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Defect segmentation is crucial for quality control in advanced manufacturing, yet data scarcity poses challenges for state-of-the-art supervised deep learning. Synthetic defect data generation is a popular approach for mitigating data challenges. However, many current methods simply generate defects following a fixed set of rules, which may not directly relate to downstream task performance. This can lead to suboptimal performance and may even hinder the downstream task. To solve this problem, we leverage a novel bi-level optimization-based synthetic defect data generation framework. We use an online synthetic defect generation module grounded in the commonly-used Cut\&Paste framework, and adopt an efficient gradient-based optimization algorithm to solve the bi-level optimization problem. We achieve simultaneous training of the defect segmentation network, and learn various parameters of the data synthesis module by maximizing the validation performance of the trained defect segmentation network. Our experimental results on benchmark datasets under limited data settings show that the proposed bi-level optimization method can be used for learning the most effective locations for pasting synthetic defects thereby improving the segmentation performance by up to 18.3\% when compared to pasting defects at random locations. We also demonstrate up to 2.6\% performance gain by learning the importance weights for different augmentation-specific defect data sources when compared to giving equal importance to all the data sources.

Code generation stands as a powerful technique in modern software development, improving development efficiency, reducing errors, and fostering standardization and consistency. Recently, ChatGPT has exhibited immense potential in automatic code generation. However, existing researches on code generation lack guidance for practical software development process. In this study, we utilized ChatGPT to develop a web-based code generation platform consisting of key components: User Interface, Prompt Builder and Backend Service. Specifically, Prompt Builder dynamically generated comprehensive prompts to enhance model generation performance. We conducted experiments on 2 datasets, evaluating the generated code through 8 widely used metrics.The results demonstrate that (1) Our Prompt Builder is effective, resulting in a 65.06% improvement in EM, a 38.45% improvement in BLEU, a 15.70% improvement in CodeBLEU, and a 50.64% improvement in Pass@1. (2) In real development scenarios, 98.5% of test cases can be validated through manual validation, highlighting the genuine assistance provided by the ChatGPT-based code generation approach.

Despite progress in vision-based inspection algorithms, real-world industrial challenges -- specifically in data availability, quality, and complex production requirements -- often remain under-addressed. We introduce the VISION Datasets, a diverse collection of 14 industrial inspection datasets, uniquely poised to meet these challenges. Unlike previous datasets, VISION brings versatility to defect detection, offering annotation masks across all splits and catering to various detection methodologies. Our datasets also feature instance-segmentation annotation, enabling precise defect identification. With a total of 18k images encompassing 44 defect types, VISION strives to mirror a wide range of real-world production scenarios. By supporting two ongoing challenge competitions on the VISION Datasets, we hope to foster further advancements in vision-based industrial inspection.

Generative adversarial networks (GANs), trained on a large-scale image dataset, can be a good approximator of the natural image manifold. GAN-inversion, using a pre-trained generator as a deep generative prior, is a promising tool for image restoration under corruptions. However, the performance of GAN-inversion can be limited by a lack of robustness to unknown gross corruptions, i.e., the restored image might easily deviate from the ground truth. In this paper, we propose a Robust GAN-inversion (RGI) method with a provable robustness guarantee to achieve image restoration under unknown \textit{gross} corruptions, where a small fraction of pixels are completely corrupted. Under mild assumptions, we show that the restored image and the identified corrupted region mask converge asymptotically to the ground truth. Moreover, we extend RGI to Relaxed-RGI (R-RGI) for generator fine-tuning to mitigate the gap between the GAN learned manifold and the true image manifold while avoiding trivial overfitting to the corrupted input image, which further improves the image restoration and corrupted region mask identification performance. The proposed RGI/R-RGI method unifies two important applications with state-of-the-art (SOTA) performance: (i) mask-free semantic inpainting, where the corruptions are unknown missing regions, the restored background can be used to restore the missing content; (ii) unsupervised pixel-wise anomaly detection, where the corruptions are unknown anomalous regions, the retrieved mask can be used as the anomalous region's segmentation mask.

This paper proposes a general fixture layout design framework that directly integrates the system equation with the convex relaxation method. Note that the optimal fixture design problem is a large-scale combinatorial optimization problem, we relax it to a convex semidefinite programming (SDP) problem by adopting sparse learning and SDP relaxation techniques. It can be solved efficiently by existing convex optimization algorithms and thus generates a near-optimal fixture layout. A real case study in the half-to-half fuselage assembly process indicates the superiority of our proposed algorithm compared to the current industry practice and state-of-art methods.

