ROM-based stochastic optimization for a continuous manufacturing process

This paper proposes a model-based optimization method for the production of automotive seals in an extrusion process. The high production throughput, coupled with quality constraints and the inherent uncertainty of the process, encourages the search for operating conditions that minimize nonconformities. The main uncertainties arise from the process variability and from the raw material itself. The proposed method, which is based on Bayesian optimization, takes these factors into account and obtains a robust set of process parameters. Due to the high computational cost and complexity of performing detailed simulations, a reduced order model is used to address the optimization. The proposal has been evaluated in a virtual environment, where it has been verified that it is able to minimize the impact of process uncertainties. In particular, it would significantly improve the quality of the product without incurring additional costs, achieving a 50% tighter dimensional tolerance compared to a solution obtained by a deterministic optimization algorithm.