Traditionally, fault detection and isolation community has used system dynamic equations to generate diagnosers and to analyze detectability and isolability of the dynamic systems. Model-based fault detection and isolation methods use system model to generate a set of residuals as the bases for fault detection and isolation. However, in many complex systems it is not feasible to develop highly accurate models for the systems and to keep the models updated during the system lifetime. Recently, data-driven solutions have received an immense attention in the industries systems for several practical reasons. First, these methods do not require the initial investment and expertise for developing accurate models. Moreover, it is possible to automatically update and retrain the diagnosers as the system or the environment change over time. Finally, unlike the model-based methods it is straight forward to combine time series measurements such as pressure and voltage with other sources of information such as system operating hours to achieve a higher accuracy. In this paper, we extend the traditional model-based fault detection and isolation concepts such as residuals, and detectable and isolable faults to the data-driven domain. We then propose an algorithm to automatically generate residuals from the normal operating data. We present the performance of our proposed approach through a comparative case study.

Several machine learning and deep learning frameworks have been proposed to solve remaining useful life estimation and failure prediction problems in recent years. Having access to the remaining useful life estimation or likelihood of failure in near future helps operators to assess the operating conditions and, therefore, provides better opportunities for sound repair and maintenance decisions. However, many operators believe remaining useful life estimation and failure prediction solutions are incomplete answers to the maintenance challenge. They argue that knowing the likelihood of failure in the future is not enough to make maintenance decisions that minimize costs and keep the operators safe. In this paper, we present a maintenance framework based on offline supervised deep reinforcement learning that instead of providing information such as likelihood of failure, suggests actions such as "continuation of the operation" or "the visitation of the repair shop" to the operators in order to maximize the overall profit. Using offline reinforcement learning makes it possible to learn the optimum maintenance policy from historical data without relying on expensive simulators. We demonstrate the application of our solution in a case study using the NASA C-MAPSS dataset.

Deep reinforcement learning (RL) algorithms can learn complex policies to optimize agent operation over time. RL algorithms have shown promising results in solving complicated problems in recent years. However, their application on real-world physical systems remains limited. Despite the advancements in RL algorithms, the industries often prefer traditional control strategies. Traditional methods are simple, computationally efficient and easy to adjust. In this paper, we first propose a new Q-learning algorithm for continuous action space, which can bridge the control and RL algorithms and bring us the best of both worlds. Our method can learn complex policies to achieve long-term goals and at the same time it can be easily adjusted to address short-term requirements without retraining. Next, we present an approximation of our algorithm which can be applied to address short-term requirements of any pre-trained RL algorithm. The case studies demonstrate that both our proposed method as well as its practical approximation can achieve short-term and long-term goals without complex reward functions.

In the last few decades, building regression models for non-scalar variables, including time series, text, image, and video, has attracted increasing interests of researchers from the data analytic community. In this paper, we focus on a multivariate time series regression problem. Specifically, we aim to learn mathematical mappings from multiple chronologically measured numerical variables within a certain time interval S to multiple numerical variables of interest over time interval T. Prior arts, including the multivariate regression model, the Seq2Seq model, and the functional linear models, suffer from several limitations. The first two types of models can only handle regularly observed time series. Besides, the conventional multivariate regression models tend to be biased and inefficient, as they are incapable of encoding the temporal dependencies among observations from the same time series. The sequential learning models explicitly use the same set of parameters along time, which has negative impacts on accuracy. The function-on-function linear model in functional data analysis (a branch of statistics) is insufficient to capture complex correlations among the considered time series and suffer from underfitting easily. In this paper, we propose a general functional mapping that embraces the function-on-function linear model as a special case. We then propose a non-linear function-on-function model using the fully connected neural network to learn the mapping from data, which addresses the aforementioned concerns in the existing approaches. For the proposed model, we describe in detail the corresponding numerical implementation procedures. The effectiveness of the proposed model is demonstrated through the application to two real-world problems.

Deep learning classifiers are assisting humans in making decisions and hence the user's trust in these models is of paramount importance. Trust is often a function of constant behavior. From an AI model perspective it means given the same input the user would expect the same output, especially for correct outputs, or in other words consistently correct outputs. This paper studies a model behavior in the context of periodic retraining of deployed models where the outputs from successive generations of the models might not agree on the correct labels assigned to the same input. We formally define consistency and correct-consistency of a learning model. We prove that consistency and correct-consistency of an ensemble learner is not less than the average consistency and correct-consistency of individual learners and correct-consistency can be improved with a probability by combining learners with accuracy not less than the average accuracy of ensemble component learners. To validate the theory using three datasets and two state-of-the-art deep learning classifiers we also propose an efficient dynamic snapshot ensemble method and demonstrate its value.

