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283
The manuscript was received on 16 June 2004 and was accepted after revision for publication on 13 January 2005.
DOI: 10.1243/095440505X28963
Keywords: statistical process control, neural networks, decision trees, pattern recognition,
control charts
B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
284 Ruey-Shiang Guh
techniques. For example, Cheng [3] demonstrated were reported to suffer from a false recognition
that a well-developed NN could perform better than problem (i.e. the patterns are misclassified), which is
a combined Shewhart-cumulative sum (CUSUM) commonly encountered in real-time CCP recognition
scheme in detecting small to moderate trends or schemes [5, 8].
shifts. Moreover, Ho and Chang [7] used a neural The false recognition problem results mainly from
fuzzy approach to monitor process mean and vari- the inherent common cause variation that could
ance changes simultaneously. A comparative study make a shift in the process appear to be a trend, or
demonstrated that the proposed NN control scheme a trend to be a shift. This issue becomes serious
outperforms other SPC charts in most situations for when the CCP recognition is being conducted in a
both individual measurements and a subgroup real-time mode. In a real-time process-monitoring
sample size of five. NN approaches to CCP recogni- scenario, only limited CCP points are available for
tion have been reported to begin having industrial analysis when an unnatural CCP is just detected by
applications, and these applications are expected to the CCP recognizer. Figure 2 illustrates the recogni-
increase [10]. tion procedure of a downward shift pattern. Notably,
Besides the better recognition performance, NN- owing to the natural process fluctuation, the feature
based CCP recognizers have two main advantages of the downward shift pattern within the recognition
over conventional statistics-based approaches for window resembles that of a downward trend pattern.
CCP recognition. Firstly, the robustness of a real- In fact, owing to underlying random process varia-
time SPC scheme to process non-normality is crucial tion, the shift, trend, cycle, and mixture patterns all
to its applicability because, according to an empirical share very similar features during the beginning seg-
investigation by Alwan and Roberts [11], the ments of the patterns. The cost or impact of false
normality assumption is often unsatisfied in practical recognition increases when a subsequent search is
situations, particularly when individual observations conducted to determine the cause(s). Consequently,
are used. The NN-based control-chart-monitoring the corrective action for a trend could be incorrectly
model, owing to its excellent noise tolerance, has applied to a shift, or vice versa. For example, a trend
been demonstrated still to perform well in a non- resulting from loose fittings could be incorrectly
normal distribution environment in terms of
accuracy and speed [2]. On the other hand, most
conventional SPC approaches are relatively sensitive
to the non-normality (especially the skewness).
Secondly, it is relatively easy to add other CCPs (i.e.
new pattern types) or to change the range settings
of CCP parameters in the control scheme by simply
adding or modifying the corresponding training
(learning) example sets. This method is considered
more convenient and more flexible than developing
new analytical approaches for different types of CCP.
Hence, NNs can be concluded to offer excellent
capabilities as a tool in recognizing and analysing
CCPs. However, NN approaches in CCP recognition Fig. 2 Real-time recognition of a downward shift pattern
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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
Real-time pattern recognition in statistical process control 285
identified as a shift, which may result from a tool chart is the major chart considered in this research.
breakage. The remedy adopted for a shift then Eight typical types of CCP (see Fig. 1) can exist in an
might be to replace an expensive part, whereas a X chart [13]. The generation of CCP examples used
simple adjustment is sufficient to fix the problem. in this study is detailed in the Appendix.
If the random variation in the manufacturing Before the hybrid CCP recognition system is
process data is also regarded as a type of CCP (i.e. a described, three research assumptions should be
natural CCP), the task of CCP recognition can be emphasized.
essentially considered as a classification problem. In
1. Only univariate quality characteristics are used.
this study, this line of thought leads to a novel appli-
2. Only one CCP exists at any given time.
cation of decision tree (DT) learning for the CCP
3. The common-cause standard deviation () is kept
recognition problem, because DT learning is one of
constant.
the most widespread classification approaches in
the field of machine learning [12]. The decision- Although assumption 3 must be recognized as a
making processing of an NN generally is difficult to significant simplifying assumption, it provides a
understand. In comparison, a DT classifier has the close approximation to many types of practical man-
advantages of conceptual simplicity and computa- ufacture. The factors that cause changes in process
tional efficiency. Besides NN, this research employed standard deviation tend to be long term compared
DT learning to develop a hybrid system capable of with the length of the production cycle between
solving the classification problem in a real-time CCP resetting events.
