UDAVA: An Unsupervised Learning Pipeline for Sensor Data Validation in Manufacturing

Manufacturing has enabled the mechanized mass production of the same (or similar) products by replacing craftsmen with assembly lines of machines. The quality of each product in an assembly line greatly hinges on continual observation and error compensation during machining using sensors that measure quantities such as position and torque of a cutting tool and vibrations due to possible imperfections in the cutting tool and raw material. Patterns observed in sensor data from a (near-)optimal production cycle should ideally recur in subsequent production cycles with minimal deviation. Manually labeling and comparing such patterns is an insurmountable task due to the massive amount of streaming data that can be generated from a production process. We present UDAVA, an unsupervised machine learning pipeline that automatically discovers process behavior patterns in sensor data for a reference production cycle. UDAVA performs clustering of reduced dimensionality summary statistics of raw sensor data to enable high-speed clustering of dense time-series data. It deploys the model as a service to verify batch data from subsequent production cycles to detect recurring behavior patterns and quantify deviation from the reference behavior. We have evaluated UDAVA from an AI Engineering perspective using two industrial case studies.