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Real-time pattern recognition in statistical process control: A hybrid neural network/decision


tree-based approach
Ruey-Shiang Guh
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 2005 219:
283
DOI: 10.1243/095440505X28963

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283

Real-time pattern recognition in


statistical process control: a hybrid neural
network/decision tree-based approach
Ruey-Shiang Guh
Department of Industrial Management, National Formosa University, Huwei, Yunlin 632, Taiwan, Republic of China

The manuscript was received on 16 June 2004 and was accepted after revision for publication on 13 January 2005.

DOI: 10.1243/095440505X28963

Abstract: Pattern recognition is an important issue in statistical process control because


unnatural patterns displayed by control charts can be associated with specific causes that
adversely impact on the manufacturing process. A common problem of existing approaches to
control chart pattern (CCP) recognition is false classification between different types of CCP
that share similar features in a real-time process-monitoring scenario, in which only limited
pattern points are available for recognition. This study proposes a hybrid learning-based
system that integrates neural networks and decision tree learning to overcome the
classification problem in a real-time CCP recognition scheme. This hybrid system consists of
three sequential modules, namely feature extraction, coarse classification, and fine
classification. The coarse-classification model employs a four-layer back propagation network
to detect and classify unnatural CCPs. The fine-classification module contains four decision
trees used in a simple heuristic algorithm for further classifying the detected CCPs. Simulation
experiments demonstrate that the false recognition problem has been effectively addressed by
the proposed hybrid system. Compared with conventional control chart approaches, the
proposed system has better performance in terms of recognition speed and also can
accurately identify the type of unnatural CCP. Although a real-time CCP recognizer for the
individual’s (X) chart is the specific application presented here, the proposed hybrid
methodology based on neural networks and decision trees can be applied to other control charts.

Keywords: statistical process control, neural networks, decision trees, pattern recognition,
control charts

1 INTRODUCTION effective recognition of unnatural patterns in control


charts can significantly narrow the set of possible
Statistical process control (SPC) is extremely useful in causes to be investigated and markedly accelerate
maintaining process stability by providing a meth- the diagnostic search. Consequently, the recognition
odology for measuring process capability and perfor- of unnatural control chart patterns (CCPs) is a critical
mance. Control charting is the key part of SPC and complementary tool to the control chart limits
implementation. The power of a control chart lies in (e.g. 3) used in control charts.  is the process
its ability to separate out special disturbances (out- standard deviation. Figure 1 illustrates some typical
of-control data) from inherent variability (in-control CCPs.
data) in the process. However, a traditional control Traditional methods (e.g. visual judgement of
chart with a control limit can indicate only when to human expert, zone tests or run rules, and expert sys-
seek a disturbance. A traditional control chart tems) have been demonstrated to be not especially
cannot directly indicate where and what to look for. useful for CCP recognition [1, 2]. Recently, neural net-
Unnatural patterns in control charts can be asso- works (NNs) have been successfully applied to detect
ciated with a specific set of causes, giving the avail- and analyse CCPs [2–9]. Pertinent literature demon-
ability of appropriate process knowledge. Hence, strates that NNs outperform other more traditional
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
284 Ruey-Shiang Guh

Fig. 1 Some typical types of CCP

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

can be deliberately configured using the cut-off


value and the setting of the recognition window size
(discussed in section 2.3). Type I error is the probabil-
ity of identifying an unnatural CCP when the process
only exhibits common-cause variation. When the
performance of the proposed system is compared
with that of other SPC approaches, configuring the
type I error of the proposed system to a specific
level is necessary to achieve an unbiased and mean-
ingful comparison. A DT-based model cannot address
this necessity. Thirdly, a DT-based model can out-
perform an NN-based model for a dichotomous
classification problem [15], as addressed in module
C of the proposed hybrid system. Additionally, the
learning speed of a DT significantly exceeds that of
an NN.

