Predictive analytics methodology for smart qualification testing of electronic components

In electronics manufacturing, the required quality of electronic modules (e.g. packaged electronic devices) are evaluated through qualification testing using standards and user-defined requirements. The challenge for the electronics industry is that product qualification testing is time-consuming and costly. This paper focuses on the development and demonstration of a novel approach for smarter qualification using test data from the production line along with integrated computational techniques for data mining/analytics and data-driven forecasting (i.e. prognostics) modelling. The most common type of testing in the electronics industry - sequentially run electrical multi-parameter tests on the Device-under-Test (DUT), is considered. The proposed data mining (DM) framework can identify the tests that have strong correlation to pending failure of the device in the qualification (tests sensitive to pending failure) as well as to evaluate the similarity in test measurements, thus generating knowledge on potentially redundant tests. Mining the data in this context and with the proposed approach represents a major new contribution because it uncovers embedded knowledge and information in the production test data that can enable intelligent optimisation of the tests’ sequence and reduce the number of tests. The intelligent manufacturing concept behind the development of data-driven prognostics models using machine learning (ML) techniques is to use data only from a small number of tests from the full qualification specification as training data in the process of model construction. This model can then forecast the overall qualification outcome for a DUT - Pass or Fail - without performing all other remaining tests. The novelty in the context of machine learning is in the selection of the data features for the training dataset using results from tests sensitive to pending failure. Support Vector Machine (SVM) binary classifiers SVM models built with data from tests sensitive to the outcome that the module will fail are shown to have superior performance compared with models trained with other datasets of tests. Case studies based on the use of real industrial production test data for an electronic module are included in the paper to demonstrate and validate the computational approach. This work is both novel and original because at present, to the best knowledge of the authors, such predictive analytics methodology applied to qualification testing and providing benefits of test time and hence cost reduction are non-existent in the electronics industry. The integrated data analytics-prognostics approach, deployable for both off-line and in-line optimisation of production test procedures, has the potential to transform current practices by exploiting in a smarter way information and knowledge available with large datasets of qualification test data

Data analytics approach for optimal qualification testing of electronic components

In electronics manufacturing, required quality of electronic components and parts is ensured through qualification testing using standards and user-defined requirements. The challenge for the industry is that product qualification testing is time-consuming and comes at a substantial cost. The work reported with this paper focus on the development and demonstration of a novel approach that can support “smart qualification testing” by using data analytics and data-driven prognostics modelling. Data analytics approach is developed and applied to historical qualification test datasets for an electronic module (Device under Test, DUT). The qualification spec involves a series of sequentially performed electrical and functional parameter tests on the DUTs. Data analytics is used to identify the tests that are sensitive to pending failure as well as to cross-evaluate the similarity in measurements between all tests, thus generating also knowledge on potentially redundant tests. The capability of data-driven prognostics modelling, using machine learning techniques and available historical qualification datasets, is also investigated. The results obtained from the study showed that predictive models developed from the identified so-called “sensitive to pending failure” tests feature superior performance compared with conventional, as measured, use of the test data. This work is both novel and original because at present, to the best knowledge of the authors, no similar predictive analytics methodology for qualification test time reduction (respectively cost reduction) is used in the electronics industry

Developing computational intelligence for smart qualification testing of electronic products

In electronics manufacturing, the necessary quality of electronic components and parts is ensured through qualification testing using standards and user requirements. The challenge is that product qualification testing is time-consuming and comes at a substantial cost. The work contributes to develop a novel prognostics framework for predicting qualification test outcomes of electronic components enabling the reduction of qualification test time and cost. The research focuses on the development of a new, prognostics-based approach to qualification of electronics parts that can enable “smart testing” using data-driven modelling techniques in order to ensure product robustness and reliability in operation. This work is both novel and original because at present such approach to qualification testing and the associated capability for test time reduction (respectively cost reduction) it offers are non-existent in the electronics industry. An effective way of using three different methods for development of prognostics models are identified and applied. Predictive models are constructed from historical qualification test data in the form of electrical parameter measurements using Machine Learning (ML) techniques. ML models can be imbedded within the sequential electrical tests qualification procedure and enable the forecasting of the pass/fail qualification outcome using only partial information from already completed electrical tests. Data-driven prognostics models are developed using the following machine learning techniques: (1) Support Vector Machine (SVM), (2) Neural Network (NN) and (3) K-Nearest Neighbor (KNN). The results show that with just over half of the individual tests completed, the models are capable of forecasting the final qualification outcome, pass or fail, with accuracy as high as 92.5%. The predictive power and overall performance of the researched models in predicting qualification test binary outcomes with varying ratios of Pass and Fail data in the processed datasets are analysed

