Large-scale neural networks possess considerable expressive power. They are well-suited for complex learning tasks in industrial applications. However, large-scale models pose significant challenges for training under the current Federated Learning (FL) paradigm. Existing approaches for efficient FL training often leverage model parameter dropout. However, manipulating individual model parameters is not only inefficient in meaningfully reducing the communication overhead when training large-scale FL models, but may also be detrimental to the scaling efforts and model performance as shown by recent research. To address these issues, we propose the Federated Opportunistic Block Dropout (FedOBD) approach. The key novelty is that it decomposes large-scale models into semantic blocks so that FL participants can opportunistically upload quantized blocks, which are deemed to be significant towards training the model, to the FL server for aggregation. Extensive experiments evaluating FedOBD against four state-of-the-art approaches based on multiple real-world datasets show that it reduces the overall communication overhead by more than 88% compared to the best performing baseline approach, while achieving the highest test accuracy. To the best of our knowledge, FedOBD is the first approach to perform dropout on FL models at the block level rather than at the individual parameter level.

Artificial intelligence (AI)-empowered industrial fault diagnostics is important in ensuring the safe operation of industrial applications. Since complex industrial systems often involve multiple industrial plants (possibly belonging to different companies or subsidiaries) with sensitive data collected and stored in a distributed manner, collaborative fault diagnostic model training often needs to leverage federated learning (FL). As the scale of the industrial fault diagnostic models are often large and communication channels in such systems are often not exclusively used for FL model training, existing deployed FL model training frameworks cannot train such models efficiently across multiple institutions. In this paper, we report our experience developing and deploying the Federated Opportunistic Block Dropout (FEDOBD) approach for industrial fault diagnostic model training. By decomposing large-scale models into semantic blocks and enabling FL participants to opportunistically upload selected important blocks in a quantized manner, it significantly reduces the communication overhead while maintaining model performance. Since its deployment in ENN Group in February 2022, FEDOBD has served two coal chemical plants across two cities in China to build industrial fault prediction models. It helped the company reduce the training communication overhead by over 70% compared to its previous AI Engine, while maintaining model performance at over 85% test F1 score. To our knowledge, it is the first successfully deployed dropout-based FL approach.