Nicholas Wright, Oliver Maclaren, Piaras Kelly +2math.OC stat.ML
In resin transfer moulding, complete saturation of the fibre preform is necessary before the resin front reaches the outlet vent(s), to prevent dry-spot formation. In practice, the flow front rarely advances uniformly due to race-tracking effects. We propose a combined estimation and control strategy to address this issue. We use pressure-sensor data collected during filling to estimate the unknown race-tracking strengths via an iterated extended Kalman filter, and to simultaneously optimise auxiliary gate pressures to prevent the resin from arriving at the vent before complete saturation occurs. To make this approach feasible in real time, we replace the expensive finite element-control volume model with neural network surrogate models. The Bayesian approximation error framework is used to account for the discrepancy between the surrogates and the original model. To make the training of the surrogates feasible with time-dependent control actions, we prove that the flow-front geometry depends only on the time-averaged gate pressures. We demonstrate the methodology on a representative forked geometry, showing that the combined estimation-and-control framework can substantially reduce the number of unfilled nodes at the end of filling compared with an uncontrolled baseline. However, the level of improvement depends strongly on the location and number of auxiliary gates.
Panagiotis Sapoutzoglou, Jessy Ribaira, Martin Kanounnikoff +3cs.CV
Automated visual inspection in manufacturing aims to replace slow and inconsistent manual checks, but its economic value depends on whether its decisions can be trusted enough to automate routine inspection while reserving human expertise for ambiguous cases. In production-line settings, defective samples are scarce, since the process is optimized to produce good parts, which limits any learning-based inspector trained on real data alone. Compounding this, defect decisions emitted as hard labels with no confidence estimate carry an asymmetric cost: a false reject wastes a good product, while a false accept may increase the risk of undetected defects progressing through the production process. We address both problems by mitigating data scarcity through the generation of synthetic defective samples with a diffusion model, and meeting the need for confidence-aware decisions with a Bayesian classifier that defers ambiguous units to human review rather than misclassifying them. These components are embedded in a staged pipeline of successive, complementary checks. We evaluate how synthetic augmentation affects classification and localization on a test set of real defects, and examine the system's trustworthiness at three points: the decision, the synthetic data, and the pipeline structure. This work-in-progress reports preliminary results suggesting that diffusion-generated defects, combined with uncertainty-aware classification, can lower the cost of reaching a trustworthy, deployable inspection model under data scarcity.
Berkcan Kapusuzoglu, Paromita Nath, Matthew Sato +2cs.CE cs.LG math.NA math.OC
This work presents a data-driven methodology for multi-objective optimization under uncertainty of process parameters in the fused filament fabrication (FFF) process. The proposed approach optimizes the process parameters with the objectives of minimizing the geometric inaccuracy and maximizing the filament bond quality of the manufactured part. First, experiments are conducted to collect data pertaining to the part quality. Then, Bayesian neural network (BNN) models are constructed to predict the geometric inaccuracy and bond quality as functions of the process parameters. The BNN model captures the model uncertainty caused by the lack of knowledge about model parameters (neuron weights) and the input variability due to the intrinsic randomness in the input parameters. Using the stochastic predictions from these models, different robustness-based design optimization formulations are investigated, wherein process parameters such as nozzle temperature, nozzle speed, and layer thickness are optimized under uncertainty for different multi-objective scenarios. Epistemic uncertainty in the prediction model and the aleatory uncertainty in the input is considered in the optimization. Finally, Pareto surfaces are constructed to estimate the tradeoffs between the objectives. Both the BNN models and the effectiveness of the proposed optimization methodology are validated using the actual manufacturing of the parts.
Manufacturing knowledge graphs that integrate data from heterogeneous industrial systems face a trust deficit: consumers cannot determine whether queried data is valid, whether it was valid when a decision was made, where it originated, or how it was acted upon. We argue that four trust capabilities -- SHACL validation, PROV-O provenance, domain-aware bi-temporal versioning, and graph-native decision objects -- compose through shared correlation identifiers to produce emergent trust properties that no single capability delivers alone. We present a composable trust infrastructure that integrates these four capabilities into a unified RDF architecture. Capabilities compose through shared entity URIs, ingestion activity identifiers, and temporal correlation keys, enabling compound queries spanning all four dimensions. An experimental ablation confirms that removing any single capability causes exactly three of six composition queries to fail, demonstrating that all four are equally load-bearing. Analysis of higher-order compositions reveals four emergent three-way properties and one irreducible four-way property (full-chain auditability, 31ms execution). The infrastructure is validated on a testbed integrating eleven industrial sources -- OPC UA, TIA Portal, eClass, AAS, ISA-95, ISA-18.2, SAP S/4HANA, Teamcenter, Opcenter EX, Insights Hub, and SCM -- under an 89-class ISA-95-aligned ontology. The unified graph contains 8,743 triples across five named graphs, stitched by 81 owl:sameAs identity edges. Evaluation uses simulated but structurally realistic data from purpose-built emulators; data structures and cross-system linkage patterns are representative of real industrial installations.
