Submitted:
29 June 2023
Posted:
30 June 2023
You are already at the latest version
Abstract
Keywords:
1. Introduction
2. Background: Machine Learning and the Manufacturing Industry
3. Material and Methods
3.1. Research Questions
- RQ1
- What are the targeted and achieved industrial benefits machine learning has brought to the manufacturing industry?
- RQ2
- What is the maturity level of the ML solutions presented in the publications?
- RQ3
- Which sectors of the manufacturing industry have used ML solutions?
- RQ4
- In which manufacturing operations have ML solutions been used?
- RQ5
- What is the relative popularity of different ML method families in the publication set?
3.1. Material
3.3. Methods
3.4. Analysis Framework
4. Results
4.1. Bibliometric Analysis
4.2. Quantitative Analysis of All Publications
4.3. Qualitative Analysis of Publications Discussing Direct Benefits
5. Discussion
6. Conclusion
Funding
Data Availability Statement
Conflicts of Interest
References
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| Field of Business | Manufacturing OR Industry AND |
|---|---|
| AI technology | "machine learning" OR "deep learning" OR "neural network" OR "support vector machine" OR svm OR "random forest" OR "decision tree" OR "Deep Transfer Learning" AND |
| Benefit | benefit OR advantages OR "productivity increase" OR "efficiency increase" OR "quality increase" OR "operational improvement" OR "efficiency improvement" OR "quality improvement" OR "cost saving" OR "cost reduction" OR "cost decrease" OR "emission reduction" OR "emission decrease" OR "energy reduction" OR "energy decrease" OR "resource reduction" OR "resource decrease" OR "material reduction" OR "material decrease" OR "waste reduction" OR "waste decrease" OR "key performance indicator" OR kpi OR "decrease downtime" OR "reduce downtime" OR "decrease inefficiency" OR "reduce inefficiency" OR "downtime reduction" OR "inefficiency reduction" OR "improve response time" OR "response time improvement" OR "improve resource management" OR "resource management improvement" |
| Time range | 2017–2022 (2022: 08.03.2022) |
| Dimension | Explanation | Related Research question |
|---|---|---|
| Benefit pursued | Business benefit (with sub-categories: productivity, cost saving or efficiency; quality management; other or not specified); environmental sustainability; societal sustainability | Benefit pursued (RQ1) |
| Treatment of benefit | Not discussed or vague, qualitative statements; indirect, e.g. accuracy of ML methods in specific case; direct, measured | Discussion on the benefit (RQ1) |
| Maturity (only in step 4) | Simulation; laboratory experiment; pilot or PoC; operational use (TRL) | Maturity of the solution (RQ2) |
| Data used (only in step 4) | Simulated; laboratory; database; off-line from industry; real-time on-line from industry | n/a |
| Sector of manufacturing industry | International Standard Industrial Classification, 24 classes | Sector of manufacturing industry (RQ3) |
| Industry function | Design and engineering; production and process control, including optimization; quality management; supply chain management; maintenance management; several functions equally | Industry function (RQ4) |
| ML method | ANN incl. DL, CNN; decision tree and variants; SVM; other; several (comparison of methods). | Machine learning method (RQ5) |
| Implementation (Maturity of) | Data (Maturity of) | Corresponding TRL (EU Commission, 2014) |
|---|---|---|
| Simulated | Simulated data or data base | TRL 3 Experimental proof of concept |
| Simulated | Real industry data off-line | TRL 4 Technology validated in lab |
| Laboratory | Lab. data | TRL 4 Technology validated in lab |
| Proof-of-concept | Real on-line | TRL 5–6 Technology validated in relevant environment |
| Operational use | Real on-line | TRL 7 System prototype demonstration in operational environment - TRL 9 Actual system proven in an operational environment |
| Citations per Publication | Field-Weighted Citation Impact | International Collaboration: Publicationc co-Authored with Institutions in Other Countries [%] | Publications in 10% Most Cited Worldwide [%] | Publications in Top 10% Journals (Source Normalized Impact per Paper) [%] |
|---|---|---|---|---|
| 11.8 | 2.24 | 21.2% | 25 | 28.5 |
| Country | Scholarly output |
|---|---|
| China | 50 |
| Germany | 28 |
| USA | 20 |
| Italy | 18 |
| India | 13 |
| UK | 11 |
