Integration of support vector machines and control charts for multivariate process monitoring

Statistical process control tools have been used routinely to improve process capabilities through reliable on-line monitoring and diagnostic processes. In the present paper, we propose a novel multivariate control chart that integrates a support vector machine (SVM) algorithm, a bootstrap method, and a control chart technique to improve multivariate process monitoring. The proposed chart uses as the monitoring statistic the predicted probability of class (PoC) values from an SVM algorithm. The control limits of SVM-PoC charts are obtained by a bootstrap approach. A simulation study was conducted to evaluate the performance of the proposed SVM–PoC chart and to compare it with other data mining-based control charts and Hotelling's T ² control charts under various scenarios. The results showed that the proposed SVM–PoC charts outperformed other multivariate control charts in nonnormal situations. Further, we developed an exponential weighed moving average version of the SVM–PoC charts for increasing sensitivity to small shifts.     

Bootstrap-Based T 2 Multivariate Control Charts

Control charts have been used effectively for years to monitor processes and detect abnormal behaviors. However, most control charts require a specific distribution to establish their control limits. The bootstrap method is a nonparametric technique that does not rely on the assumption of a parametric distribution of the observed data. Although the bootstrap technique has been used to develop univariate control charts to monitor a single process, no effort has been made to integrate the effectiveness of the bootstrap technique with multivariate control charts. In the present study, we propose a bootstrap-based multivariate T ² control chart that can efficiently monitor a process when the distribution of observed data is nonnormal or unknown. A simulation study was conducted to evaluate the performance of the proposed control chart and compare it with a traditional Hotelling's T ² control chart and the kernel density estimation (KDE)-based T ² control chart. The results showed that the proposed chart performed better than the traditional T ² control chart and performed comparably with the KDE-based T ² control chart. Furthermore, we present a case study to demonstrate the applicability of the proposed control chart to real situations.     

A Multivariate Synthetic Control Chart for Monitoring Process Mean Vector

In this article, a multivariate synthetic control chart is developed for monitoring the mean vector of a normally distributed process. The proposed chart is a combination of the Hotelling's T ² chart and Conforming Run Length chart. The operation, design, and performance of the chart are described. Average run length comparisons between some other existing control charts and the synthetic T ² chart are presented. They indicate that the synthetic T ² chart outperforms Hotelling's T ² chart and T ² chart with supplementary runs rules.     

Economic and economic statistical design of T 2 control chart with two adaptive sample sizes

The Hotelling's T ² control chart, a direct analogue of the univariate Shewhart X¯ chart, is perhaps the most commonly used tool in industry for simultaneous monitoring of several quality characteristics. Recent studies have shown that using variable sampling size (VSS) schemes results in charts with more statistical power when detecting small to moderate shifts in the process mean vector. In this paper, we build a cost model of a VSS T ² control chart for the economic and economic statistical design using the general model of Lorenzen and Vance [The economic design of control charts: A unified approach, Technometrics 28 (1986), pp. 3–11]. We optimize this model using a genetic algorithm approach. We also study the effects of the costs and operating parameters on the VSS T ² parameters, and show, through an example, the advantage of economic design over statistical design for VSS T ² charts, and measure the economic advantage of VSS sampling versus fixed sample size sampling.     

Adaptive Hotelling's T 2 Control Charts with Run Rules

This study investigates the statistical properties of the adaptive Hotelling's T ² charts with run rules in which the sample size and sampling interval are allowed to vary according on the current and past sampling points. The adaptive charts include variable sample size (VSS), variable sampling interval (VSI), and variable sample size and sampling interval (VSSI) charts. The adaptive Hotelling's T ² charts with run rules are compared with the fixed sampling rate Hotelling's T ² chart with run rules. The numerical results show that the VSS, VSI, and VSSI features improve the performance of the Hotelling's T ² chart with run rules.     

New robust estimators for detecting non-random patterns in multivariate control charts: a simulation approach

In the past decade, different robust estimators have been proposed by several researchers to improve the ability to detect non-random patterns such as trend, process mean shift, and outliers in multivariate control charts. However, the use of the sample mean vector and the mean square successive difference matrix in the T ² control chart is sensitive in detecting process mean shift or trend but less sensitive in detecting outliers. On the other hand, the minimum volume ellipsoid (MVE) estimators in the T ² control chart are sensitive in detecting multiple outliers but less sensitive in detecting trend or process mean shift. Therefore, new robust estimators using both merits of the mean square successive difference matrix and the MVE estimators are developed to modify Hotelling's T ² control chart. To compare the detection performance among various control charts, a simulation approach for establishing control limits and calculating signal probabilities is provided as well. Our simulation results show that a multivariate control chart using the new robust estimators can achieve a well-balanced sensitivity in detecting the above-mentioned non-random patterns. Finally, three numerical examples further demonstrate the usefulness of our new robust estimators.     