Modern manufacturing enterprises operate heterogeneous systems -- ERP, MES, PLM, SCADA, QMS, SCM -- each with its own data model and API. The resulting silos prevent holistic analysis, delay root-cause investigation, and obstruct Industry 4.0 traceability. Point-to-point integration scales as O(n^2) and accumulates brittle dependencies. This paper presents an open framework for semantic graph unification of industrial digital threads. An ontology-driven RDF knowledge graph unifies data from 11 simulated sources across nine domains through a five-stage ETL pipeline with automated entity resolution spanning 97 owl:sameAs identity links. The ontology encompasses 78 RDFS classes, 108 object properties, and 243 data properties, drawing on ISA-95, OPC UA, eClass, the Asset Administration Shell, RAMI 4.0, and additional standards. An automated discovery engine applies nine strategy categories -- cross-station correlation, alarm coverage, ECN impact, CUSUM/EWMA drift detection -- to surface insights spanning system boundaries. The primary empirical result: blocking 24 cross-system tools reduces recall from 1.00 to 0.31 (F1 from 1.00 to 0.48), showing that 69% of discoverable signals require cross-system graph joins. Leave-one-out ablation confirms six of nine strategies contribute unique signals. Verification against a 65-signal manifest (16 positive, 49 null) yields F1 = 1.00 (95% Clopper-Pearson CI [0.79, 1.00]); as the manifest was author-constructed, this constitutes verification not independent validation. The graph is exposed to LLM agents via 287 Model Context Protocol tools as a SPARQL-native semantic layer. Five industry templates (aerospace, CPG, pharma, medical devices, turbine blades) demonstrate schema stability across manufacturing verticals.
Injection molding is the cornerstone of mass-producing plastic components. While current algorithms can automate mold design for basic geometries using standard two-piece molds, complex parts featuring undercuts, side holes, or re-entrant features present a significant challenge. These geometries often necessitate auxiliary components beyond the primary upper and lower molds. In practice, designing these intricate assemblies is a laborious process that relies heavily on expert knowledge. Furthermore, the scarcity of public datasets has hindered the development of effective learning-based solutions. To bridge these gaps, we introduce MoldCAD, a curated dataset that pairs complex single-body CAD parts with industry-standard mold assemblies. Each entry includes the upper and lower molds, parting surfaces, demolding orientations, and necessary auxiliary components. The dataset comprises 4,934 CAD models and over 3,850 mold assemblies, totaling more than 23k individual models. Building upon this dataset, we propose a comprehensive pipeline that predicts demolding orientations, identifies auxiliary components, and constructs parting surfaces to derive a complete, manufacturing-ready mold assembly for downstream CAD/CAM workflows. Our results demonstrate a promising path toward fully automated industrial mold design and contribute to the broader advancement of manufacturing-aware CAD generation.
Lukas Kubelka, Alexander Bott, Frank Döhner +6cs.AI
We propose the Virtual Process Dossier (VPD), a Knowledge Graph-based data catalogue that also captures workflow provenance. We developed VPD for multi-stage manufacturing use-cases where downstream AI-based optimization tasks require to distinct between datasets generated during individual workflow steps. VPD provides these datasets in a FAIR manner and makes both prospective and retrospective workflow provenance explicit. Our contributions are: (1) the VPD ontology that serves as the catalogue's semantic core; (2) the VPD provenance framework that integrates ontology instantiation into the production environment; and (3) the VPD user interface that provides human-centered interaction with the VPD Knowledge Graph. The ontology and code are available at https://github.com/kubeluk/VirtualProcessDossier .
Multi-product kitting delivery imposes significant challenges for real-time scheduling in hybrid manufacturing systems that integrate processing and assembly, as dynamic order arrivals simultaneously alter supply dependencies and the set of feasible job-machine assignments. This paper proposes a sliding-window-based reinforcement learning (SWRL) framework for end-to-end online scheduling in the flexible assembly flow shop scheduling problem with complex kitting constraints. The problem is formulated as a heterogeneous graph-based Markov decision process that captures the dual-layer kitting structure and the tail-product bottleneck dynamics that produce a sparse reward landscape. To address the resulting challenges, SWRL integrates a sliding-window filtering mechanism that filters inactive nodes and prioritizes kitting-critical operations, a spatiotemporal graph encoding network that tracks bottleneck shifts across consecutive decision states, and a dynamic action mapping module with a constrained waiting strategy that adapts to the changing action space under variable topologies. Experiments on real-world instances from a home appliance manufacturer demonstrate that SWRL achieves consistent tardiness reductions over classical dispatching rules and existing deep reinforcement learning methods, and exhibits robust performance across varying resource configurations, order loads, and arrival concentrations.