2.2 Data preprocessing (module A)


Before the data were presented to the module B, two
steps of data preprocessing, namely standardization
and coding, were implemented in module A for CCP
feature extraction. Standardization is a linear trans-
formation process through which the process data
are transformed to a constant range, approximately
[3, þ1], regardless of the values taken by the data
before standardization [16]. This transformation is
necessary because a trained NN or DT can accept
only a certain range of input data. The pattern data
were standardized according to
yt ¼ ðxt  Þ= ð1Þ
where:
t ¼ time of sampling
xt ¼ sample value at time t and generated using the
Fig. 3 Architecture of the hybrid system for real-time CCP process simulator detailed in the Appendix
recognition  ¼ process mean
 ¼ process standard deviation
yt ¼ value standardized from xt and will follow a
are then solved sequentially using a simple heuristic
standard normal distribution with a zero
algorithm and several pattern recognizers dedicated
mean and a standard deviation of unity
to each subtask.
provided that xt follows a normal distribution
The back-propagation network (BPN) and the DT
learning were chosen to develop module B and A coding process was implemented following the
module C respectively for the following reasons. standardization to reduce the effect of common-
Firstly, the BPN has been successfully applied in cause variation (noise) in the input data before pre-
many CCP recognition tasks described in the litera- senting the data to the CCP recognizer. The coding
ture [6]. Although the training of BPN-based systems scheme filters the small random variations while
tends to be relatively slow, the recall process is fast. retaining the main features of the data. This scheme
This is acceptable since the main focus of this study not only facilitates network convergence in NN train-
is to design a CCP recognition system that can be ing but also produces a smaller DT in DT learning.
applied in real-time mode but is trained offline. In the coding process, the variable range [7:625,
Secondly, the output values of a BPN are continuous, þ7:625] is divided into 61 zones with a width of
generally in [0, 1]. This characteristic can be used to 0.25, each returning an integer code. Any data falling
control the detection sensitivity of the system by above þ7:625 and below 7:625 are coded as þ31
applying a cut-off value () to the output values of and 31 respectively. Here, a relatively large range
the BPN. The type I error of the proposed system of the coding process [7:625, þ7:625], which is
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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

Table 2 Details of training example CCPs



Pattern type Parameter range Description Quantity

Natural Normal distribution,  ¼ 0,  ¼ 1 500


Upward shift d ¼ ð1:0‚ 3:0‚ 0:25Þ Displacement from the process mean 720
Downward shift d ¼ ð3:0‚ 1:0‚ 0:25Þ Displacement from the process mean 720
Upward trend s ¼ ð0:10‚ 0:26‚ 0:02Þ Slope 720
Downward trend s ¼ ð0:26‚ 0:10‚ 0:02Þ Slope 720
Cycle l ¼ ð1:0‚ 3:0‚ 0:25Þ Amplitude 720
Systematic g ¼ ð1:0‚ 3:0‚ 0:25Þ Magnitude of process fluctuation 720
Mixture r ¼ ð1:0‚ 3:0‚ 0:25Þ Magnitude of process fluctuation 720

The three values in parentheses correspond to the initial value, final value, and increment respectively.

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

viewing a control chart might do, by simply taking


more observations. Based on this idea, a heuristic
algorithm for CCP classification and several special-
purpose DT classifiers was designed to address the
false recognition problem.

