Machine learning-based anomaly detection via integration of manufacturing, inspection and after-sales service data

Purpose Quality management of products is an important part of manufacturing process. One way to manage and assure product quality is to use machine learning algorithms based on relationship among various process steps. The purpose of this paper is to integrate manufacturing, inspection and after-sales service data to make full use of machine learning algorithms for estimating the products’ quality in a supervised fashion. Proposed frameworks and methods are applied to actual data associated with heavy machinery engines. Design/methodology/approach By following Lenzerini’s formula, manufacturing, inspection and after-sales service data from various sources are integrated. The after-sales service data are used to label each engine as normal or abnormal. In this study, one-class classification algorithms are used due to class imbalance problem. To address multi-dimensionality of time series data, the symbolic aggregate approximation algorithm is used for data segmentation. Then, binary genetic algorithm-based wrapper approach is applied to segmented data to find the optimal feature subset. Findings By employing machine learning-based anomaly detection models, an anomaly score for each engine is calculated. Experimental results show that the proposed method can detect defective engines with a high probability before they are shipped. Originality/value Through data integration, the actual customer-perceived quality from after-sales service is linked to data from manufacturing and inspection process. In terms of business application, data integration and machine learning-based anomaly detection can help manufacturers establish quality management policies that reflect the actual customer-perceived quality by predicting defective engines.