| Author Affiliation | Number of Publications |
|---|---|
| Academic authors only | 200 |
| Co-authored (academy and industry) | 32 |
| Industry affiliated authors only | 14 |
| Publication Type | Number of Publications |
|---|---|
| Conference proceedings | 106 |
| Article | 136 |
| Chapter in book, other | 4 |
| Section C Manufacturing | Sector of Industry (NB. Sectors with no publications are omitted) | Number of publications |
|---|---|---|
| Division 10 | Manufacture of food products and beverages | 10 |
| Division 13 | Manufacture of textiles | 11 |
| Division 16 | Manufacture of wood and of products of wood and cork, except furniture | 1 |
| Division 17 | Manufacture of paper and paper products | 2 |
| Division 18 | Publishing, printing, and reproduction of recorded media | 1 |
| Division 19 | Manufacture of coke, refined petroleum products, and nuclear fuel | 9 |
| Division 20 | Manufacture of chemicals and chemical products | 19 |
| Division 21 | Manufacture of pharmaceuticals, medicinal chemical, and botanical products | 2 |
| Division 22 | Manufacture of rubber and plastics products | 5 |
| Division 24 | Manufacture of basic metals | 6 |
| Division 25 | Manufacture of fabricated metal products, except machinery and equipment | 1 |
| Division 26 | Manufacture of computer, electronic, and optical products | 33 |
| Division 27 | Manufacture of electrical equipment | 6 |
| Division 28 | Manufacture of machinery and equipment n.e.c. | 56 |
| Division 29 | Manufacture of motor vehicles, trailers and semi-trailers | 14 |
| Division 30 | Manufacture of other transport equipment | 5 |
| Division 31 | Manufacture of furniture | 2 |
| Division 33 | Repair and installation of machinery and equipment | 32 |
| Other | Sector not specified and papers addressing manufacturing in general | 31 |
| Operation | Number of publications |
|---|---|
| Several functions equally | 18 |
| Design and engineering | 6 |
| Production and process control, including optimization | 62 |
| Quality management | 56 |
| Supply chain management | 12 |
| Maintenance management | 92 |
| ML method | Number of publications |
|---|---|
| ANN incl. deep learning and CNN | 147 |
| DT, including random forest | 20 |
| SVM | 15 |
| Other or not specified | 38 |
| Several (method comparison) | 26 |
| Benefit | Subclasses of Business Benefit | Number of Publications |
|---|---|---|
| Business benefit | Subclasses together | 228 |
| Productivity | 26 | |
| Cost saving or efficiency | 90 | |
| Quality management | 73 | |
| Other or not specified | 39 | |
| Environmental sustainability | - | 15 |
| Societal sustainability | - | 3 |
| Treatment | Number of publications |
|---|---|
| Not discussed | 12 |
| Vague, qualitative statement | 83 |
| Indirect, such as accuracy of ML methods in specific case | 111 |
| Direct, measured | 40 |
|
Abbreviations used in the table: Operation: D = design and engineering; P = process and production control, optimization; Q = quality management; M = maintenance management; S = supply chain. Benefit pursued: B = business benefit, E = environmental sustainability, S = social sustainability. Business benefit: P = productivity, E = efficiency, C = cost saving, Q = quality. Maturity: S = simulation; L = laboratory; PoC = proof-of-concept; O = operational in industry | ||||||||
| Author, year | Industry sector | Operation | ML method | Benefit pursued | Business benfit | Maturity | Source of data | Short description of the case |
| [59] | Motor vehicles … (D29) | P | ANN | B | P | S | Off-line | Predicting and then avoiding production bottlenecks and improving system throughput with a two-layer long short-term memory (LSTM). Simulations with industrial data from automotive underbody assembly lines show potential benefits. |
| [60] | Chemicals … (D20) | P | Other | B | P | S | Off-line | The DDANRO framework is deployed to an industrial multipurpose batch process in Dow Chemical Company for better process control. Bayesian nonparametric models and robust optimization are used. |
| [61] | Chemicals … (D20) | D | ANN | B | P | S | Off-line | Predicting the melt index in industrial polymerization processes for improved process control is proposed. The ensemble deep kernel learning (EDKL) model is compared with, for example, SVM. Data is from process records from an industrial polyethylene process in a Chinese plant. |
