quality control and optimization GANs to address ......model v.1 New batch of data New model v.2...
Transcript of quality control and optimization GANs to address ......model v.1 New batch of data New model v.2...
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Industrial AI
Industrial automation based on auto ML and GANs to address predictive maintenance, quality control and optimization
Conundrum
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Agenda
1. About Conundrum
2. Solution overview
3. Cases
4. Technology deep dive
5. Conclusion
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About ConundrumConundrum Industrial Limited is an international technology company focusing on research in AI and development of its proprietary machine learning technologies and software products for industries. Backed by Speedinvest, Austrian based VC.
Overview
17 completed projects
3 deployments
Wins in industrial competitions: Schneider, Aramco,
Gazprom Neft, CERN
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About ConundrumConundrum Industrial Limited is an international technology company focusing on research in AI and development of its proprietary machine learning technologies and software products for industries. Backed by Speedinvest, Austrian based VC.
Industries
Metal & Mining
Pipes manufacturing
Chemical
Oil & Gas
Pulp & Paper
Overview
17 completed projects
3 deployments
Wins in industrial competitions: Schneider, Aramco,
Gazprom Neft, CERN
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About ConundrumConundrum Industrial Limited is an international technology company focusing on research in AI and development of its proprietary machine learning technologies and software products for industries. Backed by Speedinvest, Austrian based VC.
Industries
Metal & Mining
Pipes manufacturing
Chemical
Oil & Gas
Pulp & Paper
Overview
17 completed projects
3 deployments
Wins in industrial competitions: Schneider, Aramco,
Gazprom Neft, CERN
Our partners
- our investor
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Improving Industries Performance
Reduce maintenance costs & improve throughput
Reduce manufacturing costs
Eliminate quality escapes
Predictive & prescriptive maintenance
Manufacturing process optimization
Quality control
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Conundrum System Provides the Following Solutions:
• Predictive & Prescriptive maintenance
• Quality control
• Industrial processes optimization
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Data SourcesEquipment sensors: Temperature Pressure Vibration Acoustics Amperage etc.
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Data SourcesEquipment sensors: Temperature Pressure Vibration Acoustics Amperage etc.
Measurements in laboratories:Chemical analysis
Product quality tests
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Data SourcesEquipment sensors: Temperature Pressure Vibration Acoustics Amperage etc.
Complex informationVideo
UltrasoundX-Ray
Measurements in laboratories:Chemical analysis
Product quality tests
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Data SourcesEquipment sensors: Temperature Pressure Vibration Acoustics Amperage etc.
Complex informationVideo
UltrasoundX-Ray
Measurements in laboratories:Chemical analysis
Product quality tests
Tracking of events: Failures Manual commands Control values management Operating modes
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Training in Cloud & Deployment in Cloud
ConundrumTraining Module
Historical Data
Conundrum Inference Module
Production Ready Deployed
Prepare model and assemble solution
Equipment
Automation System
Industrial Protocol
Training Module in CloudAutomated Preparation of Solution
Factory / Asset / Company Data CenterProduction
Data upload
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Training in Cloud & Deployment in Cloud
ConundrumTraining Module
Historical Data
Conundrum Inference Module
Production Ready Deployed
Prepare model and assemble solution
Equipment
Automation System
Industrial Protocol
Data Stream
Inferences
Data Stream
Training Module in CloudAutomated Preparation of Solution
Factory / Asset / Company Data CenterProduction
Engineers
Data upload
Conundrum Cloud Adapter
Communicate with Conundrum Cloud
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Training in Cloud & Deployment On-Premises
Equipment
Automation System
Industrial Protocol
Conundrum Training Module
Historical Data
Conundrum Inference Module
Production Ready
Prepare model and assemble solution
Training Module in CloudAutomated Preparation of Solution
Data upload