2.4 Decision tree-based CCP classifier (module C)


Using the DT learning approach to build knowledge-
based systems from training data has been success-
fully demonstrated in various practical applications
[21]. The advantage of this classification algorithm
lies in its simplicity and efficiency, its ability to
handle non-homogeneous and non-linearly separ-
able cases, its robustness with respect to outliers
and misclassified points, and the ease of understand-
ing and interpretation regarding the data structure.
Most of these advantages cannot be achieved using
traditional classification techniques such as linear
discrimination analysis or the k-nearest-neighbour
method. Implementations of DT algorithms are now
commercially available on numerous computer
platforms.
The See5 DT learning tool (http://www.rulequest.
com/see5-win.html), which is the C4.5 [22] subse-
quent Windows version, was applied in this study
for building DTs for CCP classification. C4.5 is the
fastest DT learning algorithm in an empirical com-
parison [15], in which the training speeds of 22 DT
learning algorithms were compared. See5 also
includes a function for converting a DT to a set of
production rules. The resulting classifiers were
linked to the main system for evaluation and applica-
tion purposes using a C source code provided by See5.
Figure 5 shows the heuristic algorithm for further
classification of the CCP type in module C. The logic
of this procedure was derived from scrutiny of the
output values from the output neurons of the NN-
based CCP recognizer for different patterns (see
Fig. 4). The algorithm, which employs four DT classi-
fiers specially developed with different learning
example sets for specific tasks, is detailed below,
Fig. 4 Average output values of the NN-based CCP recog- based on the initial alarm type (shift or trend pattern;
nizer for the first 24 moving recognition windows cycle pattern; systematic or mixture pattern) signalled
by the NN-based CCP recognizer (module B).
discussion can be applied to the recognition results of
2.4.1 Shift or trend pattern
downward shift and downward trend patterns (Figs
4(b) and 4(d)). If the initial alarm type is a shift or a trend, the recog-
The initial results using only the BPN-based nition window is moved forwards five points. The
recognizer demonstrate that, for real-time CCP recog- system thus waits for five more sample data points
nition, the general-purpose recognizer alone per- from the process. This motion is designed to solve
formed poorly in pattern discrimination. This kind the misclassification problem, which results from
of false recognition problem is considered unavoid- pattern similarity in the limited points available for
able in this field of research because CCPs are gener- analysis immediately after the pattern detection.
ally distorted by the common-cause variations The more pattern points are included in the recogni-
natural to the process [5, 8, 20]. Such false recognition tion window, the more pattern features can be
problems could be treated as a quality engineer exposed to the pattern recognizer, and thus the
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B10304 # IMechE 2005 Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture
290 Ruey-Shiang Guh

Fig. 5 The heuristic algorithm for fine classification of CCP type

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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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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Real-time pattern recognition in statistical process control 293

Table 3 Evaluation results of the proposed hybrid CCP recognizer

Upward shift d CR (%) Out-of-control ARL  of run length

1.00 82 (90) 7.3 2.7


1.25 90 (94) 6.6 2.6
1.50 95 (94) 5.5 2.1
1.75 95 (95) 4.8 1.4
2.00 96 (96) 4.7 1.3
2.25 97 (94) 4.7 1.1
2.50 97 (91) 4.6 0.9
2.75 98 (99) 4.3 0.8
3.00 99 (98) 4.3 0.6
Aggregate 94 (95) 5.2 1.5

Downward shift d CR (%) Out-of-control ARL  of run length

1.00 88 (86) 9.0 2.2


1.25 92 (86) 7.6 2.0
1.50 93 (80) 6.7 1.6
1.75 93 (86) 6.3 1.3
2.00 96 (90) 6.3 1.2
2.25 97 (90) 6.0 1.0
2.50 98 (90) 6.1 0.9
2.75 98 (91) 6.0 0.9
3.00 99 (88) 6.0 0.8
Aggregate 95 (87) 6.7 1.3

Upward trend slope s CR (%) Out-of-control ARL  of run length

0.10 91 (0) 10.2 1.9


0.12 97 (0) 9.9 1.4
0.14 86 (0) 9.8 1.2
0.16 85 (0) 9.3 1.2
0.18 91 (0) 9.0 1.1
0.20 95 (0) 9.1 1.0
0.22 95 (1) 8.8 0.9
0.24 99 (1) 8.6 0.7
0.26 94 (1) 8.5 0.7
Aggregate 93 (0) 9.2 1.1

Downward trend slope s CR (%) Out-of-control ARL  of run length

0.10 82 (0) 9.6 1.5


0.12 84 (0) 9.4 1.5
0.14 86 (2) 9.3 1.4
0.16 90 (0) 9.0 1.2
0.18 94 (2) 9.0 1.2
0.20 95 (1) 9.0 0.9
0.22 98 (1) 8.7 0.8
0.24 99 (2) 8.6 0.7
0.26 100 (3) 8.6 0.6
Aggregate 92 (1) 9.0 1.1

