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Publicações

2022

Understanding Overlap in Automatic Root Cause Analysis in Manufacturing Using Causal Inference

Autores
Oliveira, EE; Migueis, VL; Borges, JL;

Publicação
IEEE ACCESS

Abstract
Overlap has been identified in previous works as a significant obstacle to automated diagnosis using data mining algorithms, since it makes it impossible to discern how each machine influences product quality. Several solutions that handle overlap have been proposed, but the final result is a list of potential overlapped root causes. The goal of this paper is to develop a solution resilient to overlap that can determine the true root cause from a list of possible root causes, when possible, and determine the conditions in which it is possible to identify the root causes. This allows for a better understanding of overlap, and enables the development of a fully automatic root cause analysis for manufacturing. To do so, we propose an automatic root cause analysis approach that uses causal inference and do calculus to determine the true root cause. The proposed approach was validated on simulated and real case-study data, and allowed for an estimation of the effect of a product passing through a certain machine while disregarding the effect of overlap, in certain conditions. The results were on par with the state-of-the-art solutions capable of handling overlap. The contributions of this paper are a graphical definition of overlap, the identification of the conditions in which is possible to overcome the effect of overlap, and a solution that can present a single true root cause when such conditions are met.

2021

On the influence of overlap in automatic root cause analysis in manufacturing

Autores
Oliveira, EE; Migueis, VL; Borges, JL;

Publicação
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH

Abstract
To improve manufacturing processes, it is essential to find the root causes of occurring problems, in order to solve them permanently. Automatic Root Cause Analysis (ARCA) solutions aid analysts in finding such root causes, by using automatic data analysis to improve the digital decision. When trying to locate the root cause of a problem in a manufacturing process, a phenomenon can occur that disrupts the application of ARCA solutions. Overlap, as we denominated, is a phenomenon where local synchronicities in the manufacturing process lead to data where it is impossible to discern the influence of each location in the quality of products, which impedes automated diagnosis, especially when using classifiers. This paper identifies and defines overlap, and proposes a two-phase ARCA solution that uses factor-ranking algorithms, instead of classifiers. The proposed solution is evaluated in simulated and real case-study data. Results proved the presence of overlap in the datasets, and its negative impact on classifiers. The proposed solution has a positive performance detecting root causes even in the presence of overlap.