Case Study 1
Case Study 1
Case Study 1
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Abstract: Industry 4.0 enables technological trends like Big Data Analytics and Machine Learning techniques to converge into and merge with traditional
manufacturing processes, resulting in smart manufacturing. Smart manufacturing techniques leverage the use of Industrial Internet of things (IIoT)
technology using IoT sensors that are fitted on physical assets to enhance manufacturing processes. IoT Sensors enable smart manufacturing facilities
capable of autonomously exchanging information, which can be used to drive business decisions more accurately. Businesses that adopt Smart
manufacturing techniques lead to a competitive advantage for these firms as they can bring in higher profit margins, reduced maintenance costs, energy
savings, and better-quality products. This study proposes an architecture for IIoT based predictive maintenance. A case study from ancillary automobile
industry is presented to demonstrate a predictive model for predicting sudden breakdown in industrial machines, thereby enabling the production and
maintenance cycle to be ‘smart.’
Keywords: Industry 4.0, Analytic Models, Machine learning, Smart Manufacturing, Sensors
With the advent of Industry 4.0, the goal of Predictive Maintenance space where data is stored. Data from IoT sensors is transmitted to a
centralized cloud server or decentralized fog nodes via Wi-Fi, or in remote
systems is reaching Zero-Defect Manufacturing (Wang, 2016). The author
locations through Cellular networks or Bluetooth Low Energy (BLE)
defines PdM as a set of activities that can detect changes in a physical technology.
state of an asset (signs of possible equipment failure) so that the
appropriate maintenance work for maximizing the service life of an asset 3.4. Edge/Fog/Cloud Computing:
can be done optimally. The author (Wang, 2016) propose an Intelligent
Predictive Maintenance framework (IPdM) that gave an initial direction IoT sensors like Arduino, Raspberry PI, ESP8266, ESP32 have inbuilt
for the current research work. Overall, the goal is to create and deploy a computing power. Based on the criticality of the asset, processing of PdM
model for prediction of machinery failure using data collected from algorithms can be done at Edge, Fog, or Cloud. In Edge devices, the
processing is done locally. It is used to provide near to real-time insights
industrial sensors. The next section discusses the architecture of the PdM about Machine failure. In cloud computing, the server is located in a
model. centralized location, having big data centers (Chiang & Zhang, 2016).
Data generated from the IoT sensors in PdM applications are sent to
Cloud for further processing. Processing at cloud has high latency. Fog
3. IoT based Predictive Maintenance Architecture Computing has distributed architecture where fog nodes are distributed in
many locations, over large geographic areas (David Linthicum, 2016). It
The study proposes an architecture for Industrial IoT based predictive is the intermediate layer between Cloud and IoT Edge devices (Fig. 2) if
the assets are separated by the large distance it is recommended to
maintenance (Fig. 1). IoT sensors are used to monitor and collect real-
implement fog architecture over the cloud due to low latency and higher
time data. The data collected is then modelled into PdM model using computing power (Atlam, Walters & Wills, 2018).
Statistical tools and software. The following are the components of PdM
systems.
Sensors or Cyber-physical systems can interact and communicate with Fig. 2 - Fog Computing, an extension of Cloud computing
each other. Sensors capture raw data. Few Popular Industrial IoT Enabled
Sensors measure Temperature, Humidity, Pressure, Current, Vibration, 3.5. Predictive Maintenance:
Air Quality, Footfall, Gas, and Weight. Another commonly used sensor is
the Photoionization Sensor, which is used to measure levels of volatile After the data has been transferred to Fog/Cloud/Edge nodes or a
inorganic compounds and gases. The ultrasonic sound sensor is used to centralized database, the next step is PdM algorithm design. The goal of
translate high-frequency sounds due to leaks. predictive maintenance is to predict asset failure. ML algorithms
(Supervised or unsupervised) are applied to model the data. The
3.2. Digital Signal: processing of the data from IoT sensors is done at fog/cloud or edge
nodes. The algorithms process data sent from IoT sensors embedded in
Data from sensors captured in the form of analog signals is converted into the asset and predict failures.