Process twins provide real-time representations of entire production processes. By capturing how process steps interact, rather than monitoring a single machine in isolation as an asset-based digital twin does, they have the potential to drive efficiency gains across the whole process. However, developing a process twin is costly. It requires accurately modelling the entire production process: its process steps, the equipment and product-specific settings each step uses, and its process variations. The resulting model must then be bound to live operational data. We present FacProcessTwin, a system that leverages a large language model (LLM) to reduce this development time, building a process twin from a plant's process documentation and natural-language input from an operator. FacProcessTwin generates this complete process model and then automatically binds its process steps to live operational data. The generated model and its data bindings are rendered as an interactive process diagram through which manufacturing personnel can monitor and correct the system's autonomous decisions, such as resolving uncertainty at safety-critical binding steps. We evaluate FacProcessTwin through a real-world case study of an Australian food manufacturer, covering 16 production process flows that span chilled, frozen, and aseptic shelf-stable product categories and include process variations within the same product. The results show that FacProcessTwin generates these process models accurately (a mean F1 of 95.2% against ground truth) and builds each twin in roughly a sixth of the manual time. Its human-in-the-loop governance then keeps the safety-critical bindings correct: at ambiguous tags where a single-pass baseline silently mis-binds 75.0% of the time, FacProcessTwin defers to the operator and mis-binds none.
Hadi Bakhshan, Sima Farshbaf, Fernando Rastellini +1cond-mat.other cs.LG
Interest in applying data-driven approaches in manufacturing has grown significantly, particularly for mapping complex, high-dimensional relationships. The milling process is one area where predictive models can link influential parameters to surface roughness metrics prior to in situ operations. While this approach offers clear advantages, it faces challenges due to limited datasets and robustness issues in inverse design paradigms. To address these challenges, this paper proposes a machine learning (ML)-based framework for the inverse design of the surface milling process, with a focus on surface roughness as the design objective. The framework employs forward training of two ML models, a deep neural network (DNN) and a random forest (RF) ensemble, both developed using a high-fidelity synthetic dataset generated from a computational simulation framework. These trained models are integrated into a Bayesian optimization (BO) procedure to overcome the multiplicity problem arising from the many-to-one mapping inherent in the dataset. The approach identifies top-performing milling process configurations, considering both process and tool parameters, and presents them from the full solution space. The models achieve average relative errors below 5% when compared to reference results, thereby demonstrating the robustness and reliability of the proposed methodology.
Ge Song, Kiarash Naghavi Khanghah, Anandkumar Patel +2cs.LG cs.AI
Predicting process-property relationships in manufacturing is often challenged by high experimental costs and the limited interpretability of complex 'black-box' models. This paper proposes a novel knowledge distillation framework designed to achieve high-accuracy predictions in data-scarce scenarios. The framework integrates analytical physics priors, which are systematically extracted from scientific literature via Large Language Models, into a privileged teacher model. We employ a Graph-Masked Attention layer to capture the complex physical dependencies among input variables showing strict setpoints or a combination of static and high-frequency temporal signatures. This privileged knowledge is distilled into a lightweight student predictor for inference. The feasibility and robustness of the framework are evaluated through a comprehensive experiment across five diverse manufacturing processes. To ensure statistical reliability, given the small dataset sizes, a repeated K-fold cross-validation technique is employed to quantify model stability and generalization. Results indicate that the proposed framework consistently achieves high predictive accuracy across all evaluated domains. Most importantly, the architecture demonstrates significant fault tolerance by maintaining robust predictive performance even in scenarios where LLM-derived analytical priors are suboptimal or incomplete. Furthermore, the student predictor achieves an inference frequency exceeding 6000 Hz, which facilitates real-time edge deployment on standard industrial hardware. This work provides a scalable solution for bridging the gap between theoretical physics and real-time industrial monitoring in data-limited environments.
