A Time Truncated Moving Average Chart for the Weibull Distribution

A control chart of monitoring the number of failures is proposed with a moving average scheme, when the life of an item follows a Weibull distribution. A specified number of items are put on a time truncated life test and the number of failures is observed. The proposed control chart has been evaluated by the average run lengths (ARLs) under different parameter settings. The control constant and the test time multiplier are to be determined by considering the in-control ARL. It is observed that the proposed control chart is more efficient in detecting a shift in the process as compared with the existing time truncated control chart. ? 2013 IEEE.11Ysciescopu

A semi-empirical Bayesian chart to monitor Weibull percentiles

This paper develops a Bayesian control chart for the percentiles of the Weibull distribution, when both its in-control and out-of-control parameters are unknown. The Bayesian approach enhances parameter estimates for small sample sizes that occur when monitoring rare events as in high-reliability applications or genetic mutations. The chart monitors the parameters of the Weibull distribution directly, instead of transforming the data as most Weibull-based charts do in order to comply with their normality assumption. The chart uses the whole accumulated knowledge resulting from the likelihood of the current sample combined with the information given by both the initial prior knowledge and all the past samples. The chart is adapting since its control limits change (e.g. narrow) during the Phase I. An example is presented and good Average Run Length properties are demonstrated. In addition, the paper gives insights into the nature of monitoring Weibull processes by highlighting the relationship between distribution and process parameters.Comment: 21 pages, 3 figures, 5 table

A New Control Chart for Monitoring Reliability Using Sudden Death Testing Under Weibull Distribution

In this paper, a new control chart using sudden death testing is designed by assuming that the lifetime/failure time of the product follows the Weibull distribution. The structure of the proposed chart is presented. The control chart coefficient is determined using some specified average run length for the in control process and the shifted process. Simulation study is given for the illustration purpose.11Ysciescopu

Univariate And Multivariate Synthetic Control Charts For Monitoring The Process Mean Of Skewed Distributions

Alat yang paling berkuasa dalam Kawalan Kualiti Berstatistik (SQC) ialah carta kawalan. The most powerful tool in Statistical Quality Control (SQC) is the control chart. Control charts are now widely accepted and used in industries

The viability of Weibull analysis of small samples in process manufacturing

This research deals with some Statistical Quality Control (SQC) methods, which are used in quality testing. It investigates the problem encountered with statistical process control (SPC) tools when small sample sizes are used. Small sample size testing is a new area of concern especially when using expensive (or large) products, which are produced in small batches (low volume production). Critical literature review and analysis of current technologies and methods in SPC with small samples testing failed to show a conformance with conventional SPC techniques, as the confidence limits for averages and standard deviation are too wide. Therefore, using such sizes will provide unsecured results with a lack in accuracy. The current research demonstrates such problems in manufacturing by using examples, in order to show the lack and the difficulties faced with conventional SPC tools (control charts). Weibull distribution has always shown a clear and acceptable prediction of failure and life behaviour with small sample size batches. Using such distribution enables the accuracy needed with small sample size to be obtained. With small sample control charts generate inaccurate confidence limits, which are low. On the contrary, Weibull theory suggests that using small samples enable achievement of accurate confidence limits. This research highlights these two aspects and explains their features in more depth. An outline of the overall problem and solution point out success of Weibull analysis when Weibull distribution is modified to overcome the problems encountered when small sample sizes are used. This work shows the viability of Weibull distribution to be used as a quality tool and construct new control charts, which will provide accurate result and detect nonconformance and variability with the use of small sample sizes. Therefore, the new proposed Weibull deduction control charts shows a successful replacement of the conventional control chart, and these new charts will compensate the errors in quality testing when using small size samples