Hotelling’s T2 control chart with double warning lines

Recent studies have shown that the T ² control chart with variable sampling intervals (VSI) and/or variable sample sizes (VSS) detects process shifts faster than the traditional T ² chart. This article extends these studies for processes that are monitored with VSI and VSS using double warning lines (T ² —DWL). It is assumed that the length of time the process remains in control has exponential distribution. The properties of T ² —DWL chart are obtained using Markov chains. The results show that the T ² —DWL chart is quicker than VSI and/or VSS charts in detecting almost all shifts in the process mean.     

Monitoring Nonlinear Profiles with Random Effects by Nonparametric Regression

The monitoring of process/product profiles is presently a growing and promising area of research in statistical process control. This study is aimed at developing monitoring schemes for nonlinear profiles with random effects. We utilize the technique of principal components analysis to analyze the covariance structure of the profiles and propose monitoring schemes based on principal component (PC) scores. The number of the PC scores used in constructing control charts is crucial to the detecting power. In the Phase I analysis of historical data, due to the dependency of the PC-scores, we adopt the usual Hotelling T ² chart to check the stability. For Phase II monitoring, we study individual PC-score control charts, a combined chart scheme that combines all the PC-score charts, and a T ² chart. Although an individual PC-score chart may be perfect for monitoring a particular mode of variation, a chart that can detect general shifts, such as the T ² chart and the combined chart scheme, is more feasible in practice. The performances of the schemes under study are evaluated in terms of the average run length.     

A modified economic-statistical design of the T2 control chart with variable sample sizes and control limits

Recent studies have shown that using variable sampling size and control limits (VSSC) schemes result in charts with more statistical power than variable sampling size (VSS) when detecting small to moderate shifts in the process mean vector. This paper presents an economic-statistical design (ESD) of the VSSC T² control chart using the general model of Lorenzen and Vance [22]. The genetic algorithm approach is then employed to search for the optimal values of the six test parameters of the chart. We then compare the expected cost per unit of time of the optimally designed VSSC chart with optimally designed VSS and FRS (fixed ratio sampling) T² charts as well as MEWMA charts.     

Multivariate Control Charts Based on Hybrid Novelty Scores

We propose a new nonparametric multivariate control chart that integrates a novelty score. The proposed control chart uses as its monitoring statistic a hybrid novelty score, calculated based on the distance to local observations as well as on the distance to the convex hull constructed by its neighbors. The control limits of the proposed control chart were established based on a bootstrap method. A rigorous simulation study was conducted to examine the properties of the proposed control chart under various scenarios and compare it with existing multivariate control charts in terms of average run length (ARL) performance. The simulation results showed that the proposed control chart outperformed both the parametric and nonparametric Hotelling's T ² control charts, especially in nonnormal situations. Moreover, experimental results with real semiconductor data demonstrated the applicability and effectiveness of the proposed control chart. To increase the capability to detect small mean shift, we propose an exponentially weighted hybrid novelty score control chart. Simulation results indicated that exponentially weighted hybrid score charts outperformed the hybrid novelty score based control charts.     

DDMA-charts: Nonparametric multivariate moving average control charts based on data depth

Summary: This paper studies the DDMA–chart, a data depth based moving–average control chart for monitoring multivariate data. This chart is nonparametric and it can detect simultaneously location and scale changes in the process. It improves upon the existing r– and Q–chart in the efficiency of detecting location changes. Both theoretical justifications and simulation studies are provided. Comparisons with some existing multivariate control charts via simulation results are also provided. Some applications of the DDMA–chart to the analysis of airline performance data (collected by the FAA) are demonstrated. The results indicate that the DDMA–chart is an effective nonparametric multivariate control chart.*Research supported in part by grants from the National Science Foundation, the National Security Agency, and the Federal Aviation Administration. The discussion on aviation safety in this paper reects the views of the authors, who are solely responsible for the accuracy of the analysis results presented herein, and does not necessarily reect the official view or policy of the FAA. The dataset used in this paper has been partially masked in order to protect confidentiality.     

Multivariate control chart based on the highest possibility region

The T ² control chart is widely adopted in multivariate statistical process control. However, when dealing with asymmetrical or multimodal distributions using the traditional T ² control chart, some points with relatively high occurrence possibility might be excluded, while some points with relatively low occurrence possibility might be accepted. Motived by the thought of the highest posterior density credible region, we develop a control chart based on the highest possibility region to solve this problem. It is shown that the proposed multivariate control chart will not only meet the false alarm requirement, but also ensure that all the in-control points are with relatively high occurrence possibility. The advantages and effectiveness of the proposed control chart are demonstrated by some numerical examples in the end.     

Economic and economic-statistical designs of the T2 control charts with SVSSI sampling scheme

Recent studies have shown that the adaptive T² chart with two different sampling interval and three sample sizes (SVSSI) shows a good performance in detecting small to large shifts in the process mean. This paper investigates the economic and economic statistical designs of the SVSSI T² charts. We use the Markov chain approach to developing the cost model proposed by Costa and Rahim (Journal of applied statistics 2001; 28: 875–885). A genetic algorithm approach is used to find the optimal solutions. Using numerical examples, we illustrate the performance of the proposed model and compare the statistical, economic, and economic statistical designs of the SVSSI T² chart with respect to the economic and statistical criteria. Furthermore, we compare the performance of the SVSSI T² chart with the other T² control schemes.     