digital signals using Analog to digital converter. The digital signal is
machine-readable and is used for further analysis. The steps discussed above are generalized and applies to all PdM systems
in manufacturing. A case from the Auto Ancillary Company is discussed
3.3. Data Storage and Transfer: next.
• Training Testing Sample: Data was split 75:25 ratio as Training and Table 1 - Summary of Model Performance Metrics on Testing data
Test sample Metric C&RT Boosted Classification Trees SVM
• Predictor screening: An option to select dependent/independent
Precision 0.891 0.899 0.893
variables to be used for analysis. Variable ‘Output’ was set as the
Recall 0.914 0.908 0.894
categorical dependent variable. Rest of the variables in our dataset like
‘Footfall,’ ‘tempMode, ‘AQ’, ‘USS’, ‘CS’, ‘VOC’, ‘RP’, ‘IP’ and F1 Score 0.903 0.903 0.893
‘Temperature’ were set as continuous predictors Error Rate 0.099 0.097 0.106
• Algorithm: Users can select various Data mining and Machine
learning algorithms to model data. We have used binary classification
algorithms to model our data. A brief detail of classification algorithms
Fig. 4. shows the Gains chart. The chart interprets the utility that one can
used for our PdM model is
expect by using C&RT, SVM and Boosted tree algorithms, as compared
Support Vector Machine (SVM): SVM represents a powerful technique
to using baseline information only or in other words the gains chart
for the general classification, regression and outliers detection with an
represents the ratio of results obtained with and without application of any
intuitive model representation (Suykens & Vandewalle, 1999).
models. The curve with maximum area under curve represents optimal
Random Forest: An Ensemble method for classification and regression
model. As can be observed, Boosted Classification tree algorithm has
(Liaw & Wiener, 2002).
maximum area under curve.
Advanced Classification Trees (C&RT): Advanced decision trees for
PdM architectural framework and steps proposed by (Wang, 2016)
classification and regression (Lemon, Roy, et.al, 2003).
was implemented on our model using higher accuracy obtained by voted
Each algorithm generates a PMML (Predictive Model Markup Language)
average of three machine learning algorithms. The model was evaluated
script file. PMML is an open standard to represent predictive models.
based on Misclassification error rate, Precision, Recall, F1 score, and
• Rapid Deployment: This node applies PMML codes to testing data
Gains chart. It is worthwhile to note that incase of PdM where cost of a
and outputs predicted values and model comparison metrics. Rapid
false negative (when the production line failure occurs and the model is
deployment node evaluates methods that measure model performance.
unable to predict it) is higher than false positive and hence it is best to
Deployment of a model in Production is done by publishing PMML codes
focus on Recall metric to evaluate the model. The results show that the
to an enterprise by a web service.
model can predict failure with a maximum accuracy rate of 90.18% on the
• Reporting: Output model summary report and prediction accuracy.
IoT sensor dataset and using the C&RT algorithm model has the best
The algorithms are compared using the same training and testing samples.
recall.
The output data can be saved and exported to Tibco Spotfire (a tool for
The next step is to deploy the model to production via a web service
data modelling and visualization) or database export or simple export into
using PMML codes that were generated by Tibco Statistica. Further setup
static Excel/CSV files.
can be done to trigger alarm (through email, SMS notification) on
machine fault prediction and monitor system status and production line
5.2. Results and Discussion
data using real time dashboards.
the assembly line of the manufacturing industry. A model is created using Lemon, S. C., Roy, J., Clark, M. A., Friedmann, P. D., & Rakowski, W. (2003).
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A successful implementation of Industrial PdM would involve any
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Advanced Technology Services, Inc. (2006, March 29). Downtime Costs Auto
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