Change Point Estimation in Monitoring Survival Time

Precise identification of the time when a change in a hospital outcome has occurred enables clinical experts to search for a potential special cause more effectively. In this paper, we develop change point estimation methods for survival time of a clinical procedure in the presence of patient mix in a Bayesian framework. We apply Bayesian hierarchical models to formulate the change point where there exists a step change in the mean survival time of patients who underwent cardiac surgery. The data are right censored since the monitoring is conducted over a limited follow-up period. We capture the effect of risk factors prior to the surgery using a Weibull accelerated failure time regression model. Markov Chain Monte Carlo is used to obtain posterior distributions of the change point parameters including location and magnitude of changes and also corresponding probabilistic intervals and inferences. The performance of the Bayesian estimator is investigated through simulations and the result shows that precise estimates can be obtained when they are used in conjunction with the risk-adjusted survival time CUSUM control charts for different magnitude scenarios. The proposed estimator shows a better performance where a longer follow-up period, censoring time, is applied. In comparison with the alternative built-in CUSUM estimator, more accurate and precise estimates are obtained by the Bayesian estimator. These superiorities are enhanced when probability quantification, flexibility and generalizability of the Bayesian change point detection model are also considered

Modelo de apoio à decisão para a manutenção condicionada de equipamentos produtivos

Doctoral Thesis for PhD degree in Industrial and Systems EngineeringIntroduction: This thesis describes a methodology to combine Bayesian control chart and CBM (Condition-Based Maintenance) for developing a new integrated model. In maintenance management, it is a challenging task for decision-maker to conduct an appropriate and accurate decision. Proper and well-performed CBM models are beneficial for maintenance decision making. The integration of Bayesian control chart and CBM is considered as an intelligent model and a suitable strategy for forecasting items failures as well as allow providing an effectiveness maintenance cost. CBM models provides lower inventory costs for spare parts, reduces unplanned outage, and minimize the risk of catastrophic failure, avoiding high penalties associated with losses of production or delays, increasing availability. However, CBM models need new aspects and the integration of new type of information in maintenance modeling that can improve the results. Objective: The thesis aims to develop a new methodology based on Bayesian control chart for predicting failures of item incorporating simultaneously two types of data: key quality control measurement and equipment condition parameters. In other words, the project research questions are directed to give the lower maintenance costs for real process control. Method: The mathematical approach carried out in this study for developing an optimal Condition Based Maintenance policy included the Weibull analysis for verifying the Markov property, Delay time concept used for deterioration modeling and PSO and Monte Carlo simulation. These models are used for finding the upper control limit and the interval monitoring that minimizes the (maintenance) cost function. Result: The main contribution of this thesis is that the proposed model performs better than previous models in which the hypothesis of using simultaneously data about condition equipment parameters and quality control measurements improve the effectiveness of integrated model Bayesian control chart for Condition Based Maintenance.Introdução: Esta tese descreve uma metodologia para combinar Bayesian control chart e CBM (Condition- Based Maintenance) para desenvolver um novo modelo integrado. Na gestão da manutenção, é importante que o decisor possa tomar decisões apropriadas e corretas. Modelos CBM bem concebidos serão muito benéficos nas tomadas de decisão sobre manutenção. A integração dos gráficos de controlo Bayesian e CBM é considerada um modelo inteligente e uma estratégica adequada para prever as falhas de componentes bem como produzir um controlo de custos de manutenção. Os modelos CBM conseguem definir custos de inventário mais baixos para as partes de substituição, reduzem interrupções não planeadas e minimizam o risco de falhas catastróficas, evitando elevadas penalizações associadas a perdas de produção ou atrasos, aumentando a disponibilidade. Contudo, os modelos CBM precisam de alterações e a integração de novos tipos de informação na modelação de manutenção que permitam melhorar os resultados.Objetivos: Esta tese pretende desenvolver uma nova metodologia baseada Bayesian control chart para prever as falhas de partes, incorporando dois tipos de dados: medições-chave de controlo de qualidade e parâmetros de condição do equipamento. Por outras palavras, as questões de investigação são direcionadas para diminuir custos de manutenção no processo de controlo.Métodos: Os modelos matemáticos implementados neste estudo para desenvolver uma política ótima de CBM incluíram a análise de Weibull para verificação da propriedade de Markov, conceito de atraso de tempo para a modelação da deterioração, PSO e simulação de Monte Carlo. Estes modelos são usados para encontrar o limite superior de controlo e o intervalo de monotorização para minimizar a função de custos de manutenção.Resultados: A principal contribuição desta tese é que o modelo proposto melhora os resultados dos modelos anteriores, baseando-se na hipótese de que, usando simultaneamente dados dos parâmetros dos equipamentos e medições de controlo de qualidade. Assim obtém-se uma melhoria a eficácia do modelo integrado de Bayesian control chart para a manutenção condicionada