recognition scheme. This hybrid system is designed
to be applied to an automated manufacturing process
2.1 System architecture
where process data are collected automatically and
monitored with a computer-based pattern recogni- For CCP recognition, a system can be developed and
tion system, without requiring human intervention. trained either as a general-purpose system capable of
Simulation results indicate that the proposed recognizing various different types of unnatural CCP,
system can perform efficiently in real-time CCP or as a special-purpose system capable of recognizing
recognition and maintains good pattern classification only a specific type of unnatural CCP. An appro-
capability. priately designed special-purpose system should be
The rest of this paper is divided into four additional more effective than a general-purpose system in
sections. Section 2 proposes a hybrid system for real- analysing a specific type of CCP [14]. However, it is
time CCP recognition and details the algorithm for common for numerous different unnatural CCPs to
CCP classification. Section 3 then describes the per- appear in a manufacturing process separately or
formance evaluation procedure. Evaluation results together. Note that this research focused on the
are presented in section 4, together with empirical identification of single patterns only. For mixed
comparisons of the proposed hybrid system and patterns, interested readers are referred to a study
several conventional control chart approaches. This [8] that applied NNs to detect mixed (concurrent)
paper is concluded in section 5. patterns where at least two patterns coexist and
may be associated with different causes.
The hybrid intelligent classification system consists
2 HYBRID NN/DT-BASED SYSTEM FOR of three sequential modules (Fig. 3), namely module A
REAL-TIME CCP RECOGNITION (data preprocessing for feature extraction), module B
(coarse classification), and module C (fine classifica-
Owing to the wide adoption of automatic data collec- tion). Module B functions as a general-purpose CCP
tion and inspection technologies in the modern detector and classifier. This module classifies the
manufacturing industry, the X chart (individual’s detected CCPs into four CCP subsets: {natural},
chart), which plots the individual measurement {upward shift, downward shift, upward trend, down-
values rather than the averages of subgroups, recently ward trend}, {cycle}, and {systematic, mixture}. Once
has attracted increasing attention from SPC practi- the input data are processed in module A and then
tioners. Although the X chart signals false alarms analysed in module B, they are classified into one of
(identifying an unnatural CCP when the process the four CCP subsets. If an unnatural CCP is detected,
only exhibits common-cause variation), more fre- the input data are further analysed in module C using
quently it can identify the out-of-control situation several special-purpose CCP classifiers to determine
more quickly than other types of control chart. In a the pattern type of the detected CCP. This study
high-speed automatic production scenario, detecting adopts this modular design to tackle the complexity
and correcting the incipient problem as early as and mutual interference between CCP types in the
possible are important for avoiding the creation of learning process by breaking a complicated recogni-
additional defective products. Consequently, the X tion task into several straightforward subtasks that
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
286 Ruey-Shiang Guh
Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
Real-time pattern recognition in statistical process control 287
more than twice the pattern parameter range (3) applications. This window size can significantly
used in this study, was used to allow for possible influence the performance of the NN-based CCP
large variations due to special causes. The coding recognizer. A small window size typically detects
scheme is summarized as unnatural patterns more quickly and may also
produce a short in-control average run length (ARL),
yt 5 þ 7:625‚ zt ¼ þ31 which is equivalent to a high type I error. ARL repre-
7:625 þ 0:25ðk 1Þ 4 yt sents the average number of observations required
before an out-of-control signal is generated by the
4 7:625 þ 0:25k‚ zt ¼ 31 þ k chart-monitoring system. A large window size can
yt < 7:625‚ zt ¼ 31 reduce the recognition efficiency by increasing the
ð2Þ time required to detect patterns (i.e. longer out-of-
control ARL, or higher type II error). Type II error is
where the probability of failing to identify an existing
unnatural CCP. A large window size can also cause
zt ¼ value coded from yt the size of the NN to grow quickly. The appropriate
window size here balances the type I and type II
k ¼ 1‚ 2‚ 3‚ . . . ‚ 61
errors. A preliminary investigation was performed to
examine the relationship between window size and
2.3 NN-based CCP recognizer (module B) in-control ARL. A (cut-off value) was applied to
the outputs of neurons 2 to 8 in the output layer.