| [62] | Textiles (D13) | Q | ANN | B | Q | S | Off-line | Improving fault detection in fabric manufacturing is pursued. A machine vision algorithm using texture analysis and MLP-NN for a company using circular knitting machines was studied. The database consists of 76 images with defects. The detection rate is 98%. |
| [63] | Comp., electr. and optical (D26) | Q | ANN | B | Q, P | S | Off-line | Improved fault detection in the semiconductor industry is pursued. CNN-based method using variable-length status variable identification [SVID) data in semiconductor manufacturing for fault detection. Real-world data from two sets of 778 and 1546 wafers. |
| [64] | General manufacturing (C) | Q | ANN | B | Q | S | Database | Quality prediction method with back-propagation neural network and modified AdaBoost for small manufacturing. Data is from 110560 individual products (96% good, 4% faulty) via Kaggle platform. |
| [65] | Chemicals … (D20) | M | ANN | B | Q | S | Off-line | Goal is to develop a method for the early detection of process deviations. Case study with a pre-reforming reactor of hydrogen production units. Data from 3 months, 1-minute interval. The CNN regression model identified process deviation 4 hours earlier than the process engineer. |
| [66] | Fabricated metal products (D25) | P | ANN | B | Q | L | Laboratory | The goal is to find the most effective method to obtain a good surface quality by changing the laser energy in laser-assisted milling (LAML). A BP neural network is used to train specimens. |
| [67] | Comp., electr. and optical (D26) | M | Other | B | P | S | Off-line | ML algorithms are used to predict time-to-failure intervals for unplanned downtimes to be used for prescriptive maintenance. Data from different sources. In the industrial use case, a potential reduction of downtime of 12–21% and 2 percentage-point increased availability is shown. |
| [68] | Chemicals … (D20) | P | ANN | E, B | n/a | S | Off-line | Control method for reducing CO2 and energy use is proposed for the real-time optimization control of coal-to-methanol production. CNN is used for data from a factory under different conditions. The needed compressor power (kW) is reduced from 530 to 473 with the new method in the simulation. |
| [69] | Chemicals … (D20) | S | SVM | B | C | S | Simulated | The goal is to minimize the total cost of the supply chain. SVM is used. Case studies with reactor and separator systems and an industrial gas supply chain. Simulations provide costs (total, capex, operation, transport, and inventory) for various design options. |
| [70] | Fabricated metal … (D25) | M | SVM | E; B | C | PoC | Real on-line | Tool Condition Monitoring (TCM) system to maximize tool life and reduce CO2 using wavelet and SVM methods. Results with 10 cutters in the Computer numerical control (CNC) manufacturing plant. The average tool wear is improved by about 30%, while CO2 emissions declined by 29.5%. |
| [71] | General manufacturing (C) | P | Other | B; E | C | S | Simulated | The goal is to optimize the energy use of machine tools by switching them off when idle, i.e., waiting for the next job. The maximum likelihood estimation method is used. Data is from a machining center for powertrain applications (simulated or real?). With the on-line policy, the machines save 31% energy with respect to the always-on case. |
| [72] | Coke and Refined petroleum (D19) | P | Several equal | B | C | S | Off-line | The goal is to develop a soft sensor (method) for estimating the flash-point of diesel fuel and thus decrease cost and improve quality. Data from petrochemical plant for 3-year period, 1-min interval. A considerable reduction of the generated losses is estimated, from 29838$ up to 497306$/semester. |
| [73] | General manufacturing (C) | M | Several | B | C | S | Database | Goal is to build a tool for finding the best ML algorithm for predictive maintenance in each situation dynamically. Data is from a public dataset of 90 attributes describing the SMART hard-drive measurements and corresponding device failures for 125627 hard disks. |
| [74] | Chemicals … (D20) | S | Other | B | C, E | S | Simulated | The goal is to optimize the supply chain using mixed-integer linear programming. Two cases: reactor and separator; an industrial gas supply chain problem. The same authors have another publication partly covering the same topic. |
