Assembly Root Cause Analysis: A Way to Reduce Dimensional Variation in Assembled Products

The objective of root cause analysis (RCA) is to make the trouble shooting dimensional error efforts in an assembly plant more efficient and successful by pinpointing the underlying reasons for variation. The result of eliminating or limiting these sources of variation is a real and long term process improvement. Complex products are manufactured in multileveled hierarchical assembly processes using positioning fixtures. A general approach for diagnosing fixture related errors using routine measurement on products, rather than from special measurements on fixtures, is presented. The assembly variation is effectively tracked down into variation in the fixture tooling elements, referred to as locators. In this way, the process engineers can focus on adjusting the locators affected by most variation. However, depending on the assembly process configuration, inspection strategy, and the type of locator error, it can be impossible to completely sort out the variation caused by an individual locator. The reason for this is that faults in different locators can cause identical dimensional deviation in the inspection station. Conditions guaranteeing diagnosability are derived by considering multiple uncoupled locator faults, in contrast to previous research focusing on single or multiple coupled locator faults. Furthermore, even if an assembly is not diagnosable, it is still possible to gain information for diagnosis by using a novel approach to find an interval for each locator containing the true underlying locator variation. In this way, some locators can be excluded from further analysis, some can be picked out for adjustment, and others remain as potential reason for assembly variation. Another way around the problem of diagnosability is to make a higher level diagnosis by calculating the amount of variation originating from different assembly stations. Also, a design for diagnosis approach is discussed, where assembly and inspection concepts allowing for root cause analysis are the objective.     

Semiconductor fault detection and classification for yield enhancement and manufacturing intelligence

Process monitoring and profile analysis are crucial in detecting various abnormal events in semiconductor manufacturing, which consists of highly complex, interrelated, and lengthy wafer fabrication processes for yield enhancement and quality control. To address real requirements, this study aims to develop a framework for semiconductor fault detection and classification (FDC) to monitor and analyze wafer fabrication profile data from a large number of correlated process variables to eliminate the cause of the faults and thus reduce abnormal yield loss. Multi-way principal component analysis and data mining are used to construct the model to detect faults and to derive the rules for fault classification. An empirical study was conducted in a leading semiconductor company in Taiwan to validate the model. Use of the proposed framework can effectively detect abnormal wafers based on a controlled limit and the derived simple rules. The extracted information can be used to aid fault diagnosis and process recovery. The proposed solution has been implemented in the semiconductor company. This has simplified the monitoring process in the FDC system through the fewer key variables. The results demonstrate the practical viability of the proposed approach.     

A modular approach to situation identification of the dynamics of bacterial populations synthesizing poly-β-hydroxybutyrate

Biotechnological processes involving bacteria are strongly nonlinear. Therefore, both their productivity and the final product quality may be considerably improved by applying appropriate control strategies to modulate behavior of the bacteria during transitional states. This requires advance identification of indicative signals by off-line investigation (i.e. experimental analysis) and on-line monitoring, (i.e. real time evaluation). A modular scheme is presented for doing this, which incorporates an Extended Kalman Filter and a prediction filter. If this is based on a suitable process-feature vector, which must be chosen in advance, the system can provide sufficient information to trigger appropriate feedback signals. Thus, it can provide a key element in modular situation control, allowing continuously periodic process management. In this publication the individual modules involved, and their assembly into an integrated system are described. Potential problems concerning selection of the feature vector, and experimental results are also discussed.     

