Multivariate Statistical Process Control Charts: An Overview

In this paper we discuss the basic procedures for the implementation of multivariate statistical process control via control charting. Furthermore, we review multivariate extensions for all kinds of univariate control charts, such as multivariate Shewhart-type control charts, multivariate CUSUM control charts and multivariate EWMA control charts. In addition, we review unique procedures for the construction of multivariate control charts, based on multivariate statistical techniques such as principal components analysis (PCA) and partial lest squares (PLS). Finally, we describe the most significant methods for the interpretation of an out-of-control signal.quality control, process control, multivariate statistical process control, Hotelling's T-square, CUSUM, EWMA, PCA, PLS

Exploiting Robust Multivariate Statistics and Data Driven Techniques for Prognosis and Health Management

This thesis explores state of the art robust multivariate statistical methods and data driven techniques to holistically perform prognostics and health management (PHM). This provides a means to enable the early detection, diagnosis and prognosis of future asset failures. In this thesis, the developed PHM methodology is applied to wind turbine drive train components, specifically focussed on planetary gearbox bearings and gears. A novel methodology for the identification of relevant time-domain statistical features based upon robust statistical process control charts is presented for high frequency bearing accelerometer data. In total, 28 time-domain statistical features were evaluated for their capabilities as leading indicators of degradation. The results of this analysis describe the extensible multivariate “Moments’ model” for the encapsulation of bearing operational behaviour. This is presented, enabling the early degradation of detection, predictive diagnostics and estimation of remaining useful life (RUL). Following this, an extended physics of failure model based upon low frequency SCADA data for the quantification of wind turbine gearbox condition is described. This extends the state of the art, whilst defining robust performance charts for quantifying component condition. Normalisation against loading of the turbine and transient states based upon empirical data is performed in the bivariate domain, with extensibility into the multivariate domain if necessary. Prognosis of asset condition is found to be possible with the assistance of artificial neural networks in order to provide business intelligence to the planning and scheduling of effective maintenance actions. These multivariate condition models are explored with multivariate distance and similarity metrics for to exploit traditional data mining techniques for tacit knowledge extraction, ensemble diagnosis and prognosis. Estimation of bearing remaining useful life is found to be possible, with the derived technique correlating strongly to bearing life (r = .96

Seleção de variáveis aplicada ao controle estatístico multivariado de processos em bateladas

A presente tese apresenta proposições para o uso da seleção de variáveis no aprimoramento do controle estatístico de processos multivariados (MSPC) em bateladas, a fim de contribuir com a melhoria da qualidade de processos industriais. Dessa forma, os objetivos desta tese são: (i) identificar as limitações encontradas pelos métodos MSPC no monitoramento de processos industriais; (ii) entender como métodos de seleção de variáveis são integrados para promover a melhoria do monitoramento de processos de elevada dimensionalidade; (iii) discutir sobre métodos para alinhamento e sincronização de bateladas aplicados a processos com diferentes durações; (iv) definir o método de alinhamento e sincronização mais adequado para o tratamento de dados de bateladas, visando aprimorar a construção do modelo de monitoramento na Fase I do controle estatístico de processo; (v) propor a seleção de variáveis, com propósito de classificação, prévia à construção das cartas de controle multivariadas (CCM) baseadas na análise de componentes principais (PCA) para monitorar um processo em bateladas; e (vi) validar o desempenho de detecção de falhas da carta de controle multivariada proposta em comparação às cartas tradicionais e baseadas em PCA. O desempenho do método proposto foi avaliado mediante aplicação em um estudo de caso com dados reais de um processo industrial alimentício. Os resultados obtidos demonstraram que a realização de uma seleção de variáveis prévia à construção das CCM contribuiu para reduzir eficientemente o número de variáveis a serem analisadas e superar as limitações encontradas na detecção de falhas quando bancos de elevada dimensionalidade são monitorados. Conclui-se que, ao possibilitar que CCM, amplamente utilizadas no meio industrial, sejam adequadas para banco de dados reais de elevada dimensionalidade, o método proposto agrega inovação à área de monitoramento de processos em bateladas e contribui para a geração de produtos de elevado padrão de qualidade.This dissertation presents propositions for the use of variable selection in the improvement of multivariate statistical process control (MSPC) of batch processes, in order to contribute to the enhacement of industrial processes’ quality. There are six objectives: (i) identify MSPC limitations in industrial processes monitoring; (ii) understand how methods of variable selection are used to improve high dimensional processes monitoring; (iii) discuss about methods for alignment and synchronization of batches with different durations; (iv) define the most adequate alignment and synchronization method for batch data treatment, aiming to improve Phase I of process monitoring; (v) propose variable selection for classification prior to establishing multivariate control charts (MCC) based on principal component analysis (PCA) to monitor a batch process; and (vi) validate fault detection performance of the proposed MCC in comparison with traditional PCA-based and charts. The performance of the proposed method was evaluated in a case study using real data from an industrial food process. Results showed that performing variable selection prior to establishing MCC contributed to efficiently reduce the number of variables and overcome limitations found in fault detection when high dimensional datasets are monitored. We conclude that by improving control charts widely used in industry to accomodate high dimensional datasets the proposed method adds innovation to the area of batch process monitoring and contributes to the generation of high quality standard products