| [75] | Food products (D10) | M | DT | B | C | PoC | Off-line | Goal is to eventually develop a decision support system based on decision trees (DTs) for the decision-making of predictive maintenance implementation. Enable cost comparison between predictive and corrective maintenance approaches. Data from the food industry gearbox for roasting oilseeds. |
| [76] | Fabricated metal products (D25) | M | Several equal (comparison) | B; E | C | S | Off-line | Goal: maintenance decision support system which estimates cost of maintenance and a ratio of unplanned breakdowns for different scenarios. Data from 29 machine tools from 4 years. In the example case, estimated benefit: the direct cost is decreased by around 30-40%, and the value of occurrences of unplanned stops is decreased by a factor from 4 to 8. |
| [77] | Wearing apparel (D14) | P | Other | B, E, S | P, Q, C, E | S | Off-line | Goal: optimize production planning regarding backorder quantity, machine uptime and customer satisfaction as well as profits, emissions, and workforce change rate. The stochastic multi-objective mixed-integer optimization is used. Data from three textile factories. Result: improvements in profitability, emissions, workforce changing, and backorder of 21%, 37%, 30%, and 23%, respectively. |
| [78] | Comp., electr. and optical (D26) | Q | ANN, other | B | C, Q | O | Real-time on-line | Goal is cost reduction and improved quality. Three cases using ML methods are presented in Inventec Inc. company: logistics optimization, quality acceptance, and visual inspection. Results example: reducing the number of verification engineers by over half, which translates to hundreds of people. |
| [79] | General manufacturing (C) | M | Seve-ral | B | C | S | Database | Goal is to predict failure beforehand by producing alert message. Data is from a database of a water pump covering over a year of operation [Kaggle). Result: algorithm detects 6 out of 7 failures in the forehand. |
| [80] | Coke and refined petroleum (D19) | M | Other | B | C | S | Off-line | Goal is to develop data-driven framework for rotating machinery diagnosis. Data (vibration signal) from a pump in an oil refinery in China. “Our cost-sensitive learning method performs better in imbalanced fault classification.” |
| [81] | General manufacturing (C) | M | ANN | B | C, | S | Off-line | Goal is to develop an experimental predictive maintenance framework for conveyor motors. Data from the conveyor system of a small manufacturing plant was used for testing. ANN classifies conveyor motor status into critical fault, minor fault, and no-fault. |
| [82] | General manufacturing (C) | M | ANN | B | C; | S | Off-line | A framework named DoM (Doctor for Machines) to produce the best predictive model for several oil and gas industry cases. Six data sets, 4 real, 2 synthetic (pumps, turbo fans, hard disc). Result: 1) reduce the labor effort to build predictive models, 2) help to plan maintenance better. |
| [83] | Motor vehicles … (D29) | S | Other | B | P | S | Off-line | Goal is to use clustering methods to address the grouping of products into families for 3rd party logistics in supply chain. Data is from a packaging plant with 58000 different items. Result: capacitated clustering provides the highest balanced scenario with the lowest variance. |
| [84] | Comp., electr. and optical (D26) | P | Other | B | P | S | Simulated | A machine learning (ML) framework for quality improvement and estimation in PV production line is proposed. Simulated data is used. It predicts cell efficiencies with prediction errors of <0.03% absolute efficiency. Optimization method increases the mean cell efficiency of the simulated production line from 18.07% to 19.45%. |
| [85] | General manufacturing (C) | M | Other | B | C, E | S | Databases | A hybrid modeling approach that combines failure prediction with risk-based dynamic pricing (RBDP) for equipment-as-a-service business. Gradient boosting is used. Two public data sets are used: C-MPASS, a jet engine run-to-failure data set, and an Advanced planning and scheduling (APS) failure data set for heavy-duty Scania trucks. Result: improvement of 3.75% in terms of profit gains over a baseline method. |
| [86] | Comp., electr. and optical (D26) | Q | ANN | B | P, Q | S | Off-line | Goal is to develop a biology-inspired visual attention mechanism for automatic visual inspection, using DNN. Data: wafer data set originates from a real-world, laser-based dicing process of semiconductor wafers. Result: classification error rate for the faults drops from 33% to 12%. |