Factory / Asset / Company Data CenterProduction
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Training in Cloud & Deployment On-Premises
Equipment
Automation System
Industrial Protocol
Data Stream
Conundrum Inference Module
Production Ready Deployed
Integration To Production
Conundrum Training Module
Historical Data
Conundrum Inference Module
Production Ready
Prepare model and assemble solution
Training Module in CloudAutomated Preparation of Solution
Data upload
Factory / Asset / Company Data CenterProduction
Inferences Engineers
Conundrum Platform
Conundrum Supercomputer
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Conundrum Platform On-premise
Equipment
Automation System
Industrial Protocol
Data Stream
Integration To Production
Conundrum Training Module
Historical Data
Conundrum Inference Module
Production Ready
Prepare model and assemble solution
Training Module in CloudAutomated Preparation of Solution
Data upload
Factory / Asset / Company Data CenterProduction
Inferences Engineers
Conundrum Platform
Conundrum Supercomputer
Conundrum Platform
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Training Systems
Automated Machine Learning
Conundrum Cloud automatically prepares a model for specific equipment
Delivers max benefit extracted from industrial data
Transfer Learning
Conundrum Cloud enables to use models experience and transfer knowledge from pretrained models
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Inference Systems
Production Ready
Conundrum Inference Module provides API to simplify integration & deployment
Packed into container enabling platform independence
Permanent Control & Improvement in Production
Auto monitoring keeps the performance under control
Permanent updates keep the system up-to-date
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17 Successful Cases Across Industries
Chemical
Solve
d cas
es
Oil and Gas Metal & Mining
Indus
tries
Pulp and Paper
Paper tears prediction on paper mill
Kappa number (paper quality) prediction on paper production
Predictive maintenance of chemical production equipment
Prediction of produced product quality
Optimization of chemical plant operating modes
Digital twin of chemical production
Predictive maintenance of submersible pumps in oil wells (upstream)
Anomaly detection of pumps (downstream)
Prediction and classification of drilling rigs failures events (upstream)
Quality prediction of coal in coal enrichment process
Optimization of coal enrichment process
Defects detection and classification of metal sheet during zinc coating
Predictive maintenance of welding equipment
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Case: Large-Diameter Pipes ManufacturingChallenge
Manufacturing process downtime due to welding equipment (DSAW) failure.
Tasks- Predict failures of welding equipment- Detect causes of potential failures- Speed up check-ups and maintenance
61% 72%
Detected failures True check-ups Avg. check-up time reduction
25%
Downtime reduction
-32%
Before 9% After 6%
Results
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Overview
Coal mining and processing enterprise with coal enrichment factory. It sustains quality issues of coking coal which leads to losses.
Tasks- Predict coal quality (ash conc.) - Provide real-time recommendations to adjust control parameters
to improve product quality
Case: Coal Enrichment Optimization
Conc. prediction error
±0.3%
True detected quality issues
Lower number of shipments
with quality issue
88% -40%
Results
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Predictive Maintenance of PumpsChallenge
Pumps downtime and extra maintenance costs due to abrupt breakdowns. Pumps quantity is hundreds of units. Avg. breakdown events per year is 3.
Tasks- Predict abnormal behaviour of pumps several days before breakdowns- Detect causes of breakdowns- Speed up check-ups and maintenance
Detected failures True check-ups Avg. maintenance time reduction
-31%
95% 62%
Results
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Challenge
Fertilizer manufacturer has issues of low quality of product which is estimated as a P2O5 concentration.
Tasks- Predict P2O5 conc. in the output of flotation 1 hour in advance- Recommend control parameters adjustment to keep the conc.
into required range
Chemical Production Optimization
Conc. prediction error
±0.5% 88%
True detected quality issues
Quality issues decrease
20%
Results
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Challenge
Failures of paper mill happen which lead to paper tears and downtime of the whole mill.
Tasks
- Predict failure of the mill;- Recognize possible causes of failures.