The BPN was selected to develop the general-purpose
Any value above was considered to indicate the
CCP recognizer in module B. In this general-purpose
presence of an unnatural CCP. In the absence of
recognizer, the input layer contains 24 neurons used
unnatural CCPs, a type I error (false alarm) occurred
as input data for 24 consecutive points in a control
when any of the output values from the above
chart. The output layer contains eight neurons used
neurons equalled or exceeded . The results were
as recognition outputs (Table 1). Each output
calculated on the basis of 100 simulation runs for
neuron is used for one of the eight types of CCP
each of the varying window sizes and settings.
addressed in this study. The outputs of the BPN
From the experimental results, the window size of
were scaled within [0‚ þ1], where 1 indicates that
24, which has an in-control ARL of 366 when
the data are totally fitted to a specific pattern. Two
¼ 0:9, was chosen to provide the NN-based recogni-
hidden layers exist, both containing 16 neurons.
zer with a similar in-control ARL to that of a standard
Based on the preliminary experiments, networks
Shewhart chart (3 limits) which has an in-control
with two hidden layers performed better than those
ARL of around 370.
with one hidden layer. Additionally, with the increase
Table 2 lists details of the training examples. There
in the number of hidden neurons, the learning results
were 80 CCP examples generated for each CCP
are also generally improved. However, once the
parameter setting; therefore, both the training
number of hidden neurons exceeds 16, learning
and the test example sets contained 5540
does not improve and the total training time
ð¼80 9 7 þ 500Þ CCP examples generated with
increases. This agrees with the results of Cheng [5]
different random seeds. These pattern parameters
that, given sufficient number of hidden neurons, the
were selected so that the simulated CCPs occur
addition of more neurons has little effect on the
mainly within the range of 3 from the process
recognition capability.
mean, because an important reason for using CCP
The number of neurons in the input layer is termed
recognition is to identify CCPs before the data
the size of the ‘recognition window’ in real-time SPC
points breach the Shewhart control limits. To enable
faster detection of a large process deviation, some
Table 1 Output types of NN-based CCP recognizer shift and trend pattern examples were generated
that included both in-control and out-of-control
Type for the following outputs points. For shift patterns, the pattern commenced at
point 20 for large displacement of the mean
Pattern 1 2 3 4 5 6 7 8
ðd 5 2:25 or d 4 2:25Þ in the recognition
Natural 1 0 0 0 0 0 0 0 window. Furthermore, for d 4 2:00 or d 5 2:00,
Upward shift 0 1 0 0 0 0 0 0 the starting point was set in the middle of the
Downward shift 0 0 1 0 0 0 0 0
Upward trend 0 0 0 1 0 0 0 0 recognition window (point 13). For trend patterns,
Downward trend 0 0 0 0 1 0 0 0 the starting point was set at point 6 for trends with
Cycle 0 0 0 0 0 1 0 0 larger slopes ðs 5 0:20 or s 4 0:20Þ. For s 4 0:18
Systematic 0 0 0 0 0 0 1 0
Mixture 0 0 0 0 0 0 0 1 or s 5 0:18, the starting point was set at the
beginning of the recognition window (point 1).
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
288 Ruey-Shiang Guh
The initial network connection weights were performance evaluation will be detailed in section 3.
