Designing industrial systems, such as building, improving, and automating distribution centers and manufacturing plants, involves critical decision-making with limited information in the early phases. The lack of information leads to less accurate designs of the systems, which are often difficult to resolve later. It is effective to use simulators to model the designed system and find out the issues early. However, the modeling time required by conventional simulators is too long to allow for rapid model creation to meet decision-making demands. In this paper, we propose a Rapid Modeling Architecture (RMA) for a lightweight industrial simulator that mitigates the modeling burden while maintaining the essential details in order to accelerate and improve decision-making. We have prototyped a simulator based on the RMA and applied it to the actual factory layout design problem. We also compared the modeling time of our simulator to that of an existing simulator, and as a result, our simulator achieved a 78.3% reduction in modeling time compared to conventional simulators.

This paper presents a new complex optimization problem in the field of automatic design of advanced industrial systems and proposes a hybrid optimization approach to solve the problem. The problem is multi-objective as it aims at finding solutions that minimize CO2 emissions, transportation time, and costs. The optimization approach combines an evolutionary algorithm and classical mathematical programming to design resilient and sustainable global manufacturing networks. Further, it makes use of the OWL ontology for data consistency and constraint management. The experimental validation demonstrates the effectiveness of the approach in both single and double sourcing scenarios. The proposed methodology, in general, can be applied to any industry case with complex manufacturing and supply chain challenges.

Machine learning and optimisation techniques (MLOPT) hold significant potential to accelerate the decarbonisation of industrial systems by enabling data-driven operational improvements. However, the practical application of MLOPT in industrial settings is often hindered by a lack of domain compliance and system-specific consistency, resulting in suboptimal solutions with limited real-world applicability. To address this challenge, we propose a novel human-in-the-loop (HITL) constraint-based optimisation framework that integrates domain expertise with data-driven methods, ensuring solutions are both technically sound and operationally feasible. We demonstrate the efficacy of this framework through a case study focused on enhancing the thermal efficiency and reducing the turbine heat rate of a 660 MW supercritical coal-fired power plant. By embedding domain knowledge as constraints within the optimisation process, our approach yields solutions that align with the plant's operational patterns and are seamlessly integrated into its control systems. Empirical validation confirms a mean improvement in thermal efficiency of 0.64\% and a mean reduction in turbine heat rate of 93 kJ/kWh. Scaling our analysis to 59 global coal power plants with comparable capacity and fuel type, we estimate a cumulative lifetime reduction of 156.4 million tons of carbon emissions. These results underscore the transformative potential of our HITL-MLOPT framework in delivering domain-compliant, implementable solutions for industrial decarbonisation, offering a scalable pathway to mitigate the environmental impact of coal-based power generation worldwide.

Remaining useful life (RUL) prediction is crucial for maintaining modern industrial systems, where equipment reliability and operational safety are paramount. Traditional methods, based on small-scale deep learning or physical/statistical models, often struggle with complex, multidimensional sensor data and varying operating conditions, limiting their generalization capabilities. To address these challenges, this paper introduces an innovative regression framework utilizing large language models (LLMs) for RUL prediction. By leveraging the modelling power of LLMs pre-trained on corpus data, the proposed model can effectively capture complex temporal dependencies and improve prediction accuracy. Extensive experiments on the Turbofan engine's RUL prediction task show that the proposed model surpasses state-of-the-art (SOTA) methods on the challenging FD002 and FD004 subsets and achieves near-SOTA results on the other subsets. Notably, different from previous researches, our framework uses the same sliding window length and all sensor signals for all subsets, demonstrating strong consistency and generalization. Moreover, transfer learning experiments reveal that with minimal target domain data for fine-tuning, the model outperforms SOTA methods trained on full target domain data. This research highlights the significant potential of LLMs in industrial signal processing and RUL prediction, offering a forward-looking solution for health management in future intelligent industrial systems.

A new unsupervised predictive maintenance analysis method based on the renormalization group approach used to discover critical behavior in complex systems has been proposed. The algorithm analyzes univariate time series and detects critical points based on a newly proposed theorem that identifies critical points using a Log Periodic Power Law function fits. Application of a new algorithm for predictive maintenance analysis of industrial data collected from reciprocating compressor systems is presented. Based on the knowledge of the dynamics of the analyzed compressor system, the proposed algorithm predicts valve and piston rod seal failures well in advance.