Unsupervised pixel-level defective region segmentation is an important task in image-based anomaly detection for various industrial applications. The state-of-the-art methods have their own advantages and limitations: matrix-decomposition-based methods are robust to noise but lack complex background image modeling capability; representation-based methods are good at defective region localization but lack accuracy in defective region shape contour extraction; reconstruction-based methods detected defective region match well with the ground truth defective region shape contour but are noisy. To combine the best of both worlds, we present an unsupervised patch autoencoder based deep image decomposition (PAEDID) method for defective region segmentation. In the training stage, we learn the common background as a deep image prior by a patch autoencoder (PAE) network. In the inference stage, we formulate anomaly detection as an image decomposition problem with the deep image prior and domain-specific regularizations. By adopting the proposed approach, the defective regions in the image can be accurately extracted in an unsupervised fashion. We demonstrate the effectiveness of the PAEDID method in simulation studies and an industrial dataset in the case study.

Display front-of-screen (FOS) quality inspection is essential for the mass production of displays in the manufacturing process. However, the severe imbalanced data, especially the limited number of defect samples, has been a long-standing problem that hinders the successful application of deep learning algorithms. Synthetic defect data generation can help address this issue. This paper reviews the state-of-the-art synthetic data generation methods and the evaluation metrics that can potentially be applied to display FOS quality inspection tasks.

Unstructured point clouds with varying sizes are increasingly acquired in a variety of environments through laser triangulation or Light Detection and Ranging (LiDAR). Predicting a scalar response based on unstructured point clouds is a common problem that arises in a wide variety of applications. The current literature relies on several pre-processing steps such as structured subsampling and feature extraction to analyze the point cloud data. Those techniques lead to quantization artifacts and do not consider the relationship between the regression response and the point cloud during pre-processing. Therefore, we propose a general and holistic "Bayesian Nonlinear Tensor Learning and Modeler" (ANTLER) to model the relationship of unstructured, varying-size point cloud data with a scalar or multivariate response. The proposed ANTLER simultaneously optimizes a nonlinear tensor dimensionality reduction and a nonlinear regression model with a 3D point cloud input and a scalar or multivariate response. ANTLER has the ability to consider the complex data representation, high-dimensionality,and inconsistent size of the 3D point cloud data.

Image-based anomaly detection systems are of vital importance in various manufacturing applications. The resolution and acquisition rate of such systems is increasing significantly in recent years under the fast development of image sensing technology. This enables the detection of tiny defects in real-time. However, such a high resolution and acquisition rate of image data not only slows down the speed of image processing algorithms but also increases data storage and transmission cost. To tackle this problem, we propose a fast and data-efficient method with theoretical performance guarantee that is suitable for sparse anomaly detection in images with a smooth background (smooth plus sparse signal). The proposed method, named Compressed Smooth Sparse Decomposition (CSSD), is a one-step method that unifies the compressive image acquisition and decomposition-based image processing techniques. To further enhance its performance in a high-dimensional scenario, a Kronecker Compressed Smooth Sparse Decomposition (KronCSSD) method is proposed. Compared to traditional smooth and sparse decomposition algorithms, significant transmission cost reduction and computational speed boost can be achieved with negligible performance loss. Simulation examples and several case studies in various applications illustrate the effectiveness of the proposed framework.

Cyber-physical systems (CPS) have been increasingly attacked by hackers. Recent studies have shown that CPS are especially vulnerable to insider attacks, in which case the attacker has full knowledge of the systems configuration. To better prevent such types of attacks, we need to understand how insider attacks are generated. Typically, there are three critical aspects for a successful insider attack: (i) Maximize damage, (ii) Avoid detection and (iii) Minimize the attack cost. In this paper we propose a Stealthy Attack GEneration (SAGE) framework by formulizing a novel optimization problem considering these three objectives and the physical constraints of the CPS. By adding small worst-case perturbations to the system, the SAGE attack can generate significant damage, while remaining undetected by the systems monitoring algorithms. The proposed methodology is evaluated on several anomaly detection algorithms. The results show that SAGE attacks can cause severe damage while staying undetected and keeping the cost of an attack low. Our method can be accessed in the supplementary material of this paper to aid researcher and practitioners in the design and development of resilient CPS and detection algorithms.

Heterogeneous but complementary sources of data provide an unprecedented opportunity for developing accurate statistical models of systems. Although the existing methods have shown promising results, they are mostly applicable to situations where the system output is measured in its complete form. In reality, however, it may not be feasible to obtain the complete output measurement of a system, which results in observations that contain missing values. This paper introduces a general framework that integrates tensor regression with tensor completion and proposes an efficient optimization framework that alternates between two steps for parameter estimation. Through multiple simulations and a case study, we evaluate the performance of the proposed method. The results indicate the superiority of the proposed method in comparison to a benchmark.