Data-driven Context Awareness of Smart Products in Discrete Smart Manufacturing Systems

Abstract Traditionally, smart-connected products are predominantly utilized during the usage phase of the product lifecycle. However, we argue that there are distinct benefits of system-integrated sensor systems during the beginning of life, more specifically in manufacturing and assembly. In this paper, we analyze the ability of a smart-connected product with an integrated sensor system to recognize and label different manufacturing processes, generating a distinct process fingerprint within a discrete smart manufacturing system. The ability of the smart-connected product to detect distinct manufacturing process patterns ('process fingerprint') enables the production planner and operator, e.g., to optimize the scheduling, improve part quality, and/or reduce the energy footprint. The experimental setup is based on a FestoDidactics CPlab with eight different manufacturing processes. The smart-connected product is equipped with a sensor system providing data from eight different sensors (e.g., temperature, humidity, acceleration). We used an Artificial Neural Network (ANN) algorithm to create a model to detect specific events/patterns within the dataset after labelling it manually over the course of a complete production cycle. The focal manufacturing process was the heating tunnel where the smart-connected product was exposed to a heat treatment process and sequence. The results of this prototypical implementation indicate that a smart-connected product can reliably recognize specific process patterns with a system-integrated sensor system during a simulated manufacturing process. While this work is only a first step, the potential applications and benefits are promising and further research should focus on the potential quality implications within smart manufacturing of product-integrated sensor readings compared to machine tool-based sensors, both of which monitored during the beginning of life. Smart products' integrated sensor systems provide the means to obtain measurements relevant for smart manufacturing systems that are not obtainable with common external sensor systems today

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Industry 4.0 (also referred to as digitization of manufacturing) is characterized by cyber physical systems, automation, and data exchange. It is no longer a future trend and is being employed worldwide by manufacturing organizations, to gain benefits of improved performance, reduced inefficiencies, and lower costs, while improving flexibility. However, the implementation of Industry 4.0 enabling technologies is a difficult task and becomes even more challenging without any standardized approach. The barriers include, but are not limited to, lack of knowledge, inability to realistically quantify the return on investment, and lack of a skilled workforce. This study presents a systematic and content-centric literature review of Industry 4.0 enabling technologies, to highlight their impact on the manufacturing industry. It also provides a strategic roadmap for the implementation of Industry 4.0, based on lean six sigma approaches. The basis of the roadmap is the design for six sigma approach for the development of a new process chain, followed by a continuous improvement plan. The reason for choosing lean six sigma is to provide manufacturers with a sense of familiarity, as they have been employing these principles for removing waste and reducing variability. Major reasons for the rejection of Industry 4.0 implementation methodologies by manufactures are fear of the unknown and resistance to change, whereas the use of lean six sigma can mitigate them. The strategic roadmap presented in this paper can offer a holistic view of phases that manufacturers should undertake and the challenges they might face in their journey toward Industry 4.0 transition

An Assessment of PIER Electric Grid Research 2003-2014 White Paper

This white paper describes the circumstances in California around the turn of the 21st century that led the California Energy Commission (CEC) to direct additional Public Interest Energy Research funds to address critical electric grid issues, especially those arising from integrating high penetrations of variable renewable generation with the electric grid. It contains an assessment of the beneficial science and technology advances of the resultant portfolio of electric grid research projects administered under the direction of the CEC by a competitively selected contractor, the University of California’s California Institute for Energy and the Environment, from 2003-2014