PdM of Paper Mill
Results
Detected failures True check-ups Avg. maintenance time reduction
-24%
58% 62%
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Training Module
Get Data From Storage
Build/Rebuild Digital Twin
Auto ML,RCGAN,
Attention MethodNvidia GPUs
Nvidia Docker
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Training Module
Get Data From Storage
Build/Rebuild Digital Twin
Auto ML,RCGAN,
Attention Method
Train\Retrainadditional layers
Supervised Learning
Nvidia GPUs
Nvidia Docker
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Training Module
Get Data From Storage
Build/Rebuild Digital Twin
Auto ML,RCGAN,
Attention Method
Train\Retrainadditional layers
Supervised Learning
Optimization,Clustering
Optimize Thresholds
Check Quality
Recognize Causes
Inference Control Policy
Assemble and Deploy
the Model Docker
Nvidia GPUs
Nvidia Docker
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Technology Workflow
Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Data Preprocessing
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Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Train Digital Twin
Data Preprocessing
RCGAN
Technology Workflow
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Conundrum 34
Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Train Digital Twin
Data Preprocessing
Quality Prediction
RCGAN
Train Additional
Model
Semi-Supervised Learning
Technology Workflow
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Conundrum 35
Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Train Digital Twin
Data Preprocessing
Predictive Maintenance
Quality Prediction
Train Additional Model
Anomaly Detection
Supervised Learning
RCGAN
Train Additional
Model
Semi-Supervised Learning
Technology Workflow
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Conundrum 36
Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Train Digital Twin
Data Preprocessing
Train Agent
Predictive Maintenance
Optimization Task
Quality Prediction
Train Additional Model
Anomaly Detection
Supervised Learning
RCGAN
RLTrain
Additional Model
Semi-Supervised Learning
Technology Workflow
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Conundrum 37
Task Definition Uploading Data MetaData Generation
Model ArchitectureGeneration
Train Digital Twin
Data Preprocessing
Train Agent
Explore Interpretations
Predictive Maintenance
Optimization Task
Quality Prediction
Train Additional Model
Anomaly Detection
Supervised Learning
RCGAN
RLTrain
Additional Model
Semi-Supervised Learning
Optimise Thresholds
Software Assemble and
Deploy
Economic Effect Maximization
Attention Techniques Clusterization
Docker + API + UI
Conundrum Technology Workflow
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Conundrum 38
Inference Module
Preprocess Data
normalization, denoising, cleaning,
measurements frequency normalization,
delayed signals handling
Nvidia GPUs
Sensor, Labs and Cameras
data flow
Nvidia Docker
API
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Conundrum 39
Inference Module
Preprocess Data
normalization, denoising, cleaning,
measurements frequency normalization,
delayed signals handling
Inference
Online learning
Nvidia GPUs
Sensor, Labs and Cameras
data flow
Nvidia Docker
API
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Conundrum 40
Inference Module
Preprocess Data
normalization, denoising, cleaning,
measurements frequency normalization,
delayed signals handling
Inference
Online learning
Real-time dashboard
3d Party Systems
Nvidia GPUs
Sensor, Labs and Cameras
data flow
Nvidia Docker
Store data
Docker
Docker
API
API
API
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Permanent Improvement In Production
Fine tuning of model v.1
New batch of data
New model v.2
Data stream
Model v.1 operates
Model v.2 test in production
Model v.2 operates
New version is deployed to production
Steps of improvement are repeated
Conundrum enables to keep the performance of it’s models under control and permanently improve the performance using new data.
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Permanent Improvement In Production
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Transfer Learning ImpactPrecision/Recall curve for
− Traditional supervised (light blue);− Traditional unsupervised (blue);− Conundrum solution (red);− Pretrained Conundrum solution using transfer
learning (green).
Conundrum Transfer Learning technology enables to leverage other datasets from similar cases to boost the performance of the solution.
Here the solution has been pre-trained using the data from 3 other pumps (from energy industry), 1 year.
Method AreaMax F1 Recall = 0.8
Prec Rec F1 Prec Rec F1
Conundrum + TL 0.70 0.74 0.53 0.62 0.46 0.80 0.59
Conundrum 0.49 0.44 0.69 0.54 0.37 0.80 0.50
Trad. superv 0.29 0.23 0.97 0.37 0.21 0.80 0.33
Trad. unsuperv 0.28 0.28 0.49 0.35 0.20 0.80 0.32
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Conclusion
Conundrum is targeting to become a leader provider of AI powered automation solutions for industries helping industrial companies to leapfrog into an Industry 4.0 era and attain the next level of intelligent control.