Dynamic dispatching aims to smartly allocate the right resources to the right place at the right time. Dynamic dispatching is one of the core problems for operations optimization in the mining industry. Theoretically, deep reinforcement learning (RL) should be a natural fit to solve this problem. However, the industry relies on heuristics or even human intuitions, which are often short-sighted and sub-optimal solutions. In this paper, we review the main challenges in using deep RL to address the dynamic dispatching problem in the mining industry.

Explosive growth in spatio-temporal data and its wide range of applications have attracted increasing interests of researchers in the statistical and machine learning fields. The spatio-temporal regression problem is of paramount importance from both the methodology development and real-world application perspectives. Given the observed spatially encoded time series covariates and real-valued response data samples, the goal of spatio-temporal regression is to leverage the temporal and spatial dependencies to build a mapping from covariates to response with minimized prediction error. Prior arts, including the convolutional Long Short-Term Memory (CovLSTM) and variations of the functional linear models, cannot learn the spatio-temporal information in a simple and efficient format for proper model building. In this work, we propose two novel extensions of the Functional Neural Network (FNN), a temporal regression model whose effectiveness and superior performance over alternative sequential models have been proven by many researchers. The effectiveness of the proposed spatio-temporal FNNs in handling varying spatial correlations is demonstrated in comprehensive simulation studies. The proposed models are then deployed to solve a practical and challenging precipitation prediction problem in the meteorology field.

Dynamic dispatching is one of the core problems for operation optimization in traditional industries such as mining, as it is about how to smartly allocate the right resources to the right place at the right time. Conventionally, the industry relies on heuristics or even human intuitions which are often short-sighted and sub-optimal solutions. Leveraging the power of AI and Internet of Things (IoT), data-driven automation is reshaping this area. However, facing its own challenges such as large-scale and heterogenous trucks running in a highly dynamic environment, it can barely adopt methods developed in other domains (e.g., ride-sharing). In this paper, we propose a novel Deep Reinforcement Learning approach to solve the dynamic dispatching problem in mining. We first develop an event-based mining simulator with parameters calibrated in real mines. Then we propose an experience-sharing Deep Q Network with a novel abstract state/action representation to learn memories from heterogeneous agents altogether and realizes learning in a centralized way. We demonstrate that the proposed methods significantly outperform the most widely adopted approaches in the industry by $5.56\%$ in terms of productivity. The proposed approach has great potential in a broader range of industries (e.g., manufacturing, logistics) which have a large-scale of heterogenous equipment working in a highly dynamic environment, as a general framework for dynamic resource allocation.

Prognostics is concerned with predicting the future health of the equipment and any potential failures. With the advances in the Internet of Things (IoT), data-driven approaches for prognostics that leverage the power of machine learning models are gaining popularity. One of the most important categories of data-driven approaches relies on a predefined or learned health indicator to characterize the equipment condition up to the present time and make inference on how it is likely to evolve in the future. In these approaches, health indicator forecasting that constructs the health indicator curve over the lifespan using partially observed measurements (i.e., health indicator values within an initial period) plays a key role. Existing health indicator forecasting algorithms, such as the functional Empirical Bayesian approach, the regression-based formulation, a naive scenario matching based on the nearest neighbor, have certain limitations. In this paper, we propose a new `generative + scenario matching' algorithm for health indicator forecasting. The key idea behind the proposed approach is to first non-parametrically fit the underlying health indicator curve with a continuous Gaussian Process using a sample of run-to-failure health indicator curves. The proposed approach then generates a rich set of random curves from the learned distribution, attempting to obtain all possible variations of the target health condition evolution process over the system's lifespan. The health indicator extrapolation for a piece of functioning equipment is inferred as the generated curve that has the highest matching level within the observed period. Our experimental results show the superiority of our algorithm over the other state-of-the-art methods.

Efficient dispatching rule in manufacturing industry is key to ensure product on-time delivery and minimum past-due and inventory cost. Manufacturing, especially in the developed world, is moving towards on-demand manufacturing meaning a high mix, low volume product mix. This requires efficient dispatching that can work in dynamic and stochastic environments, meaning it allows for quick response to new orders received and can work over a disparate set of shop floor settings. In this paper we address this problem of dispatching in manufacturing. Using reinforcement learning (RL), we propose a new design to formulate the shop floor state as a 2-D matrix, incorporate job slack time into state representation, and design lateness and tardiness rewards function for dispatching purpose. However, maintaining a separate RL model for each production line on a manufacturing shop floor is costly and often infeasible. To address this, we enhance our deep RL model with an approach for dispatching policy transfer. This increases policy generalization and saves time and cost for model training and data collection. Experiments show that: (1) our approach performs the best in terms of total discounted reward and average lateness, tardiness, (2) the proposed policy transfer approach reduces training time and increases policy generalization.