Open Source Platforms for Big Data Analytics

O conceito de Big Data tem tido um grande impacto no campo da tecnologia, em particular na gestão e análise de enormes volumes de informação. Atualmente, as organizações consideram o Big Data como uma oportunidade para gerir e explorar os seus dados o máximo possível, com o objetivo de apoiar as suas decisões dentro das diferentes áreas operacionais. Assim, é necessário analisar vários conceitos sobre o Big Data e o Big Data Analytics, incluindo definições, características, vantagens e desafios. As ferramentas de Business Intelligence (BI), juntamente com a geração de conhecimento, são conceitos fundamentais para o processo de tomada de decisão e transformação da informação. Ao investigar as plataformas de Big Data, as práticas industriais atuais e as tendências relacionadas com o mundo da investigação, é possível entender o impacto do Big Data Analytics nas pequenas organizações. Este trabalho pretende propor soluções para as micro, pequenas ou médias empresas (PME) que têm um grande impacto na economia portuguesa, dado que representam a maioria do tecido empresarial. As plataformas de código aberto para o Big Data Analytics oferecem uma grande oportunidade de inovação nas PMEs. Este trabalho de pesquisa apresenta uma análise comparativa das funcionalidades e características das plataformas e os passos a serem tomados para uma análise mais profunda e comparativa. Após a análise comparativa, apresentamos uma avaliação e seleção de plataformas Big Data Analytics (BDA) usando e adaptando a metodologia QSOS (Qualification and Selection of software Open Source) para qualificação e seleção de software open-source. O resultado desta avaliação e seleção traduziu-se na eleição de duas plataformas para os testes experimentais. Nas plataformas de software livre de BDA foi usado o mesmo conjunto de dados assim como a mesma configuração de hardware e software. Na comparação das duas plataformas, demonstrou que a HPCC Systems Platform é mais eficiente e confiável que a Hortonworks Data Platform. Em particular, as PME portuguesas devem considerar as plataformas BDA como uma oportunidade de obter vantagem competitiva e melhorar os seus processos e, consequentemente, definir uma estratégia de TI e de negócio. Por fim, este é um trabalho sobre Big Data, que se espera que sirva como um convite e motivação para novos trabalhos de investigação.The concept of Big Data has been having a great impact in the field of technology, particularly in the management and analysis of huge volumes of information. Nowadays organizations look for Big Data as an opportunity to manage and explore their data the maximum they can, with the objective of support decisions within its different operational areas. Thus, it is necessary to analyse several concepts about Big Data and Big Data Analytics, including definitions, features, advantages and disadvantages. Business intelligence along with the generation of knowledge are fundamental concepts for the process of decision-making and transformation of information. By investigate today's big data platforms, current industrial practices and related trends in the research world, it is possible to understand the impact of Big Data Analytics on small organizations. This research intends to propose solutions for micro, small or médium enterprises (SMEs) that have a great impact on the Portuguese economy since they represente approximately 90% of the companies in Portugal. The open source platforms for Big Data Analytics offers a great opportunity for SMEs. This research work presents a comparative analysis of those platforms features and functionalities and the steps that will be taken for a more profound and comparative analysis. After the comparative analysis, we present an evaluation and selection of Big Data Analytics (BDA) platforms using and adapting the Qualification and Selection of software Open Source (QSOS) method. The result of this evaluation and selection was the selection of two platforms for the empirical experiment and tests. The same testbed and dataset was used in the two Open Source Big Data Analytics platforms. When comparing two BDA platforms, HPCC Systems Platform is found to be more efficient and reliable than Hortonworks Data Platform. In particular, Portuguese SMEs should consider for BDA platforms an opportunity to obtain competitive advantage and improve their processes and consequently define an IT and business strategy. Finally, this is a research work on Big Data; it is hoped that this will serve as an invitation and motivation for new research

Big data for monitoring educational systems

This report considers “how advances in big data are likely to transform the context and methodology of monitoring educational systems within a long-term perspective (10-30 years) and impact the evidence based policy development in the sector”, big data are “large amounts of different types of data produced with high velocity from a high number of various types of sources.” Five independent experts were commissioned by Ecorys, responding to themes of: students' privacy, educational equity and efficiency, student tracking, assessment and skills. The experts were asked to consider the “macro perspective on governance on educational systems at all levels from primary, secondary education and tertiary – the latter covering all aspects of tertiary from further, to higher, and to VET”, prioritising primary and secondary levels of education

Industrial internet of things: What does it mean for the bioprocess industries?

Industrial Internet of Things (IIoT) is a system of interconnected devices that, via the use of various technologies, such as soft sensors, cloud computing, data analytics, machine learning and artificial intelligence, provides real-time insight into the operations of any industrial process from product conceptualisation, process optimisation and manufacturing to the supply chain. IIoT enables wide-scope data collection and utilisation, and reduces errors, increases efficiency, and provides an improved understanding of the process in return. While this novel solution is the pillar of Industry 4.0, the inherent operational complexity of bioprocessing arising from the involvement of living systems or their components in manufacturing renders the sector a challenging one for the implementation of IIoT. A large segment of the industry comprises the manufacturing of biopharmaceuticals and advanced therapies, some of the most valuable biotechnological products available, which undergo tight regulatory evaluations and scrutinization from product conceptualisation to patient delivery. Extensive process understanding is what biopharmaceutical industry strives for, however, the complexity of transition into a new mode of operation, potential misalignment of priorities, the need for substantial investments to facilitate transition, the limitations imposed by the downtime required for transition and the essentiality of regulatory support, render it challenging for the industry to adopt IIoT solutions to integrate with biomanufacturing operations. There is currently a need for universal solutions that would streamline the implementation of IIoT and overcome the widespread reluctance observed in the sector, which will recommend accessible implementation strategies, effective employee training and offer valuable insights in return to advance any processing and manufacturing operation within their respective regulatory frameworks