ON THE ECONOMIC DESIGN OF MULTIVARIATE CONTROL CHARTS

ABSTRACT

It is an increasingly common practice to monitor several related quality characteristics of a product or process using a multivariate control chart procedure. Several types of multivariate control charts, including Hotelling's χ ² and T ² control charts, have been developed in attempts to improve monitoring by using the correlation structure that exists between quality characteristics. The purpose of this paper is to summarize the assumptions made regarding the out-of-control process shift in the economic design of multivariate control charts and to address their consequences. We study the average run length (ARL) properties of the χ ² control chart using a numerical example and show that this chart can perform ineffectively under the assumed out-of-control conditions when designed using the economic approach. Following Healy,[1] Healy, J.D. 1987. A Note on the Multivariate CUSUM Procedures. Technometrics, 29: 409–412. [Taylor & Francis Online], [Web of Science ®] , [Google Scholar] we offer an alternative procedure that has improved ARL properties and overall performance. These results can be important to researchers and practitioners who are interested in using the economic design of multivariate control procedures.     

On constructing T 2 control charts for retrospective examination

In this paper we consider the issue of constructing retrospective T ² control chart limits so as to control the overall probability of a false alarm at a specified value. We describe an exact method for constructing the control limits for retrospective examination. We then consider Bonferroni-adjustments to Alt's control limit and to the standard x ² control limit as alternatives to the exact limit since it is computationally cumbersome to find the exact limit. We present the results of some simulation experiments that are carried out to compare the performance of these control limits. The results indicate that the Bonferroni-adjusted Alt's control limit performs better that the Bonferroni-adjusted x ² control limit. Furthermore, it appears that the Bonferroni-adjusted Alt's control limit is more than adequate for controlling the overall false alarm probability at a specified value.     

The Design and Performance of the Multivariate Synthetic-T 2 Control Chart

One of the objectives of research in statistical process control is to obtain control charts that show few false alarms but, at the same time, are able to detect quickly the shifts in the distribution of the quality variables employed to monitor a productive process. In this article, the synthetic-T ² control chart is developed, which consists of the simultaneous use of a CRL chart and a Hotelling's T ² control chart. The ARL is calculated employing Markov chains for steady and zero-state scenarios. A procedure of optimization has been developed to obtain the optimum parameters of the synthetic-T ², for zero and steady cases, given the values of in-control ARL and magnitude of shift which needs to be detected rapidly. A comparison between (standard T ², MEWMA, T ² with variable sample size, and T ² with double sampling) charts reveals that the synthetic-T ² chart always performs better than the standard T ² chart. The comparison with the remaining charts demonstrate in which cases the performance of this new chart makes it interesting to employ in real applications.     

A new Markov chain approach for the economic statistical design of the VSS T2 control chart

An economic statistical design model for a T² chart which uses a variable sample size (VSS) feature is developed in this article. This study mainly differs from the others conducted in the field. In that a new approach is offered to achieve closed form of some statistical criteria. In other words, the proposed formulas can be considered as a better alternative approach in designing the VSS control charts in terms of simplicity and yet providing the users with better optimal solutions.     

Identification of out of control quality characteristics in a multivariate manufacturing environment

There are many instances in which the quality of a product or constancy of a process is determined by the joint levels of several attributes or properties. During the conduct of such a process or the production of such a product, one wishes to detect as quickly as possible any departure from a satisfactory state, while at the same time identifying which attributes are responsible for the deviation. In most cases of practical interest, however, there exist correlations among the several properties of interest; this makes it advisable to monitor certain aggregate characteristics of the process, rather than observing its various components separately. When the mean vector of the quality attributes is the major concern, this aggregate monitoring function is most commonly implemented via a T ² chart. The dependencies among attributes, however, complicate the determination of which are responsible when a deviation occurs. This paper presents an approach to help identify aberrant variables when Shewhart type multivariate control charts based on Hotelling's T ² are in use.     

Bivariate copulas on the Hotelling's T2 control chart

In this paper, we propose five types of copulas on the Hotelling's T² control chart when observations are from exponential distribution and use the Monte Carlo simulation to compare the performance of the control chart, which is based on the Average Run Length (ARL) for each copula. Five types of copulas function for specifying dependence between random variables are used and measured by Kendall's tau. The results show that the copula approach can be fitted the observation and we can use copula as an option for application on Hotelling's T² control chart.     

Double-objective economic statistical design of the VP T2 control chart: Wald's identity approach

Research has shown that applying the T² control chart by using a variable parameters (VP) scheme yields rapid detection of out-of-control states. In this paper, the problem of economic statistical design of the VP T²control chart is considered as a double-objective minimization problem with the statistical objective being the adjusted average time to signal and the economic objective being expected cost per hour. We then find the Pareto-optimal designs in which the two objectives are met simultaneously by using a multi-objective genetic algorithm. Through an illustrative example, we show that relatively large benefits can be achieved by applying the VP scheme when compared with usual schemes, and in addition, the multi-objective approach provides the user with designs that are flexible and adaptive.