randomly set between ½0:01‚ þ0:01. Moreover, the The aggregate CRs for upward shifts, downward
learning rate and momentum factors were set at 0.5 shifts, upward trends, downward trends, cycles,
and 0.4 respectively. These two parameters were systematics, and mixtures were 94.6 per cent, 87.4
gradually reduced during the training. Hyperbolic per cent, 0.3 per cent, 1.2 per cent, 78.8 per cent,
tangent functions are used as activation functions 65.6 per cent, and 81.3 per cent respectively. These
for the hidden and output layers. The connection significantly variable results indicate that trends
weights were updated using the delta rule [17], and were only rarely correctly classified. The major prob-
the convergence condition was established when lems occurred when upward trends were incorrectly
the classification rate (CR) (the number of correctly classified as upward shifts. Similarly, incorrect identi-
identified training examples divided by the total fication occurred for downward trends as downward
number of training examples) exceeded 0.95. These shifts. Moreover, some of the upward shifts, down-
NN training parameters were set based on experience ward shifts, upward trends, and downward trends
from previous work [8] in a similar problem domain. were incorrectly identified as cycles. With the
These parameters are not necessarily optimal here. presence of cycle patterns, most false alarms were
Because of the possible interactions among the NN shifts, and less frequently trends. Most false alarms
structure and training parameters involved, the tradi- for systematics were mixtures, and less frequently
tional trial-and-error experiments for determining cycles. Finally, most false alarms for mixtures were
the ‘best’ NN structure and training parameters systematics, and less frequently cycles.
generally take a long time, hindering the application The very poor recognition accuracy for some pat-
of the proposed NN-based approach in an online terns was believed to result from the feature similarity
real-time mode. Interested readers are referred to of different patterns within the limited pattern points
the paper by Guh [18], in which the genetic algorithm available for recognition in a real-time process-mon-
is used to ‘evolve’ an NN structure while simulta- itoring scenario. The average network output values
neously determining a training parameter set (includ- from each unnatural output neuron (neurons 2 to 8)
ing learning rate, momentum factor, initial weights for the first 24 moving recognition windows are
range, activation function, etc.) to obtain efficiently shown in Fig. 4. In Fig. 4(a), regarding recognition of
a near-optimal NN-based CCP recognizer for a upward shift, the average output values from the
specific SPC application. upward shift neuron reach at around the fifth recog-
The training examples were presented to the nition window, significantly earlier than the sixteenth
network in a shuffled random order. The networks window at which average output values from the
converged within ten learning cycles with a final CR upward trend neuron reach . This observation can
of 0.9720 and a r.m.s. error of 0.0322. The test result explain the high percentage of correct classification
of CR is 0.9628, which indicated that the training for the upward shift pattern. For upward trend recog-
was successful. The NN in this research was devel- nition (Fig. 4(c)), the average output values from the
oped using NeuralWorks Professional II Plus [19]. upward trend neuron reach at around the four-
Following the completion of the training and test teenth recognition window. However, owing to the
procedures, the networks were transformed into the feature similarity between shifts and trends, the aver-
C program and embedded into the main system for age output values from the upward shift neuron reach
evaluation and application. much earlier – at the ninth window. This phenom-
After the network training and test were completed, enon implies that the network will always signal an
a preliminary study of 100 simulation runs for each upward shift alarm first, despite the fact that the
pattern parameter setting was conducted to assess unnatural CCP is an upward trend. This observation
roughly the performance of the BPN-based CCP could explain the very poor recognition accuracy
recognizer with ¼ 0:9. The procedure of the (0.3 per cent) for the upward trend pattern. A similar
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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
Real-time pattern recognition in statistical process control 289
B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
290 Ruey-Shiang Guh
more accurate the recognition will be. Ideally, waiting low (e.g. 0.3), sufficient evidence exists that the
for 24 points (i.e. the size of the recognition window in pattern is actually a cycle. The choice of a relatively
this research) will guarantee that a full unnatural low threshold value here is based on the considera-
pattern is presented to the recognizer. However, one tion that the output from the cycle neuron presently
of the main goals of the CCP recognition scheme is may not be very high (close to 1.0) because only
to detect and classify patterns as quickly as possible. about half of the recognition window consists of
‘Five points’ is the minimum number for obtaining cycle pattern at this stage. The probability of recog-
satisfactory results here. This empirical rule can be nizing the cycle pattern increases with reducing
extracted from close examination of the network threshold value used (producing a lower type II
outputs for the first 24 moving recognition windows error). However, the type I error tends to increase. A
(Fig. 4) and further proved by the experimental threshold value of 0.2 is an appropriate value herein
results. for satisfactorily balancing type I and type II errors.
