectueux de la machine-outil (près de 100%), d'autre part, les machines-outils désignées fournissent les références pour la reconnaissance de l'état d’autre machines-outils lors du traitement de nouvelles données d'erreurs volumétriques. En résumé, le travail de recherche effectué dans cette thèse a contribué à la mise au point d’une solution efficace de surveillance de l’état de la précision des machines-outils à l’aide des erreurs volumétriques des machines-outils, basées sur des méthodes d’extraction de caractéristiques, de reconnaissance des modifications et de classification des états. Le système développé peut reconnaître les points de changement exacts des défauts réels du codeur d'axe C, des pseudo-défauts EXX et EYX. De plus, il atteint une précision proche de 100% dans la classification de l'état défectueux et normal de la machine-outil. ---------- Abstract Unexpected or undetected machine tool failures or deterioration results in production and quality losses, hence proactive and prescriptive maintenance using machine tool condition monitoring is sought. This research presents the methodology and solutions developed to monitor the accuracy state of five-axis machine tools by analyzing the machine tool volumetric errors which are defined as the Cartesian error vector of the deviation of the actual tool position compared to its expected position relative to the workpiece frame and projected into the foundation frame. The scale and master ball artefact (SAMBA) method has been used for the measurement of volumetric errors of the experimental five-axis machine tool. The acquired volumetric errors containing machine tool normal and faulty states provide the database for this research. In addition, pseudo-faults and the simulated gradual and sudden faults have also been used. Volumetric error vector features extracted by vector similarity measures are used as the input for the exponential weight moving average control chart where the abnormal change of the single volumetric error vector can be detected. To comprehensively monitor the machine tool accuracy state, a combined vector similarity measure array containing all acquired volumetric errors features has been proposed and processed by the exponential weight moving average control chart. Towards the same faults, the above two data processing can all automatically detect the exact fault occurrence time. Based on the logic of comprehensive monitoring of volumetric errors, fractal analysis of volumetric error coordinates has also been explored. The testing results reveal that it is an effective tool for volumetric errors features representing. To understand the change process of the machine tool state, the acquired historical volumetric errors have been processed by principal component analysis and K-means. For one thing, the proposed methods separate the normal and faulty states of the machine tool (Nearly 100%), for another thing, the designated machine tools provide the references for machine tools state recognition when processing new volumetric errors data. In summary, this research contributed to the development of an efficient solution for machine tool accuracy state monitoring using machine tools volumetric errors based on feature extraction, change recognition and state classification methods. The developed system can recognize the exact change points of real C-axis encoder faults, pseudo-faults EXX and EYX. In addition, it achieves close to 100% accuracy in machine tool faulty and normal state classification

Design of an intelligent embedded system for condition monitoring of an industrial robot

PhD ThesisIndustrial robots have long been used in production systems in order to improve productivity, quality and safety in automated manufacturing processes. There are significant implications for operator safety in the event of a robot malfunction or failure, and an unforeseen robot stoppage, due to different reasons, has the potential to cause an interruption in the entire production line, resulting in economic and production losses. Condition monitoring (CM) is a type of maintenance inspection technique by which an operational asset is monitored and the data obtained is analysed to detect signs of degradation, diagnose the causes of faults and thus reduce maintenance costs. So, the main focus of this research is to design and develop an online, intelligent CM system based on wireless embedded technology to detect and diagnose the most common faults in the transmission systems (gears and bearings) of the industrial robot joints using vibration signal analysis. To this end an old, but operational, PUMA 560 robot was utilized to synthesize a number of different transmission faults in one of the joints (3 - elbow), such as backlash between the gear pair, gear tooth and bearing faults. A two-stage condition monitoring algorithm is proposed for robot health assessment, incorporating fault detection and fault diagnosis. Signal processing techniques play a significant role in building any condition monitoring system, in order to determine fault-symptom relationships, and detect abnormalities in robot health. Fault detection stage is based on time-domain signal analysis and a statistical control chart (SCC) technique. For accurate fault diagnosis in the second stage, a novel implementation of a time-frequency signal analysis technique based on the discrete wavelet transform (DWT) is adopted. In this technique, vibration signals are decomposed into eight levels of wavelet coefficients and statistical features, such as standard deviation, kurtosis and skewness, are obtained at each level and analysed to extract the most salient feature related to faults; the artificial neural network (ANN) is then used for fault classification. A data acquisition system based on National Instruments (NI) software and hardware was initially developed for preliminary robot vibration analysis and feature extraction. The transmission faults induced in the robot can change the captured vibration spectra, and the robot’s natural frequencies were established using experimental modal analysis, and also the fundamental fault frequencies for the gear transmission and bearings were obtained and utilized for preliminary robot condition monitoring. In addition to simulation of different levels of backlash fault, gear tooth and bearing faults which have not been previously investigated in industrial robots, with several levels of ii severity, were successfully simulated and detected in the robot’s joint transmission. The vibration features extracted, which are related to the robot healthy state and different fault types, using the data acquisition system were subsequently used in building the SCC and ANN, which were trained using part of the measured data set that represents the robot operating range. Another set of data, not used within the training stage, was then utilized for validation. The results indicate the successful detection and diagnosis of faults using the key extracted parameters. A wireless embedded system based on the ZigBee communication protocol was designed for the application of the proposed CM algorithm in real-time, using an Arduino DUE as the core of the wireless sensor unit attached on the robot arm. A Texas Instruments digital signal processor (TMS320C6713 DSK board) was used as the base station of the wireless system on which the robot’s fault diagnosis algorithm is run. To implement the two stages of the proposed CM algorithm on the designed embedded system, software based on the C programming language has been developed. To demonstrate the reliability of the designed wireless CM system, experimental validations were performed, and high reliability was shown in the detection and diagnosis of several seeded faults in the robot. Optimistically, the established wireless embedded system could be envisaged for fault detection and diagnostics on any type of rotating machine, with the monitoring system realized using vibration signal analysis. Furthermore, with some modifications to the system’s hardware and software, different CM techniques such as acoustic emission (AE) analysis or motor current signature analysis (MCSA), can be applied.Iraqi government, represented by the Ministry of Higher Education and Scientific Research, the Iraqi Cultural Attaché in London, and the University of Technology in Baghda