Online coherency identification and stability condition for large interconnected power systems using an unsupervised data mining technique

Identification of coherent generators and the determination of the stability system condition in large interconnected power system is one of the key steps to carry out different control system strategies to avoid a partial or complete blackout of a power system. However, the oscillatory trends, the larger amount data available and the non-linear dynamic behaviour of the frequency measurements often mislead the appropriate knowledge of the actual coherent groups, making wide-area coherency monitoring a challenging task. This paper presents a novel online unsupervised data mining technique to identify coherent groups, to detect the power system disturbance event and determine status stability condition of the system. The innovative part of the proposed approach resides on combining traditional plain algorithms such as singular value decomposition (SVD) and K -means for clustering together with new concept based on clustering slopes. The proposed combination provides an added value to other applications relying on similar algorithms available in the literature. To validate the effectiveness of the proposed method, two case studies are presented, where data is extracted from the large and comprehensive initial dynamic model of ENTSO-E and the results compared to other alternative methods available in the literature

Robust Control Charts for Time Series Data

This article presents a control chart for time series data, based on the one-step- ahead forecast errors of the Holt-Winters forecasting method. We use robust techniques to prevent that outliers affect the estimation of the control limits of the chart. Moreover, robustness is important to maintain the reliability of the control chart after the occurrence of alarm observations. The properties of the new control chart are examined in a simulation study and on a real data example.Control chart;Holt-Winters;Non-stationary time series;Out- lier detection;Robustness;Statistical process control

Sensor Fusion and Process Monitoring for Ultrasonic Welding of Lithium-ion Batteries.

Ultrasonic metal welding is used for joining lithium-ion batteries of electric vehicles. The quality of the joints is essential to the performance of the entire battery pack. Hence, the ultrasonic welding process that creates the joints must be equipped with online sensing and real-time process monitoring systems. This would help ensure the process to be operated under the normal condition and quickly address quality-related issues. For this purpose, this dissertation develops methods in process monitoring and fault diagnosis using online sensing signals for ultrasonic metal welding. The first part of this dissertation develops a monitoring algorithm that targets near-zero misdetection by integrating univariate control charts and a multivariate control chart using the Mahalanobis distance. The proposed algorithm is capable of monitoring non-normal multivariate observations with adjustable control limits to achieve a near-zero misdetection rate while keeping a low false alarm rate. The proposed algorithm proves to be effective in achieving near-zero misdetection in process monitoring in ultrasonic welding processes. The second part of the dissertation develops a wavelet-based profile monitoring method that is capable of making decisions within a welding cycle and guiding real-time process adjustments. The proposed within-cycle monitoring technique integrates real-time monitoring and within-cycle control opportunity for defect prevention. The optimal decision point for achieving the most benefit in defect prevention is determined through the formulation of an optimization problem. The effectiveness of the proposed method is validated and demonstrated by simulations and case studies. The third part of this dissertation develops a method for effective monitoring and diagnosis of multi-sensor heterogeneous profile data based on multilinear discriminant analysis. The proposed method operates directly on the multi-stream profiles and then extracts uncorrelated discriminative features through tensor-to-vector projection, and thus preserving the interrelationship of different sensors. The extracted features are then fed into classifiers to detect faulty operations and recognize fault types. The research presented in this dissertation can be applied to general discrete cyclic manufacturing processes that have online sensing and control capabilities. The results of this dissertation are also applicable or expandable to mission-critical applications when improving product quality and preventing defects are of high interests.PhDIndustrial and Operations EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/113405/1/graceguo_1.pd

A New SVDD-Based Multivariate Non-parametric Process Capability Index

Process capability index (PCI) is a commonly used statistic to measure ability of a process to operate within the given specifications or to produce products which meet the required quality specifications. PCI can be univariate or multivariate depending upon the number of process specifications or quality characteristics of interest. Most PCIs make distributional assumptions which are often unrealistic in practice. This paper proposes a new multivariate non-parametric process capability index. This index can be used when distribution of the process or quality parameters is either unknown or does not follow commonly used distributions such as multivariate normal