Bayesian-Based Predictive Analytics for Manufacturing Performance Metrics in the Era of Industry 4.0

The research in this dissertation proposes Bayesian-based predictive analytics for modeling and prediction of the manufacturing metrics such as cutting force, tool life and reliability in the technological era of Industry 4.0. Bayesian statistics is a probabilistic method, which can quantify and minimize manufacturing process uncertainties. The Bayesian method combines previous knowledge about the manufacturing models with experimental data to predict the manufacturing metrics

Augmenting Milling Process Data for Shape Error Prediction

New integrated sensors and connected machine tools generate a tremendous amount of in-depth process data. The continuous transformation of the obtained data into deployable machining knowledge allows for faster ramp-ups, more reliable process outcome and higher profitability. A system for recording data from various sources - including a simultaneous material removal simulation - is implemented to aggregate and store process data. In addition to the simulation results, process data from the machine control, cutting forces and shape error samples are collected. A series of slot milling processes are carried out with varying cutting speed, feed per tooth and width of cut in a full factional design. In order to continuously evaluate process data, automatized methods are required. This is achieved using the simulation results to determine all relevant cutting conditions. Dependencies between cutting parameters, sensor signals and cutting result are identified and quantified. However, a one-dimensional model does not predict the shape error accurately. As an alternative model, a multidimensional model based on a Support Vector Machine is trained, using process forces and simulation data. The obtained prediction accuracy is significantly higher compared to the one-dimensional model and can be used to design highly reliable cutting processes.DFG/CRC/65

A big data MapReduce framework for fault diagnosis in cloud-based manufacturing

This research develops a MapReduce framework for automatic pattern recognition based on fault diagnosis by solving data imbalance problem in a cloud-based manufacturing (CBM). Fault diagnosis in a CBM system significantly contributes to reduce the product testing cost and enhances manufacturing quality. One of the major challenges facing the big data analytics in cloud-based manufacturing is handling of datasets, which are highly imbalanced in nature due to poor classification result when machine learning techniques are applied on such datasets. The framework proposed in this research uses a hybrid approach to deal with big dataset for smarter decisions. Furthermore, we compare the performance of radial basis function based Support Vector Machine classifier with standard techniques. Our findings suggest that the most important task in cloud-based manufacturing, is to predict the effect of data errors on quality due to highly imbalance unstructured dataset. The proposed framework is an original contribution to the body of literature, where our proposed MapReduce framework has been used for fault detection by managing data imbalance problem appropriately and relating it to firm’s profit function. The experimental results are validated using a case study of steel plate manufacturing fault diagnosis, with crucial performance matrices such as accuracy, specificity and sensitivity. A comparative study shows that the methods used in the proposed framework outperform the traditional ones

Business analytics in industry 4.0: a systematic review

Recently, the term “Industry 4.0” has emerged to characterize several Information Technology and Communication (ICT) adoptions in production processes (e.g., Internet-of-Things, implementation of digital production support information technologies). Business Analytics is often used within the Industry 4.0, thus incorporating its data intelligence (e.g., statistical analysis, predictive modelling, optimization) expert system component. In this paper, we perform a Systematic Literature Review (SLR) on the usage of Business Analytics within the Industry 4.0 concept, covering a selection of 169 papers obtained from six major scientific publication sources from 2010 to March 2020. The selected papers were first classified in three major types, namely, Practical Application, Reviews and Framework Proposal. Then, we analysed with more detail the practical application studies which were further divided into three main categories of the Gartner analytical maturity model, Descriptive Analytics, Predictive Analytics and Prescriptive Analytics. In particular, we characterized the distinct analytics studies in terms of the industry application and data context used, impact (in terms of their Technology Readiness Level) and selected data modelling method. Our SLR analysis provides a mapping of how data-based Industry 4.0 expert systems are currently used, disclosing also research gaps and future research opportunities.The work of P. Cortez was supported by FCT - Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020. We would like to thank to the three anonymous reviewers for their helpful suggestions

Harnessing the Power of Digital Twins for Enhanced Material Behavior Prediction and Manufacturing Process Optimization in Materials Engineering