The new process window is then analysed by the Notably, the threshold value ‘0.2’ used here is
NN-based CCP recognizer again. If the output value simply an empirical setting and is not necessarily
from the cycle neuron exceeds 0.2, the occurrence optimal.
of an unnatural pattern is concluded to be a cycle; If the unnatural pattern is an upward shift or trend,
otherwise it is confirmed to be a shift or a trend. the process window is analysed using a DT-based
This step was included because some cycles may be classifier. The DT-based approach here views each
falsely identified as shifts or trends because they observation in the monitoring window as a real-
possess features similar to those of shifts or trends valued attribute of an ongoing manufacturing
in the earlier portion of a cycle pattern. In situations process. Based on these attributes, the DT can classify
where the pattern presented is a shift or trend, the the CCP type. This classifier (DT classifier 1) is
output from the cycle neuron should be a very low dedicated to classifying upward shift and upward
value (close to zero) after five further points have trend. There were 2700 shift patterns and 2700 trend
been included in the recognition window. Therefore, patterns generated in the learning and test data sets
if the output value from the cycle neuron is not very for DT classifier 1. The 24 attributes in the data set
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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
Real-time pattern recognition in statistical process control 291
Fig. 6 Example of a cycle pattern classified using the algorithm of fine classification in module C
(i.e. the 24 consecutive points in a control chart) were pattern can be falsely recognized as a cycle pattern.
labelled X1, X2, . . . , X24. With the m parameter (the However, after taking five more data points from the
minimum number of instances represented by a process, if the output values from the systematic,
node) and c parameter (the confidence level of prun- mixture, and cycle neurons are all smaller than 0.2,
ing) set to 4 and 10 respectively, See5 obtained a DT the pattern can be a shift or a trend that is falsely
with a classification accuracy (CR) of 92.3 per cent identified as a cycle. In this occasion, both upward
on the test example set. The See5 rule induction and downward patterns (shift and trend) can be
program then was applied to produce a rule set (pro- falsely identified as a cycle, therefore another
duction rules) with an accuracy of 94.5 per cent. The special-purpose classifier (DT classifier 3), which
tree size (the number of leaves in the tree) was 86, aims to classify between upward patterns and down-
while the number of rules was 62. The rule set gener- ward patterns for shifts and trends, was created to
ated from the DT in this study is more accurate and address this occasion. DT classifier 3 was trained
smaller than the DT. Previous studies [23] have using 5400 upward patterns and 5400 downward pat-
stated that a collection of classification rules can be terns in the training and test sets. Here the upward
expected to produce more accurate classification of patterns included both upward shifts and upward
cases that were not in the training set. Using the trends, while the downward patterns included both
rule set, rather than the tree, may lead to the building downward shifts and downward trends. The final
of more reliable but smaller systems. Two examples of test result (CR) was 99.6 per cent.
rules are
2.4.3 Systematic or mixture pattern
Rule 13: (165/11, lift 6.6)
X23 > 4 X19 > 0 X20 > 1 X15 < 4 X16 < 3 If the initial alarm type is a systematic or mixture type,
X24 > 2 ! class ‘US’ [0.933] after taking five more observations from the process,
the data window is analysed directly using DT classi-
Rule 45: (157/9, lift 6.6) fier 4 for classifying systematic and mixture patterns.
X15 ( 8 X19 > 5 X21 > 13 X12 > 1 The DT classifier 4 was trained using 2700 systematic
! class ‘UT’ [0.937] patterns and 2700 mixture patterns, and the final test
A value between 0 and 1 (in the square brackets) indi- CR was 96.8 per cent.
cates the confidence (accuracy) with which this rule is Figure 6 shows a simple example showing the usage
made. The dichotomous DT-based CCP classifier per- of this classification algorithm. In Fig. 6, a cycle
formed better than the NN-based CCP classifier in (amplitude, 1:75) initiated at data point 25, is falsely
this study. A BPN, which was trained using the same identified as an upward shift at data point 29. After
training example set as the DT classifier 1, achieved waiting for five more data points from the process,
a test result of 85.6 per cent. The building process of the pattern was correctly classified as a cycle at
DT classifier 2, designed for the situation in which point 34 using the procedure described above.
the initial alarm indicates downward patterns (shift
or trend), is similar to that of DT classifier 1.