Cycle amplitude l CR (%) Out-of-control ARL  of run length

1.00 81 (88) 12.8 3.4


1.25 88 (85) 12.1 2.4
1.50 96 (92) 11.5 1.9
1.75 98 (85) 11.2 2.1
2.00 98 (80) 10.8 1.4
2.25 99 (75) 10.9 1.4
2.50 99 (75) 10.6 1.2
2.75 99 (76) 10.6 0.9
3.00 100 (53) 10.5 0.8
Aggregate 95 (79) 11.2 1.7

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294 Ruey-Shiang Guh

Table 3 Continued

Systematic magnitude g CR (%) Out-of-control ARL  of run length

1.00 88 (70) 10.9 2.8


1.25 93 (73) 10.3 1.6
1.50 95 (64) 10.0 1.7
1.75 95 (62) 9.8 1.4
2.00 96 (61) 9.6 1.1
2.25 96 (63) 9.6 0.8
2.50 98 (66) 9.5 0.8
2.75 99 (69) 9.4 0.7
3.00 100 (62) 9.4 0.4
Aggregate 96 (66) 9.8 1.3

Mixture r CR (%) Out-of-control ARL  of run length

1.00 93 (87) 11.5 4.3


1.25 94 (90) 10.8 1.8
1.50 94 (80) 10.5 1.4
1.75 96 (78) 10.2 1.6
2.00 97 (77) 10.1 0.9
2.25 99 (78) 9.9 0.8
2.50 99 (81) 9.8 0.8
2.75 100 (84) 9.8 0.5
3.00 100 (77) 9.7 0.3
Aggregate 97 (81) 10.3 1.4

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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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005
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.

Table 4 Output values from the recognizer network (module B)

Extent of recognition Upward Downward Upward Downward Cycle Systematic


window Natural shift shift trend slope trend slope amplitude magnitude Mixture

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

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in process control charts. J. Intell. Mfg, 1999, 10(5), Trend slope
449–462.
dt ¼ s  t
26 Lucas, J. M. Combined Shewhart–CUSUM quality con-
trol schemes. J. Qual. Technol., 1982, 14(2), 51–59. where
27 Gan, F. F. CUSUM control charts under linear drift.
Statistician, 1992, 41(1), 71–84. s ¼ trend slope in terms of 
28 Devor, R. E., Chang, T. H., and Sutherland, J. W.
Cycle amplitude
Statistical Quality Design and Control – Contemporary  
Concepts and Methods, 1992, pp. 349–361 (Macmillan, 2pt
dt ¼ l  sin
London). 
29 Law, A. M. and Kelton, W. D. Simulation Modelling and
Analysis, 1982 (McGraw-Hill, New York). l ¼ cycle amplitude in terms of 
 ¼ cycle period ( ¼ 8 in this research)
Systematic magnitude
APPENDIX dt ¼ g  ð1Þt
In this research, the Monte Carlo simulation where
approach was used to generate the required sets g ¼ magnitude of the systematic pattern in terms
of CCPs for training, test, and evaluation examples of , determining the fluctuations above or
for several reasons. Firstly, large numbers of below the process mean
example CCPs are needed in the training and test
process. Secondly, simulation can be used to vary Mixture
elaborately the difficulty of the data sets (e.g. the dðt‚pÞ ¼ r  ð1Þh
strength of the pattern feature). Thirdly, the simulated
CCPs are easily reproduced by other researchers. The where
CCP herein is expressed in a general form that p ¼ a random number, 0 < p < 1
consists of the process mean, the common-cause r ¼ magnitude of the mixture pattern in terms of ,
variation, and a special disturbance from specific determining the fluctuations above or below
causes. the process mean
h ¼ 0 if p < rp, 1 if p 5 rp where
rp ¼ prespecified probability value that
Process simulator
determines the switch between
xt ¼  þ nt þ dt distributions and was fixed at 0.5 in this
research

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Proc. IMechE Vol. 219 Part B: J. Engineering Manufacture B10304 # IMechE 2005

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