Monitoring regression models for lifetimes

Abstract. Monitoring regression models for lifetimes The current study addresses the monitoring of regression models with response variable having a distribution for lifetimes. Certain aspects of this research have relevant importance. First of all, in most of the existing literature, monitoring regression models is treated as a special case of profile monitoring. However, especially in some industrial and healthcare applications, regression models can adequately represent process quality but cannot always be qualified as profiles. This is the case of regression models for lifetimes. The fact is that lifetimes can be measured just once at most in the same experimental unit. Consequently, the nature of responses while monitoring regression models is not multivariate necessarily. However, the main goal of monitoring regression models for lifetimes aims to check the stability of the distributions of n response variables Yi , i = 1, · · · , n. As all these distributions are linked by the same parameter vector, the stability of the formers depends on the one of the latter. Thus, it is clear that profile monitoring and regression monitoring share the same purpose. Techniques from profile monitoring can be used for successfully monitoring regression models for lifetimes as well. Some methodologies for monitoring Weibull regression models for lifetimes with common shape parameter and in phase II processes will be addressed depending on the composition of available regression data structures. The monitoring of the parameter vector characterizing the Weibull regression model allows us to make conclusions about the mean value of the response variable. It will be shown that the monitoring of regression models for lifetimes can be carried out by redesigning existing methods from monitoring continuous quality variables and profile monitoring. In the presence of uncensored lifetimes, it was found out that it is possible to adapt conventional control charts for single observations to the monitoring of the common shape parameter. It is also possible to adapt control techniques and methodologies from profile monitoring to the case of monitoring the entire parameter vector characterizing the basic model. In both cases, chart designing depends on the asymptotic normality of the maximum likelihood estimator of the parameter vector. Thus, it is necessary to implement some existing corrections to the monitoring statistics so that existing control charts work acceptably well when non-large enough data sets are available. When a type I right-censored mechanism is operating on lifetimes, the monitoring can be carried out with the help of one-sided likelihood ratio based cumulative sum control charts. Theese procedures can be used for monitoring one or more of the parameters in the parameter vector and has practically no restrictions respect to the dataset dimension needed for monitoring. Conducted simulations suggest that this chart is more effective than the multivariate exponentially weighted moving average method when detecting the deterioration of the process is wanted.Monitoreo de modelos de regresión para tiempos de vida El presente estudio se aborda el monitoreo de modelos de regresión para tiempos de vida. Ciertos aspectos de este trabajo son de crucial importancia. Como primera medida, en gran parte de la literatura especializada, el monitoreo de modelos de regresión se trata como un caso particular del monitoreo de perfiles. Sin embargo, existen muchas aplicaciones, especialmente en ingeniería y en cuidados en salud, en las cuales los modelos de regresión pueden caracterizar adecuadamente la calidad de los procesos pero no siempre pueden considerarse como perfiles. Es el caso de los modelos de regresión para tiempos de vida. El hecho es que, en general, un tiempo de vida puede medirse a lo sumo una vez en la misma unidad experimental. Consecuentemente, la naturaleza de las respuestas en el monitoreo de modelos de regresión no necesariamente es multivariada. Sin embargo, el objetivo principal del montireo de modelos regresión apunta a verificar la estabilidad de las distribuciones n variables respuesta Yi , i = 1, · · · , n. Como todas estas distribuciones están relacionadas entre sí por un único vector de parámetros, la estabilidad de las primeras depende de la estabilidad de este último. De este modo, es claro que tanto el monitoreo de modelos de regresión como el de perfiles comparten el mismo propósito. Es así como las técnicas usadas para monitorear perfiles pueden también usarse par monitorear acertadamente los modelos de regresión para tiempos de vida. Se presentan algunas metodologías para monitorear modelos de regresión para tiempos de vida con respuesta Weibull, dependiendo de cómo están conformadas los conjuntos de datos disponibles. El monitoreo del vector de parámetros de modelos de regresión Weibull permite hacer conclusiones acerca del valor medio de la variable respuesta. Se mostrará además que se puede encarar el monitoreo de modelos de regresión para tiempos de vida mediante el rediseño de las metodologías de control que comúnmente se usan para monitorear variables de calidad continuas o para monitorear perfiles. Cuando la respuesta no es censurada, se encontr´o que es posible adaptar las cartas de control convencionales para observaciones individuales de la característica de calidad, al monitoreo del parámtero de forma de un modelo de regresión Weibull. Es posible también adaptar las metodologías de control usadas en el monitoreo de perfiles para monitorear todo el vector de parámetros que caracterizan los modelos de regresión Weibull. En ambos casos, el diseño de las cartas se basa en la normalidad asintótica del estimador máximo verosímil del vector de parámetros. Por consiguiente, se hace necesario implementar correcciones existentes a las estadísticas de monitoreo para que las cartas de control trabajen aceptablemente aún cuando no se disponga de conjuntos de datos lo suficientemente grandes. Cuando un mecanismo de censura a derecha de tipo I opera sobre los tiempos de vida, se puede realizar el monitoreo con la ayuda de cartas de control unilaterales de sumas acumuladas basadas en la estadística de razón de verosimilitudes. Estos esquemas se pueden utilizar para monitorear uno o varios parámetros que conforman el vector de parámetros y prácticamente no tienen restricciones respecto a la cantidad de observaciones necesarias para realizar el monitoreo. Los estudios de simulación sugieren que estos esquemas son más efectivos que los métodos multivariados de promedios móviles ponderados exponencialmente cuando se desea detectar el deterioro de los procesos de calidad.Doctorad