3 PERFORMANCE EVALUATION
2.4.2 Cycle pattern
The operations following an initial cycle alarm are Generally, a real-time CCP recognition scheme has
similar to those with an initial shift or trend alarm two performance indices: detecting the underlying
described above, because a systematic or mixture pattern as soon as possible, and classifying the type
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
292 Ruey-Shiang Guh
of the detected pattern as accurately as possible. That by 1, and go to step 2. This procedure is repeated
is, shorter ARL and higher pattern classification until an unnatural CCP is detected.
capability are the two main goals of real-time CCP
recognition. Besides out-of-control ARL (recognition
speed) and CR (recognition accuracy), the recogni- 4 EVALUATION RESULTS OF THE PROPOSED
tion speed stability (i.e. the standard deviation of SYSTEM
the run length) is also considered an important
criterion for CCP recognition in this study, because Owing to the large number of example CCPs required
it is helpful to spot the starting point of the detected for assessing the performance of the proposed CCP
CCP [10]. Therefore, this study employed three recognition system, simulation was also used to
performance indices (CR, out-of-control ARL, and generate the CCPs for performance evaluation. All
of the run length) to evaluate the proposed real- the unnatural CCPs began at point 25 in the simu-
time CCP recognition system. lated process data stream. The first 24 data points
A moving-window analysis method was used to were generated using a normal distribution. Because
evaluate the CCP recognizer in this study. A sequence it was assumed herein that no unnatural pattern
of simulated process data was presented to the recog- exists in the first recognition window, the first
nizer in the moving window, which was incremented window was checked for unnatural CCPs before the
forwards by one process measurement, representing start of the recognition process. If the first window
a single sampling interval (see Fig. 2). Additionally, is not free of unnatural CCPs, the simulated process
the performance evaluation approach of this study data are discarded and the next process data stream
assumes that the process begins with an in-control is generated. The CR, ARL, and of the ARL were
condition. The initial recognition window contains calculated on the basis of the results of 10 000 simula-
no unnatural CCP points. Unnatural CCPs begin to tion runs for each CCP parameter setting. Notably, the
appear as the recognition window moves along the ARL here was calculated only for the correct recogni-
time series (the 25th point in the time series). The tions of the actual pattern. Table 3 lists the evaluation
pattern features gradually strengthen as the recogni- results for each type of CCP.
tion window moves forwards through the process In Table 3, the numbers in parentheses listed in the
data stream. This assumption simulates the scenario CR column represent the results based on 100 simula-
that the proposed system will encounter in a practical tion runs conducted in the preliminary study (described
CCP recognition scheme. Although the evaluation in section 2.3) using only modules A and B. Notably, the
results using this approach are inferior to those with CRs were significantly improved, after introducing the
the commonly used method, which assumes that a heuristic algorithm for fine classification in module C.
full (complete) pattern is already shown in the recogni- The overall CR was improved from 57.9 to 94.6 per
tion window at the start of the recognition scheme [16, cent. For trends, the CRs were significantly improved
24, 25], this evaluation approach is considered more from 0 to 93 per cent and from 1 to 92 per cent for the
practical because, in a real-time process-monitoring upward trend and downward trend respectively. The
scheme, an unnatural CCP often occurs after a proposed hybrid system outperforms the BPN-based
period during which the process is in control, and CCP recognizer by Cheng [5] in terms of CR. The CRs
the starting point of the unnatural CCP is generally of Cheng’s model are 82.3 per cent, 82.3 per cent, 78.9
unknown [2, 5]. The performance evaluation pro- per cent, 79.0 per cent, 90.0 per cent, 98.9 per cent,
cedure consists of the following steps. and 71.4 per cent for upward shift, downward shift,
upward trend, downward trend, cycle, systematic, and
1. Set t (time of sampling) to 24. mixture patterns respectively (extracted from Table
2. Take the most recent 24 sample values, xi , 4(a) of reference [5]). The overall CR is 83.2 per cent. It
i ¼ t 23‚ t 22‚ . . . ‚ t 1‚ t, from the process. should be noted that it might not be appropriate to
3. The input sample values xi , are preprocessed in compare the performances of these two studies directly,
module A. Denote the preprocessed values by because the AMPRL (termed in-control ARL in the
zi , i ¼ t 23‚ t 22‚ . . . ‚ t 1‚ t. Form an input present study) of Cheng’s model is 800, which is
vector V I ½V I ¼ ðzt 23 ‚ zt 22 ‚ . . . ‚ zt 1 ‚ zt Þ at time t]. longer than the in-control ARL (equal to 366) of the