Raman spectroscopy and chemometrics for on‐line control of glucose fermentation by Saccharomyces cerevisiae

This work presents the use of Raman spectroscopy and chemometrics for on‐line control of the fermentation process of glucose by Saccharomyces cerevisiae. In a first approach, an on‐line determination of glucose, ethanol, glycerol, and cells was accomplished using multivariate calibration based on partial least squares (PLS). The PLS models presented values of root mean square error of prediction (RMSEP) of 0.53, 0.25, and 0.02% for glucose, ethanol and glycerol, respectively, and RMSEP of 1.02 g L^?1 for cells. In a second approach, multivariate control charts based on multiway principal component analysis (MPCA) were developed for detection of fermentation fault‐batch. Two multivariate control charts were developed, based on the squared prediction error (Q) and Hotelling's T². The use of the Q control chart in on‐line monitoring was efficient for detection of the faults caused by temperature, type of substrate and contamination, but the T² control chart was not able to monitor these faults. On‐line monitoring by Raman spectroscopy in conjunction with chemometric procedures allows control of the fermentative process with advantages in relation to reference methods, which require pretreatment, manipulation of samples and are time consuming. Also, the use of multivariate control charts made possible the detection of faults in a simple way, based only on the spectra of the system. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

Fault diagnosis of a benchmark fermentation process: a comparative study of feature extraction and classification techniques

This paper investigates fault diagnosis in batch processes and presents a comparative study of feature extraction and classification techniques applied to a specific biotechnological case study: the fermentation process model by Birol et al. (Comput Chem Eng 26:1553–1565, 2002), which is a benchmark for advanced batch processes monitoring, diagnosis and control. Fault diagnosis is achieved using four approaches on four different process scenarios based on the different levels of noise so as to evaluate their effects on the performance. Each approach combines a feature extraction method, either multi-way principal component analysis (MPCA) or multi-way independent component analysis (MICA), with a classification method, either artificial neural network (ANN) or support vector machines (SVM). The performance obtained by the different approaches is assessed and discussed for a set of simulated faults under different scenarios. One of the faults (a loss in mixing power) could not be detected due to the minimal effect of mixing on the simulated data. The remaining faults could be easily diagnosed and the subsequent discussion provides practical insight into the selection and use of the available techniques to specific applications. Irrespective of the classification algorithm, MPCA renders better results than MICA, hence the diagnosis performance proves to be more sensitive to the selection of the feature extraction technique.     

Adaptive multiscale principal component analysis for on-line monitoring of a sequencing batch reactor

In recent years, multiscale monitoring approaches, which combine principal component analysis (PCA) and multi-resolution analysis (MRA), have received considerable attention. These approaches are potentially very efficient for detecting and analyzing diverse ranges of faults and disturbances in chemical and biochemical processes. In this work, multiscale PCA is proposed for fault detection and diagnosis of batch processes. Using MRA, measurement data are decomposed into approximation and details at different scales. Adaptive multiway PCA (MPCA) models are developed to update the covariance structure at each scale to deal with changing process conditions. Process monitoring by a unifying adaptive multiscale MPCA involves combining only those scales where significant disturbances are detected. This multiscale approach facilitates diagnosis of the detected fault as it hints to the time-scale under which the fault affects the process. The proposed adaptive multiscale method is successfully applied to a pilot-scale sequencing batch reactor for biological wastewater treatment.     

Nonlinear modeling and adaptive monitoring with fuzzy and multivariate statistical methods in biological wastewater treatment plants

A new approach to nonlinear modeling and adaptive monitoring using fuzzy principal component regression (FPCR) is proposed and then applied to a real wastewater treatment plant (WWTP) data set. First, principal component analysis (PCA) is used to reduce the dimensionality of data and to remove collinearity. Second, the adaptive credibilistic fuzzy-c-means method is used to appropriately monitor diverse operating conditions based on the PCA score values. Then a new adaptive discrimination monitoring method is proposed to distinguish between a large process change and a simple fault. Third, a FPCR method is proposed, where the Takagi-Sugeno-Kang (TSK) fuzzy model is employed to model the relation between the PCA score values and the target output to avoid the over-fitting problem with original variables. Here, the rule bases, the centers and the widths of TSK fuzzy model are found by heuristic methods. The proposed FPCR method is applied to predict the output variable, the reduction of chemical oxygen demand in the full-scale WWTP. The result shows that it has the ability to model the nonlinear process and multiple operating conditions and is able to identify various operating regions and discriminate between a sustained fault and a simple fault (or abnormalities) occurring within the process data.     

