AssemAI: Interpretable Image-Based Anomaly Detection for Manufacturing Pipelines

Anomaly detection in manufacturing pipelines remains a critical challenge, intensified by the complexity and variability of industrial environments. This paper introduces AssemAI, an interpretable image-based anomaly detection system tailored for smart manufacturing pipelines. Our primary contributions include the creation of a tailored image dataset and the development of a custom object detection model, YOLO-FF, designed explicitly for anomaly detection in manufacturing assembly environments. Utilizing the preprocessed image dataset derived from an industry-focused rocket assembly pipeline, we address the challenge of imbalanced image data and demonstrate the importance of image-based methods in anomaly detection. The proposed approach leverages domain knowledge in data preparation, model development and reasoning. We compare our method against several baselines, including simple CNN and custom Visual Transformer (ViT) models, showcasing the effectiveness of our custom data preparation and pretrained CNN integration. Additionally, we incorporate explainability techniques at both user and model levels, utilizing ontology for user-friendly explanations and SCORE-CAM for in-depth feature and model analysis. Finally, the model was also deployed in a real-time setting. Our results include ablation studies on the baselines, providing a comprehensive evaluation of the proposed system. This work highlights the broader impact of advanced image-based anomaly detection in enhancing the reliability and efficiency of smart manufacturing processes.

Evaluating the Role of Data Enrichment Approaches Towards Rare Event Analysis in Manufacturing

Rare events are occurrences that take place with a significantly lower frequency than more common regular events. In manufacturing, predicting such events is particularly important, as they lead to unplanned downtime, shortening equipment lifespan, and high energy consumption. The occurrence of events is considered frequently-rare if observed in more than 10% of all instances, very-rare if it is 1-5%, moderately-rare if it is 5-10%, and extremely-rare if less than 1%. The rarity of events is inversely correlated with the maturity of a manufacturing industry. Typically, the rarity of events affects the multivariate data generated within a manufacturing process to be highly imbalanced, which leads to bias in predictive models. This paper evaluates the role of data enrichment techniques combined with supervised machine-learning techniques for rare event detection and prediction. To address the data scarcity, we use time series data augmentation and sampling methods to amplify the dataset with more multivariate features and data points while preserving the underlying time series patterns in the combined alterations. Imputation techniques are used in handling null values in datasets. Considering 15 learning models ranging from statistical learning to machine learning to deep learning methods, the best-performing model for the selected datasets is obtained and the efficacy of data enrichment is evaluated. Based on this evaluation, our results find that the enrichment procedure enhances up to 48% of F1 measure in rare failure event detection and prediction of supervised prediction models. We also conduct empirical and ablation experiments on the datasets to derive dataset-specific novel insights. Finally, we investigate the interpretability aspect of models for rare event prediction, considering multiple methods.

A Comprehensive Survey on Rare Event Prediction

Rare event prediction involves identifying and forecasting events with a low probability using machine learning and data analysis. Due to the imbalanced data distributions, where the frequency of common events vastly outweighs that of rare events, it requires using specialized methods within each step of the machine learning pipeline, i.e., from data processing to algorithms to evaluation protocols. Predicting the occurrences of rare events is important for real-world applications, such as Industry 4.0, and is an active research area in statistical and machine learning. This paper comprehensively reviews the current approaches for rare event prediction along four dimensions: rare event data, data processing, algorithmic approaches, and evaluation approaches. Specifically, we consider 73 datasets from different modalities (i.e., numerical, image, text, and audio), four major categories of data processing, five major algorithmic groupings, and two broader evaluation approaches. This paper aims to identify gaps in the current literature and highlight the challenges of predicting rare events. It also suggests potential research directions, which can help guide practitioners and researchers.