| [87] | Other non-metallic … (D23) | P | Several | B, E | E | S | Off-line | Goal is to establish an architecture for predictive production planning for the energy-intensive industry to achieve cleaner production and decreasing energy use. ML methods: recursive neural networks and long short-term memory. Data: energy consumption of a large ceramic factory. |
| [88] | General manufacturing (C) | P | ANN | B, E | C | S | Off-line | Goal is to forecast manufacturing facility energy consumption and optimize building energy consumption. Energy data is from an industrial building. Results: predicting energy consumption to an accuracy of 96.8%. Accurate forecasting helps optimization with the potential for 30% energy cost reduction by avoiding an oscillatory energy profile. |
| [89] | General manufacturing (C) | Q | DT | B, E | Q, C | S | Databases | Goal is to develop a hyper-learning quality classification system. Data is from published databases, including red vine, used cars, steel plates, and glass. Result: a generalizable framework where economic viability and environmental sustainability can be combined for cost-imbalanced quality classification is demonstrated. |
| [90] | Fabricated metal (D25) | P, Q | ANN | B, E | Q | L | Real data (lab) | Goal: minimizing surface roughness and energy consumption in a CNC end milling. Data from experimental set-up with CNC machine. Improvements in surface quality and reduction in energy consumption were found to be 28% and 30%, respectively. |
| [91] | Comp., electr. and optical (D26) | Q, P | ANN | B | Q P | S | Off-line | Goal is to use data-based methods in the semiconductor industry for defect analysis, design, and other needs. Data from semiconductor production (incl. defect data, images). Results, e.g., automating the potential for defect detection and reducing the human load by about two-thirds. |
| [92] | General manufacturing (C) | Q, P | ANN | E | - | L | Laboratory | Goal: less rework and thus energy use with early machine vision quality control. Data is from a laboratory set-up (“learning factory”). System has enhanced energy efficiency and reduced the total carbon footprint by 18% or more. Reduced labor need. (Note: laboratory set-up). |
| [93] | Comp., electr. and optical (D26) | M | ANN | B | E | S | Off-line | Goal: integrating preventive maintenance (PM) into production planning; to minimize the impact on production and to optimize the number of repairmen to save cost. Data from production line in semiconductor multi-workstation system with 153 workstations and 29 repairmen. Result: reduce personnel numbers while guaranteeing maintenance tasks. |
| [94] | General manuf. (C) | S | DT | B | C | S | Off-line | Goal: cost-based, multi-dimensional inventory classification system. Data from three industry data sets. |
| [95] | Paper and paper products (D17) | P | Other | B | C | S | Database | Goal: predict and classify rare problems in the production process, case leaf breakage. Autoencoder method used on a real-world dataset obtained from a pulp-and-paper manufacturing industry. Potential savings of up to 22 to 38 thousand dollars per month (based on simulation results). |
| [96] | Fabricated metal products (D25) | P | ANN | B, E | C | S | Off-line | Goal: multi-objective batch-based flowshop scheduling optimization (energy, cost, makespan). Shop floor data collection solution was implemented. Result: Scenario simulation decision support models can help decision makers evaluate options and make the best decisions automatically. |
| [97] | Other non-metallic … (D23) | M | ANN | B | C | O | Real data | The goal was to decrease the maintenance costs of production equipment. Data: production data from cement factories and macro-economic data. Result: maintenance costs were reduced to 4% in comparison with initial status. |
| [98] | Fabricated metal products fD25) | P | Other | B, E | C | S | Simulated | The goal is to develop an adaptive policy for on-line energy-efficient control of machine tools under throughput constraint (turning machines off when idle). Data: simulated scenarios partly based on real machines. In the simulated scenarios, the approach reduces the energy consumption up to 25% with respect to the baseline. |
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