A Model for Maintenance Planning and Process Quality Control Optimization Based on EWMA and CUSUM Control Charts

The performance of a production system is highly dependent on the smooth operation of various equipment and processes. Thus, reducing failures of the equipment and processes in a cost-effective manner improves overall performance; this is often achieved by carrying out maintenance and quality control policies. In this study, an integrated optimization method that addresses both maintenance strategies and quality control practices is proposed using an exponentially weighted moving average (EWMA) chart, in which both corrective and preventive maintenance policies are considered. The integrated model has been proposed to find optimal decision variables of both the process quality decision parameters and the optimal interval of preventive maintenance (i.e., Ns, Hs, L, λ, and t_PM) to result in overall optimal expected hourly total system costs. A case study is then utilized to investigate the impact of cost criteria on the proposed integrated model and to compare the proposed model with a model using the cumulative sum (CUSUM) control chart. The improved model outputs indicate that there is a reduction of 34.6% in the total expected costs compared with those of the other model using the CUSUM chart. Finally, an analysis of sensitivity to present the effectiveness of the model parameters and the main variables in the overall costs of the system is provided

Applications and Modeling Techniques of Wind Turbine Power Curve for Wind Farms - A Review

In the wind energy industry, the power curve represents the relationship between the “wind speed” at the hub height and the corresponding “active power” to be generated. It is the most versatile condition indicator and of vital importance in several key applications, such as wind turbine selection, capacity factor estimation, wind energy assessment and forecasting, and condition monitoring, among others. Ensuring an effective implementation of the aforementioned applications mostly requires a modeling technique that best approximates the normal properties of an optimal wind turbines operation in a particular wind farm. This challenge has drawn the attention of wind farm operators and researchers towards the “state of the art” in wind energy technology. This paper provides an exhaustive and updated review on power curve based applications, the most common anomaly and fault types including their root-causes, along with data preprocessing and correction schemes (i.e., filtering, clustering, isolation, and others), and modeling techniques (i.e., parametric and non-parametric) which cover a wide range of algorithms. More than 100 references, for the most part selected from recently published journal articles, were carefully compiled to properly assess the past, present, and future research directions in this active domain