In Industry 4.0, Cyber-Physical Systems (CPS) generate vast data sets that can be leveraged by Artificial Intelligence (AI) for applications including predictive maintenance and production planning. However, despite the demonstrated potential of AI, its widespread adoption in sectors like manufacturing remains limited. Our comprehensive review of recent literature, including standards and reports, pinpoints key challenges: system integration, data-related issues, managing workforce-related concerns and ensuring trustworthy AI. A quantitative analysis highlights particular challenges and topics that are important for practitioners but still need to be sufficiently investigated by academics. The paper briefly discusses existing solutions to these challenges and proposes avenues for future research. We hope that this survey serves as a resource for practitioners evaluating the cost-benefit implications of AI in CPS and for researchers aiming to address these urgent challenges.

In the era of Industry 4.0, artificial intelligence (AI) is assuming an increasingly pivotal role within industrial systems. Despite the recent trend within various industries to adopt AI, the actual adoption of AI is not as developed as perceived. A significant factor contributing to this lag is the data issues in AI implementation. How to address these data issues stands as a significant concern confronting both industry and academia. To address data issues, the first step involves mapping out these issues. Therefore, this study conducts a meta-review to explore data issues and methods within the implementation of industrial AI. Seventy-two data issues are identified and categorized into various stages of the data lifecycle, including data source and collection, data access and storage, data integration and interoperation, data pre-processing, data processing, data security and privacy, and AI technology adoption. Subsequently, the study analyzes the data requirements of various AI algorithms. Building on the aforementioned analyses, it proposes a data management framework, addressing how data issues can be systematically resolved at every stage of the data lifecycle. Finally, the study highlights future research directions. In doing so, this study enriches the existing body of knowledge and provides guidelines for professionals navigating the complex landscape of achieving data usability and usefulness in industrial AI.

Fault detection is crucial in industrial systems to prevent failures and optimize performance by distinguishing abnormal from normal operating conditions. Data-driven methods have been gaining popularity for fault detection tasks as the amount of condition monitoring data from complex industrial systems increases. Despite these advances, early fault detection remains a challenge under real-world scenarios. The high variability of operating conditions and environments makes it difficult to collect comprehensive training datasets that can represent all possible operating conditions, especially in the early stages of system operation. Furthermore, these variations often evolve over time, potentially leading to entirely new data distributions in the future that were previously unseen. These challenges prevent direct knowledge transfer across different units and over time, leading to the distribution gap between training and testing data and inducing performance degradation of those methods in real-world scenarios. To overcome this, our work introduces a novel approach for continuous test-time domain adaptation. This enables early-stage robust anomaly detection by addressing domain shifts and limited data representativeness issues. We propose a Test-time domain Adaptation Anomaly Detection (TAAD) framework that separates input variables into system parameters and measurements, employing two domain adaptation modules to independently adapt to each input category. This method allows for effective adaptation to evolving operating conditions and is particularly beneficial in systems with scarce data. Our approach, tested on a real-world pump monitoring dataset, shows significant improvements over existing domain adaptation methods in fault detection, demonstrating enhanced accuracy and reliability.

This study focuses on two important problems related to applying offline model-based optimization to real-world industrial control problems. The first problem is how to create a reliable probabilistic model that accurately captures the dynamics present in noisy industrial data. The second problem is how to reliably optimize control parameters without actively collecting feedback from industrial systems. Specifically, we introduce a novel cGAN ensemble-based uncertainty-aware surrogate model for reliable offline model-based optimization in industrial control problems. The effectiveness of the proposed method is demonstrated through extensive experiments conducted on two representative cases, namely a discrete control case and a continuous control case. The results of these experiments show that our method outperforms several competitive baselines in the field of offline model-based optimization for industrial control.

Industrial particle accelerators inherently operate in much dirtier environments than typical research accelerators. This leads to an increase in noise both in the RF system and in other electronic systems. Combined with the fact that industrial accelerators are mass produced, there is less attention given to optimizing the performance of an individual system. As a result, industrial systems tend to under perform considering their hardware hardware capabilities. With the growing demand for accelerators for medical sterilization, food irradiation, cancer treatment, and imaging, improving the signal processing of these machines will increase the margin for the deployment of these systems. Our work is focusing on using machine learning techniques to reduce the noise of RF signals used for pulse-to-pulse feedback in industrial accelerators. We will review our algorithms, simulation results, and results working with measured data. We will then discuss next steps for deployment and testing on an industrial system.