In the production process of network cables, ensuring the correct color sequence of wire pairs inside the standard connector plays a critical role in the final performance of the cable, as any misplacement or color-ordering error can lead to defective products and impose significant costs. Traditional inspection methods based on visual examination through digital microscopes are typically time-consuming, tedious, and prone to human error. In this study, an intelligent system based on the twelfth version of the YOLO1 object detection model was developed to identify the position and verify the correct color sequence of wires in patch cords. The dataset used consisted of 2,500 images captured from microscopic views of network connectors, which were divided into 70% for training, 15% for validation, and 15% for testing. The proposed model, leveraging a single-stage architecture and attention mechanisms during learning, achieved highly accurate wire detection with approximately 98% precision. Additionally, the overall mean accuracy, classification precision, and recall were around 95%, 99%, and 98%, respectively. The results demonstrate that this system can reliably and in real time verify the correctness of wire color sequencing on the production line without the need for human intervention, thereby reducing human error and enhancing efficiency in the manufacturing process.
Constitutive modeling of the relationship between process-imposed material states and fundamental material properties is critical to control of material microstructure in manufacturing processes. The limited accuracy resulting from the typical reliance on fallible human expertise and intuition for postulation and revision of the models functional form results in incremental and time consuming model discovery. Conventional Machine Learning (ML) incurs significant cost and time of data generation. Model discovery using Large Language Models (LLMs) suffers from the above issues and/or ignores the inviolability of fundamental thermodynamics laws. This work creates a novel GPT-Micro paradigm for autonomous, data sparse, and thermodynamics-compliant discovery of de-novo constitutive models. This framework seamlessly integrates semantic knowledge extraction from literature, enforcement of thermodynamics-based conservation laws, and sparse datasets, with LLM-driven generation and refinement of model hypotheses. Validation is performed for a long-intractable constitutive modeling problem in a printed electronics process testbed. This reveals significant and simultaneous advantages over the state-of-the-art including: (a) More than 70 percent reduction in data burden relative to ML-based modeling without loss in accuracy; (b) 400X reduction in discovery time after data generation, from months to hours, relative to human-driven modeling; (c) Discovery of models with novel functional forms without subjective human choice of a starting hypothesis; (d) Enhanced physics-rooted trustworthiness, human interpretability, and mechanistic insight via synthesis of compact, conservation-compliant, and physically complete analytical models. The potential of GPT-Micro to realize rapid, low-cost, physically trustworthy, and interpretable microstructure modeling across the manufacturing landscape is discussed.
Xiaofeng Xiao, Jianhong Chen, Qiuzhuang Sun +2cs.LG stat.ME
Textual event records, such as alarm logs, have become an increasingly common data source in engineering and manufacturing systems. Beyond identifying correlations or recurring patterns, engineers are often interested in understanding which types of events causally trigger or influence other events during system operation. Textual event descriptions may contain semantic clues about such causal relationships, and recent large language models (LLMs) provide a promising tool for extracting these signals. However, relying solely on LLM-encoded textual information is insufficient for accurate causal discovery, since semantic patterns do not directly reveal causal mechanisms and may confuse causation with correlation or frequent sequential patterns. To address these challenges, we propose \textbf{LMT}, a Bayesian causal discovery framework for engineering event data that jointly leverages textual descriptions and timestamps. Specifically, LMT first uses LLMs to extract semantic causal signals from event descriptions and constructs a prior distribution over causal graphs among event types or event clusters. It then incorporates temporal evidence through a Poisson-process-based likelihood, allowing the LLM-informed prior to be refined by timestamp-based statistical evidence. By integrating the textual and temporal information, LMT produces a causal graph that is both interpretable and data-supported. Simulation studies show that the proposed framework is effective across different settings and is especially advantageous in small-sample alarm-event scenarios.
This comprehensive review examines the evolution and the current state of the art in three-dimensional (3D) reconstruction techniques in manufacturing applications. The analysis covers both traditional approaches and emerging deep learning methods, showing a critical research gap in unified 3d reconstruction frameworks. Through systematic review of 106 recent publications, we classify reconstruction techniques into three primary categories: data acquisition, point cloud generation, post-processing and applications. Non-contact methods, particularly structured light scanning and stereo vision, have shown significant adoption in manufacturing, with 47% of surveyed applications focusing on quality inspection. The integration of deep learning has enhanced reconstruction accuracy and processing speed, particularly in feature extraction and matching. Key applications span design and development (13%), machining (8%), process (17%), assembly (22%), and quality inspection (40%). While current technologies achieve sub-millimeter accuracy in controlled environments, challenges persist in handling reflective surfaces and dynamic environments. Our findings indicate a trend toward hybrid systems combining multiple sensor types and processing methods to overcome individual limitations. This survey provides a structured framework for understanding current capabilities and future directions in manufacturing-focused 3D reconstruction.