A Fault Diagnosis Methodology for Gear Pump Based on EEMD and Bayesian Network

This paper proposes a fault diagnosis methodology for a gear pump based on the ensemble empirical mode decomposition (EEMD) method and the Bayesian network. Essentially, the presented scheme is a multi-source information fusion based methodology. Compared with the conventional fault diagnosis with only EEMD, the proposed method is able to take advantage of all useful information besides sensor signals. The presented diagnostic Bayesian network consists of a fault layer, a fault feature layer and a multi-source information layer. Vibration signals from sensor measurement are decomposed by the EEMD method and the energy of intrinsic mode functions (IMFs) are calculated as fault features. These features are added into the fault feature layer in the Bayesian network. The other sources of useful information are added to the information layer. The generalized three-layer Bayesian network can be developed by fully incorporating faults and fault symptoms as well as other useful information such as naked eye inspection and maintenance records. Therefore, diagnostic accuracy and capacity can be improved. The proposed methodology is applied to the fault diagnosis of a gear pump and the structure and parameters of the Bayesian network is established. Compared with artificial neural network and support vector machine classification algorithms, the proposed model has the best diagnostic performance when sensor data is used only. A case study has demonstrated that some information from human observation or system repair records is very helpful to the fault diagnosis. It is effective and efficient in diagnosing faults based on uncertain, incomplete information.     

动态MPCA在发酵过程监测与故障诊断中的应用

针对发酵过程非线性和时变特点,提出了一种具有实时性的动态MPCA方法,采用多模型非线性结构代替传统MPCA单模型线性化结构,克服了后者不能处理非线性过程和实时性的问题,并避免了MPCA在线应用时预报未来测量值带来的误差,提高了发酵过程性能监测和故障诊断的准确性。对头孢菌素C发酵过程的拟在线仿真研究,验证了基于动态MPCA的统计过程监测的有效性。     

Fault detection and diagnosis in an industrial fed-batch cell culture process

A flexible process monitoring method was applied to industrial pilot plant cell culture data for the purpose of fault detection and diagnosis. Data from 23 batches, 20 normal operating conditions (NOC) and three abnormal, were available. A principal component analysis (PCA) model was constructed from 19 NOC batches, and the remaining NOC batch was used for model validation. Subsequently, the model was used to successfully detect (both offline and online) abnormal process conditions and to diagnose the root causes. This research demonstrates that data from a relatively small number of batches (approximately 20) can still be used to monitor for a wide range of process faults.     

Conformational states and folding pathways of peptides revealed by principal-independent component analyses

Principal component analysis is a powerful method for projecting multidimensional conformational space of peptides or proteins onto lower dimensional subspaces in which the main conformations are present, making it easier to reveal the structures of molecules from e.g. molecular dynamics simulation trajectories. However, the identification of all conformational states is still difficult if the subspaces consist of more than two dimensions. This is mainly due to the fact that the principal components are not independent with each other, and states in the subspaces cannot be visualized. In this work, we propose a simple and fast scheme that allows one to obtain all conformational states in the subspaces. The basic idea is that instead of directly identifying the states in the subspace spanned by principal components, we first transform this subspace into another subspace formed by components that are independent of one other. These independent components are obtained from the principal components by employing the independent component analysis method. Because of independence between components, all states in this new subspace are defined as all possible combinations of the states obtained from each single independent component. This makes the conformational analysis much simpler. We test the performance of the method by analyzing the conformations of the glycine tripeptide and the alanine hexapeptide. The analyses show that our method is simple and quickly reveal all conformational states in the subspaces. The folding pathways between the identified states of the alanine hexapeptide are analyzed and discussed in some detail.     