4. V I is presented to the NN-based CCP recognizer proposed hybrid system.
in module B and an output vector V O ½V O ¼ The ARL performances of the proposed system were
ðo1 ‚ o2 ‚ o3 ‚ o4 ‚ o5 ‚ o6 ‚ o7 ‚ o8 Þ is generated. compared with those of the conventional control
5. If oj ð j ¼ 2–8Þ 5 (cut-off value), conclude that chart approaches described in the literature. Figure 7
an unnatural CCP has been detected in the current compares the ARLs of the combined Shewhart–
recognition window. The process data in the cur- CUSUM scheme K ¼ 0:25, H ¼ 8:0, and Shewhart con-
rent window then are further analysed in module trol limit ðSCLÞ ¼ 4:0 [26], and the proposed hybrid
C for fine classification. Otherwise, increment t NN–DT system for both upward shift and downward
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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
Real-time pattern recognition in statistical process control 293
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
294 Ruey-Shiang Guh
Table 3 Continued
Fig. 7 Comparison of ARLs between the two-sided Shewhart–CUSUM chart, with K ¼ 0:25, H ¼ 8:0,
and SCL ¼ 4:0 [26], and the proposed hybrid NN–DT system for shift patterns
shift detection. The combined Shewhart–CUSUM Figure 8 compares the optimal CUSUM charts [27]
scheme is an improved control chart scheme that and the proposed hybrid system in terms of their
attempts to detect both large and small process mean ability to detect trends. The values of K and H for
changes simultaneously. For the comparison to be each CUSUM chart were optimally set to the corre-
unbiased, the type I errors (expressed as in-control sponding trend slope s to optimize the results (i.e.
ARL) of both control schemes were kept roughly the shortest out-of-control ARLs). The in-control ARL of
same. The in-control ARLs of the Shewhart–CUSUM the optimal CUSUM chart is 350. Figure 8 shows
scheme and the proposed system are 361 and 366 that the proposed system outperforms the optimal
respectively. The proposed hybrid system has better CUSUM charts for upward and downward trends,
performance than the combined Shewhart–CUSUM except when the slope s ¼ 0:20. Again, the proposed
scheme when detecting upward and downward shift system possesses the ability to classify patterns when
patterns, except for cases involving a large mean an out-of-control alarm is signalled.
displacement ðd ¼ 3:00Þ. This comparison implies Figures 9 and 10 compare the proposed hybrid
that the proposed system is better able to detect small system with a pattern recognition algorithm
and moderate shifts than the combined Shewhart– proposed by Cheng and Hubele [20] for detecting
CUSUM scheme with K ¼ 0:25, H ¼ 8:0, and cycle and systematic patterns. This algorithm was
SCL ¼ 4:0. Notably, the proposed system also based on traditional methods, for example statistical
provides the pattern classification capability that the and syntactic approaches, modified for CCP recog-
combined Shewhart–CUSUM scheme cannot handle. nition. Figure 9 demonstrates that the proposed
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Real-time pattern recognition in statistical process control 295
Fig. 8 Comparison of ARLs between the optimal CUSUM charts [27], and the proposed hybrid system
for trend patterns
Fig. 9 Comparison of ARLs between a modified pattern recognition algorithm [20], and the proposed
hybrid system for cycle patterns with period of 8
system outperforms this algorithm, with a threshold operation of the proposed hybrid system. The white
equal to 0.3, for detecting the cycles with a period millbase is used in the manufacture of topcoats. The
of 8, particularly for the cycles with a small amplitude quality characteristic under control in this example
ð1:00 4 l 4 1:50Þ. Figure 10 shows that the is the weight (pounds) per gallon of each batch. The
proposed system performs better than this algo- weight of 60 consecutive batches of the millbase is
rithm, with a threshold of 0.3, for the systematic displayed in Fig. 11. The in-control mean and stan-
