Data-driven drift detection and diagnosis framework for predictive maintenance of heterogeneous production processes: Application to a multiple tapping process

Abstract

The rise of Industry 4.0 technologies has revolutionized industries, enabled seamless data access, and fostered data-driven methodologies for improving key production processes such as maintenance. Predictive maintenance has notably advanced by aligning decisions with real-time system degradation. However, data-driven approaches confront challenges such as data availability and complexity, particularly at the system level. Most approaches address component-level issues, but system complexity exacerbates problems. In the realm of predictive maintenance, this paper proposes a framework for addressing drift detection and diagnosis in heterogeneous manufacturing processes. The originality of the paper is twofold. First, this paper proposes algorithms for handling drift detection and diagnosing heterogeneous processes. Second, the proposed framework leverages several machine learning techniques (e.g., novelty detection, ensemble learning, and continuous learning) and algorithms (e.g., K-Nearest Neighbors, Support Vector Machine, Random Forest and Long-Short Term Memory) for enabling the concrete implementation and scalability of drift detection and diagnostics on industrial processes. The effectiveness of the proposed framework is validated through metrics such as accuracy, precision, recall, F1-score, and variance. Furthermore, this paper demonstrates the relevance of combining machine learning and deep learning algorithms in a production process of SEW USOCOME, a French manufacturer of electric gearmotors and a market leader. The results indicate a satisfactory level of accuracy in detecting and diagnosing drifts, and the adaptive learning loop effectively identifies new drift and nominal profiles, thereby validating the robustness of the framework in real industrial settings.