Optimal door fitting with systematic fixture adjustment

A systematic approach is presented to obtain the best door gap quality through optimal door fitting in automobile body manufacturing. First, three indexes of gap quality are defined; they are: (1) door gap width deviation relative to design nominal; (2) door gap parallelism; and (3) car-to-car gap consistency. Then the door-fitting problem is formulated into a general constrained optimization problem. The effects of optimal door fitting on the three quality indexes are evaluated through computer simulation. These results provide a lower bound on the design of nominal door gap by considering process capability. Finally, a computer-aided fixture adjustment scheme is developed to orient a door in a body side opening to achieve the optimal fitting. The amount of adjustment, with the desired orientation obtained from optimization, is calculated based on parametrically modeled local surface features of the fixture and the door. The adequacy of door feature modeling is verified through a door-fitting experiment.     

Enhanced process monitoring of fed-batch penicillin cultivation using time-varying and multivariate statistical analysis

On-line monitoring of penicillin cultivation processes is crucial to the safe production of high-quality products. In the past, multiway principal component analysis (MPCA), a multivariate projection method, has been widely used to monitor batch and fed-batch processes. However, when MPCA is used for on-line batch monitoring, the future behavior of each new batch must be inferred up to the end of the batch operation at each time and the batch lengths must be equalized. This represents a major shortcoming because predicting the future observations without considering the dynamic relationships may distort the data information, leading to false alarms. In this paper, a new statistical batch monitoring approach based on variable-wise unfolding and time-varying score covariance structures is proposed in order to overcome the drawbacks of conventional MPCA and obtain better monitoring performance. The proposed method does not require prediction of the future values while the dynamic relations of data are preserved by using time-varying score covariance structures, and can be used to monitor batch processes in which the batch length varies. The proposed method was used to detect and identify faults in the fed-batch penicillin cultivation process, for four different fault scenarios. The simulation results clearly demonstrate the power and advantages of the proposed method in comparison to MPCA.     

Time-Based Competition in Multistage Manufacturing: Stream-of-Variation Analysis (SOVA) Methodology—Review

Frequency of model change and the vast amounts of time and cost required to make a changeover, also called time-based competition, has become a characteristic feature of modern manufacturing and new product development in automotive, aerospace, and other industries. This paper discusses the concept of time-based competition in manufacturing and design based on a review of on-going research related to stream-of-variation (SOVA or SoV) methodology. The SOVA methodology focuses on the development of modeling, analysis, and control of dimensional variation in complex multistage assembly processes (MAP) such as the automotive, aerospace, appliance, and electronics industries. The presented methodology can help in eliminating costly trial-and-error fine-tuning of new-product assembly processes attributable to unforeseen dimensional errors throughout the assembly process from design through ramp-up and production. Implemented during the product design phase, the method will produce math-based predictions of potential downstream assembly problems, based on evaluations of the design and a large array of process variables. By integrating product and process design in a pre-production simulation, SOVA can head off individual assembly errors that contribute to an accumulating set of dimensional variations, which ultimately result in out-of-tolerance parts and products. Once in the ramp-up stage of production, SOVA will be able to compare predicted misalignments with actual measurements to determine the degree of mismatch in the assemblies, diagnose the root causes of errors, isolate the sources from other assembly steps, and then, on the basis of the SOVA model and product measurements, recommend solutions.     

A fault detection service for wide area distributed computations

The potential for faults in distributed computing systems is a significant complicating factor for application developers. While a variety of techniques exist for detecting and correcting faults, the implementation of these techniques in a particular context can be difficult. Hence, we propose a fault detection service designed to be incorporated, in a modular fashion, into distributed computing systems, tools, or applications. This service uses well-known techniques based on unreliable fault detectors to detect and report component failure, while allowing the user to trade off timeliness of reporting against false positive rates. We describe the architecture of this service, report on experimental results that quantify its cost and accuracy, and describe its use in two applications, monitoring the status of system components of the GUSTO computational grid testbed and as part of the NetSolve network-enabled numerical solver. This revised version was published online in July 2006 with corrections to the Cover Date.     