patterns. dard deviation of the process are 14.311 and 0.261
respectively. The upper specification limit and lower
specification limit are 15.3289 and 13.2931 respec-
5 ILLUSTRATED EXAMPLE OF THE PROPOSED tively. The upper control limit and lower control
HYBRID SYSTEM limit ð 3Þ are calculated as 15.094 and 13.528
respectively. Because of an assignable cause (a new
The data of a white millbase dispersion process in an control method), the process mean shifted to 13.77
automotive paint plant [28] are used to illustrate the (displacement of the mean equal to 2:07) at
Fig. 10 Comparison of ARLs between a modified pattern recognition algorithm [20], and the proposed
hybrid system for systematic patterns
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
296 Ruey-Shiang Guh
Fig. 11 Control chart data: a sequence of 60 consecutive weight measurements of white millbase in a
millbase dispersion process [28] (UCL, upper control limit; LCL, lower control limit)
sample 31. For the purpose of illustration, these Module B of the proposed system detects an un-
process data are stored in a file and presented to natural CCP at sample 35 with samples 12 to 35 in
the proposed model during the illustrative procedure. the recognition window (see Table 4). It can be seen
Note that, in a practical application, the process data in Table 4 that the output value from the downward
would be input in real time via a data acquisition shift neuron (indicated in bold) is 0.9177. It is greater
system. than the threshold value (0.9). Then the system
In the beginning of the recognition process, further identifies the type of this unnatural CCP
samples 1 to 24 are input in the recognition using the fine-classification algorithm in module C.
window, preprocessed by module A, and analysed After the recognition window moves forwards by
by module B (NN-based CCP recognizer) of the five samples, the output value of the cycle neuron
proposed system. Then samples 2 to 25 are input in (indicated in bold in Table 4) is 0.0596 for the
the recognition window for analysis, and so on. This window of samples 17 to 40. This confirms that the
moving window recognition scheme continues until detected unnatural CCP is a downward shift or a
an out-of-control condition (unnatural CCP) is downward trend. Then this CCP is classified as a
detected. The output values from the eight output downward shift by DT classifier 2 that is dedicated
neurons of the recognizer network are shown in to the discrimination between downward shift and
Table 4. downward trend.
Samples 1–24 0.3979 0.0563 0.0717 0.0438 0.0381 0.8064 0.0951 0.0282
Samples 2–25 0.0896 0.0225 0.0067 0.0659 0.0316 0.8820 0.0833 0.0258
Samples 3–26 0.9279 0.0126 0.0665 0.0561 0.0211 0.1298 0.0330 0.0131
Samples 4–27 0.9434 0.0160 0.0099 0.0084 0.0282 0.0773 0.0190 0.0246
Samples 5–28 0.9459 0.0192 0.0130 0.0034 0.0274 0.0676 0.0185 0.0175
Samples 6–29 0.9537 0.0299 0.0261 0.0261 0.0510 0.0497 0.0428 0.0329
Samples 7–30 0.9499 0.0170 0.0131 0.0020 0.0212 0.0645 0.0212 0.0283
Samples 8–31 0.9506 0.0166 0.0128 0.0016 0.0260 0.0639 0.0216 0.0264
Samples 9–32 0.9468 0.0189 0.0125 0.0040 0.0276 0.0665 0.0181 0.0151
Samples 10–33 0.8029 0.0698 0.0017 0.0132 0.0258 0.2169 0.0394 0.0091
Samples 11–34 0.8136 0.0590 0.0026 0.0042 0.0333 0.2285 0.0290 0.0037
Samples 12–35 0.0334 0.0201 0.9177 0.0176 0.0174 0.0086 0.0431 0.0245
Samples 13–36 0.0314 0.0517 0.9484 0.0080 0.0071 0.0136 0.0539 0.0182
Samples 14–37 0.0153 0.0149 0.9805 0.0266 0.0276 0.0034 0.0115 0.0146
Samples 15–38 0.0153 0.0150 0.9805 0.0266 0.0276 0.0035 0.0116 0.0115
Samples 16–39 0.0153 0.0150 0.9805 0.0266 0.0275 0.0035 0.0116 0.0264
Samples 17–40 0.0183 0.0571 0.7148 0.0340 0.2724 0.0596 0.0090 0.0365
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Real-time pattern recognition in statistical process control 297
6 CONCLUSIONS REFERENCES
B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
298 Ruey-Shiang Guh
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