The advent of Industry 4.0 and the digital revolution have brought forth innovative technologies such as digital twins, which have the potential to redefine the landscape of materials engineering. Digital twins, virtual representations of physical entities, can model and predict material behavior, enabling enhanced design, testing, and manufacturing of materials. However, the comprehensive utilization of digital twins for predictive analysis and process optimization in materials engineering remains largely uncharted. This research intends to delve into this intriguing intersection, investigating the capabilities of digital twins in predicting material behavior and optimizing manufacturing processes, thereby contributing to the evolution of advanced materials manufacturing. Our study will commence with a detailed exploration of the concept of digital twins and their specific applications in materials engineering, emphasizing their ability to simulate intricate material behaviors and processes in a virtual environment. Subsequently, we will focus on exploiting digital twins for predicting diverse material behaviors such as mechanical properties, failure modes, and phase transformations, demonstrating how digital twins can utilize a combination of historical data, real-time monitoring, and sophisticated algorithms to predict outcomes accurately. Furthermore, we will delve into the role of digital twins in optimizing materials manufacturing processes, including casting, machining, and additive manufacturing, illustrating how digital twins can model these processes, identify potential issues, and suggest optimal parameters. We will present detailed case studies to provide practical insights into the implementation of digital twins in materials engineering, including the advantages and challenges. The final segment of our research will address the current challenges in implementing digital twins, such as data quality, model validation, and computational demands, proposing potential solutions and outlining future directions. This research aims to underline the transformative potential of digital twins in materials engineering, thereby paving the way for more efficient, sustainable, and intelligent material design and manufacturing processes

Hybrid modeling to support the smart manufacturing: concepts, theoretic contributions and real-case applications about Hybrid and Wisdom-based Systems

L'abstract è presente nell'allegato / the abstract is in the attachmen

Sensors Data Analysis in Supervisory Control and Data Acquisition (SCADA) Systems to Foresee Failures with an Undetermined Origin

This paper presents the design and implementation of a supervisory control and data acquisition (SCADA) system for automatic fault detection. The proposed system offers advantages in three areas: the prognostic capacity for preventive and predictive maintenance, improvement in the quality of the machined product and a reduction in breakdown times. The complementary technologies, the Industrial Internet of Things (IIoT) and various machine learning (ML) techniques, are employed with SCADA systems to obtain the objectives. The analysis of different data sources and the replacement of specific digital sensors with analog sensors improve the prognostic capacity for the detection of faults with an undetermined origin. Also presented is an anomaly detection algorithm to foresee failures and to recognize their occurrence even when they do not register as alarms or events. The improvement in machine availability after the implementation of the novel system guarantees the accomplishment of the proposed objectives.This work was supported partially by the Basque Government through project IT1207-19, and by the MCIU/MINECO through RTI2018-094902-B-C21/RTI2018-094902-B-C22 (MCIU/AEI/FEDER, UE). The authors would like to thank Intenance Company for its collaboration and help

Discharge Moisture Prediction of the Corn Gluten Feed Drying Process Using Machine Learning Algorithms

Modern manufacturing processes have multiple sensors (or instruments) installed that provide constant data stream outputs; however, there are some critical performance and quality variables where installing physical sensors is either impractical, expensive, not hardy enough for hostile environments or the sensor technology is not sufficiently advanced. An example of such a problem is measure moisture of solid products in real-time. If this scenario happens, Machine Learning (ML) approaches are a suitable solution as are capable of learning and representing complex relationships. ML algorithms establish a mathematical relationship between the quantity of interest and other measurable quantities such as readings from already available sensors (e.g., SCADA, historian softwares, SQL Databases, etc.). This study details how ML algorithms (Such as Multiple Linear Regression, Support Vector Machine Regression and Regression Trees) are used to predict critical variable moisture in gluten feed (a by-product of the wet-milling of maize grain for starch or ethanol production) as a simple, robust and fast solution for the lack of this variable real-time information for a corn products manufacturer. The resulting model performance demonstrates the feasibility of the ML algorithms approach to predict moisture behaviour

5G-Based Multi-Sensor Platform for Monitoring of Workpieces and Machines: Prototype Hardware Design and Firmware

In this paper, we introduce a 5G-based multi-sensor platform for monitoring workpieces and machines. The prototype is realized within the EU-funded 5G-SMART project, which aims to enable smart manufacturing through 5G, demonstrating and validating new generation network technology in industrial processes. There are already state-of-the-art solutions, but with drawbacks such as limited flexibility, brief real-time capability, and sensors aimed at single applications. The 5G-SMART multi-sensor platform is designed to overcome these points and meet the requirements of Industry 4.0. The device is equipped with different sensors to acquire multiple data from workpieces and machines of the shop floor, wirelessly connected by 5G to the factory cloud. A hardware design description of the prototype is provided, focusing on the electronic components and their interaction with the microcontroller. Verification of the correct functioning of the board is given, with a basic library for the main peripherals used as a basis for the final firmware