Reconfigurable control system design for fault diagnosis and accommodation

The growing demand in system reliability and survivability under failures has urged ever-increasing research effort on the development of fault diagnosis and accommodation. In this paper, the on-line fault tolerant control problem for dynamic systems under unanticipated failures is investigated from a realistic point of view without any specific assumption on the type of system dynamical structure or failure scenarios. The sufficient conditions for system on-line stability under catastrophic failures have been derived using the discrete-time Lyapunov stability theory. Based upon the existing control theory and the modern computational intelligence techniques, an on-line fault accommodation control strategy is proposed to deal with the desired trajectory-tracking problems for systems suffering from various unknown and unanticipated catastrophic component failures. Theoretical analysis indicates that the control problem of interest can be solved on-line without a complete realization of the unknown failure dynamics provided an on-line estimator satisfies certain conditions. Through the on-line estimator, effective control signals to accommodate the dynamic failures can be computed using only the partially available information of the faults. Several on-line simulation studies have been presented to demonstrate the effectiveness of the proposed strategy. To investigate the feasibility of using the developed technique for unanticipated fault accommodation in hardware under the real-time environment, an on-line fault tolerant control test bed has been constructed to validate the proposed technology. Both on-line simulations and the real-time experiment show encouraging results and promising futures of on-line real-time fault tolerant control based solely upon insufficient information of the system dynamics and the failure dynamics.     

Monitoring and classification of dimensional faults for automotive body assembly

Sudden process changes occurring during automobile body assembly processes will influence the downstream assembly process and the functionality and final appearance of the vehicle. Furthermore, these faults could result in a decreased production rate and an increase in the cost if sudden process changes are so serious that the production line has to be stopped for investigation. Thus, sudden process changes should be detected and eliminated as soon as possible to prevent defective products from being produced and to reduce the cost of repairs/reworks. A monitoring algorithm is developed to detect, classify, and group process changes by analyzing the dimensional data of car bodies. The results of this monitoring algorithm can help diagnose the root causes of variation according to the locations of measurement points, body structure, assembly sequence, and tooling layout. Measurement data obtained from an optical coordinate measuring machine (OCMM) are used to demonstrate the monitoring technique.     

Interpreting principal components in biomechanics: Representative extremes and single component reconstruction

Principal component analysis is a powerful tool in biomechanics for reducing complex multivariate datasets to a subset of important parameters. However, interpreting the biomechanical meaning of these parameters can be a subjective process. Biomechanical interpretations that are based on visual inspection of extreme 5th and 95th percentile waveforms may be confounded when extreme waveforms express more than one biomechanical feature. This study compares interpretation of principal components using representative extremes with a recently developed method, called single component reconstruction, which provides an uncontaminated visualization of each individual biomechanical feature. Example datasets from knee joint moments, lateral gastrocnemius EMG, and lumbar spine kinematics are used to demonstrate that the representative extremes method and single component reconstruction can yield equivalent interpretations of principal components. However, single component reconstruction interpretation cannot be contaminated by other components, which may enhance the use and understanding of principal component analysis within the biomechanics community.     

Using hydropathy features for function prediction of membrane proteins

A novel alignment-free method for computing functional similarity of membrane proteins based on features of hydropathy distribution is presented. The features of hydropathy distribution are used to represent protein families as hydropathy profiles. The profiles statistically summarize the hydropathy distribution of member proteins. The summation is made by using hydropathy features that numerically represent structurally/functionally significant portions of protein sequences. The hydropathy profiles are numerical vectors that are points in a high dimensional 'hydropathy' space. Their similarities are identified by projection of the space onto principal axes. Here, the approach is applied to the secondary transporters. The analysis using the presented approach is validated by the standard classification of the secondary transporters. The presented analysis allows for prediction of function attributes for proteins of uncharacterized families of secondary transporters. The results obtained using the presented analysis may help to characterize unknown function attributes of secondary transporters. They also show that analysis of hydropathy distribution can be used for function prediction of membrane proteins.