Abstract
Unnatural patterns in process control charts exhibit out-of-control conditions. Therefore, increase in sensitivities in control charts is mandatory to study these situations. Because of the existence of inevitable natural variations, real-time detection and analysis of the significant patterns is a problem, especially when sensitivity level of the process to unnatural patterns formation is high. In the previous studies, most researchers have applied neural networks techniques to monitor significant patterns. Although this approach is effective, but structures of networks are complex and their architectures are difficult. The current paper develops fitted line and fitted cosine curve of samples to recognize and analyze the unnatural patterns. This simpler solution is more efficient and consumes less feedback time. The proposed model alarms occurrence of single and concurrent patterns and estimates their corresponding parameters. These fitted line and curve facilitate recognition and analysis of significant patterns at different levels of sensitivity, while the presented models often face with patterns misclassification error when high level of sensitivity is desired for unnatural patterns discrimination. To implement the proposed model, S2 control chart has been selected as a case study. The accuracy and precision of the proposed tools are evaluated by simulated experiments.
Similar content being viewed by others
References
Montgomery DC (2001) Introduction to statistical quality control, 4th edn. Wiley Publishing Company, New York
Pham DT, Oztemel E (1994) Control chart pattern recognition using learning vector quantization networks. Int J Prod Res 32(3):721–729
Cheng CS (1995) A multi-layer neural network model for detecting changes in the process mean. Comput Ind Eng 28(1):51–61
Cheng CS (1997) A neural network approach for the analysis of control chart patterns. Int J Prod Res 35(3):667–697
Hwarng HB (1995) Proper and effective training of a pattern recognizer for cyclic data. IIE Trans 27(6):746–756
Chang SA, Aw C (1996) A neural fuzzy control chart for detecting and classifying process mean shifts. Int J Prod Res 34(8):2265–2278
Anagun AS (1998) A neural network applied to pattern recognition in statistical process control. Comput Ind Eng 35(1–2):185–188
Pham DT, Sagiroglu S (2001) Training multilayered perceptron for pattern recognition: a comparative study of four training algorithms. Int J Mach Tools Manuf 41(3):419–430
Chiu C, Chen M, Lee K (2001) Shifts recognition in correlated process data using a neural network. Int J Syst Sci 32(2):137–143
Guh RS, Hsieh YC (1999) A neural network based model for abnormal pattern recognition of control charts. Comput Ind Eng 36(1):97–108
Guh RS, Zorriassatine F, Tannock JDT, O’Brien C (1999) On line control chart pattern detection and discrimination—a neural network approach. Artif Intell Eng 13(4):413–425
Guh RS, Tannock JDT (1999) Recognition of control chart concurrent patterns using a neural network approach. Int J Prod Res 37(8):1743–1765
Guh RS (2003) Integrating artificial intelligence into on-line statistical process control. Qual Reliab Eng Int 19(1):1–20
Guh RS (2004) Optimizing feed forward neural networks for control chart pattern recognition through genetic algorithms. Int J Pattern Recognit Artif Intell 18(2):75–99
Guh RS (2005) A hybrid learning-based model for on line detection and analysis of control chart patterns. Comput Ind Eng 49(1):35–62
Guh RS (2010) Simultaneous process mean and variance monitoring using artificial neural network. Comput Ind Eng 58(4):739–753
Chen Z, Lu S, Lam S (2007) A hybrid system for SPC concurrent pattern recognition. Adv Eng Inform 21(3):303–310
Fatemi Ghomi SMT, Lesany SA, Koockakzadeh A (2011) Recognition of unnatural patterns in process control charts through combining two types of neural network. Appl Soft Comput 11(8):5444–5456
Ebrahimzadeh A, Addeh J, Rahmani Z (2012) Control chart pattern recognition using K-MICA clustering and neural networks. ISA Trans 51(1):111–119
Yang W, Yu G, Liao W (2013) A hybrid learning based model for simultaneous monitoring of process mean and variance. Qual Reliab Eng Int 31(3):445–463
Lesany SA, Koochakzadeh A, Fatemi Ghomi SMT (2013) Recognition and classification of single and concurrent unnatural patterns in control charts via neural networks and fitted line of samples. Int J Prod Res 52(6):1771–1786
Cheng CS, Huang KK, Chen PW (2015) Recognition of control chart patterns using a neural network-based pattern recognizer with features extracted from correlation analysis. Pattern Anal Appl 18(1):75–86
Yang JH, Yang MSh (2005) A control chart pattern recognition system using a statistical correlation coefficient method. Comput Ind Eng 48(2):205–221
Lin SY, Guh RS, Shiue YR (2011) Effective recognition of control chart patterns in autocorrelated data using a support vector machine based approach. Comput Ind Eng 61(4):1123–1134
Freund JE (1992) Mathematical statistics, 5th edn. Prentice-Hall Publisher, New Jersey
Grant EG, Leavenworth RS (1996) Statistical quality control, 7th edn. McGraw Hill Book Company, New York
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lesany, S.A., Fatemi Ghomi, S.M.T. & Koochakzadeh, A. Development of fitted line and fitted cosine curve for recognition and analysis of unnatural patterns in process control charts. Pattern Anal Applic 22, 747–765 (2019). https://doi.org/10.1007/s10044-018-0682-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10044-018-0682-7