Errors or failures in a high-volume manufacturing environment can have significant impact that can result in both the loss of time and money. Identifying such failures early has been a top priority for manufacturing industries and various rule-based algorithms have been developed over the years. However, catching these failures is time consuming and such algorithms cannot adapt well to changes in designs, and sometimes variations in everyday behavior. More importantly, the number of units to monitor in a high-volume manufacturing environment is too big for manual monitoring or for a simple program. Here we develop a novel program that combines both rule-based decisions and machine learning models that can not only learn and adapt to such day-to-day variations or long-term design changes, but also can be applied at scale to the high number of manufacturing units in use today. Using the current state-of-the-art technologies, we then deploy this program at-scale to handle the needs of ever-increasing demand from the manufacturing environment.

With the rapid development of AI technology in recent years, there have been many studies with deep learning models in soft sensing area. However, the models have become more complex, yet, the data sets remain limited: researchers are fitting million-parameter models with hundreds of data samples, which is insufficient to exercise the effectiveness of their models and thus often fail to perform when implemented in industrial applications. To solve this long-lasting problem, we are providing large scale, high dimensional time series manufacturing sensor data from Seagate Technology to the public. We demonstrate the challenges and effectiveness of modeling industrial big data by a Soft Sensing Transformer model on these data sets. Transformer is used because, it has outperformed state-of-the-art techniques in Natural Language Processing, and since then has also performed well in the direct application to computer vision without introduction of image-specific inductive biases. We observe the similarity of a sentence structure to the sensor readings and process the multi-variable sensor readings in a time series in a similar manner of sentences in natural language. The high-dimensional time-series data is formatted into the same shape of embedded sentences and fed into the transformer model. The results show that transformer model outperforms the benchmark models in soft sensing field based on auto-encoder and long short-term memory (LSTM) models. To the best of our knowledge, we are the first team in academia or industry to benchmark the performance of original transformer model with large-scale numerical soft sensing data.

IEEE BigData 2021 Cup: Soft Sensing at Scale is a data mining competition organized by Seagate Technology, in association with the IEEE BigData 2021 conference. The scope of this challenge is to tackle the task of classifying soft sensing data with machine learning techniques. In this paper we go into the details of the challenge and describe the data set provided to participants. We define the metrics of interest, baseline models, and describe approaches we found meaningful which may be a good starting point for further analysis. We discuss the results obtained with our approaches and give insights on what potential challenges participants may run into. Students, researchers, and anyone interested in working on a major industrial problem are welcome to participate in the challenge!