Tensor data with rich structural information becomes increasingly important in process modeling, monitoring, and diagnosis. Here structural information is referred to structural properties such as sparsity, smoothness, low-rank, and piecewise constancy. To reveal useful information from tensor data, we propose to decompose the tensor into the summation of multiple components based on different structural information of them. In this paper, we provide a new definition of structural information in tensor data. Based on it, we propose an additive tensor decomposition (ATD) framework to extract useful information from tensor data. This framework specifies a high dimensional optimization problem to obtain the components with distinct structural information. An alternating direction method of multipliers (ADMM) algorithm is proposed to solve it, which is highly parallelable and thus suitable for the proposed optimization problem. Two simulation examples and a real case study in medical image analysis illustrate the versatility and effectiveness of the ATD framework., Comment: This work has been submitted to the IEEE for possible publication

In the machine learning domain, active learning is an iterative data selection algorithm for maximizing information acquisition and improving model performance with limited training samples. It is very useful, especially for the industrial applications where training samples are expensive, time-consuming, or difficult to obtain. Existing methods mainly focus on active learning for classification, and a few methods are designed for regression such as linear regression or Gaussian process. Uncertainties from measurement errors and intrinsic input noise inevitably exist in the experimental data, which further affects the modeling performance. The existing active learning methods do not incorporate these uncertainties for Gaussian process. In this paper, we propose two new active learning algorithms for the Gaussian process with uncertainties, which are variance-based weighted active learning algorithm and D-optimal weighted active learning algorithm. Through numerical study, we show that the proposed approach can incorporate the impact from uncertainties, and realize better prediction performance. This approach has been applied to improving the predictive modeling for automatic shape control of composite fuselage.

Carbon nanotube (CNT) thin sheet, or buckypaper, has shown great potential as a multifunctional platform material due to its desirable properties, including its lightweight nature, high mechanical properties, and good conductivity. However, their mass adoption and applications by industry have run into significant bottlenecks because of large variability and uncertainty in quality during fabrication. There is an urgent demand to produce high-quality, high-performance buckypaper at an industrial scale. Raman spectroscopy provides detailed nanostructure information within seconds, and the obtained spectra can be decomposed into multiple effects associated with diverse quality characteristics of buckypaper. However, the decomposed effects are high-dimensional, and a systematic quantification method for buckypaper quality assessment has been lacking. In this paper, we propose a real-time data-driven quality assessment method, which fills in the blank of quantifying the quality for continuous manufacturing processes of CNT buckypaper. The composite indices derived from the proposed method are developed by analyzing in-line Raman spectroscopy sensing data. Weighted cross-correlation and maximum margin clustering are used to fuse the fixed effects into an inconsistency index to monitor the long-term mean shift of the process and to fuse the normal effects into a uniformity index to monitor the within-sample normality. Those individual quality indices are then combined into a composite index to reflect the overall quality of buckypaper. A case study indicates that our proposed approach can determine the quality rank for ten samples, and can provide quantitative quality indices for single-walled carbon nanotube buckypaper after acid processing or functionalization. The quality assessment results are consistent with evaluations from the experienced engineers.

Estimation of model parameters of computer simulators, also known as calibration, is an important topic in many engineering applications. In this paper, we consider the calibration of computer model parameters with the help of engineering design knowledge. We introduce the concept of sensible (calibration) variables. Sensible variables are model parameters which are sensitive in the engineering modeling, and whose optimal values differ from the engineering design values.We propose an effective calibration method to identify and adjust the sensible variables with limited physical experimental data. The methodology is applied to a composite fuselage simulation problem., Comment: 25 pages, 7 figures, 5 tables

In point-based sensing systems such as coordinate measuring machines (CMM) and laser ultrasonics where complete sensing is impractical due to the high sensing time and cost, adaptive sensing through a systematic exploration is vital for online inspection and anomaly quantification. Most of the existing sequential sampling methodologies focus on reducing the overall fitting error for the entire sampling space. However, in many anomaly quantification applications, the main goal is to estimate sparse anomalous regions in the pixel-level accurately. In this paper, we develop a novel framework named Adaptive Kernelized Maximum-Minimum Distance AKM$^2$D to speed up the inspection and anomaly detection process through an intelligent sequential sampling scheme integrated with fast estimation and detection. The proposed method balances the sampling efforts between the space-filling sampling (exploration) and focused sampling near the anomalous region (exploitation). The proposed methodology is validated by conducting simulations and a case study of anomaly detection in composite sheets using a guided wave test., Comment: Under review in IISE Transaction

Fourier-transform infrared spectroscopy (FTIR) is a versatile technique for characterizing the chemical composition of the various uncertainties, including baseline shift and multiplicative error. This study aims at analyzing the effect of certain treatment on the FTIR responses subject to these uncertainties. A two-step method is proposed to quantify the treatment effect on the FTIR signals. First, an optimization problem is solved to calculate the template signal by aligning the pre-treatment FTIR signals. Second, the effect of treatment is decomposed as the pattern of modification $\mathbf{g}$ that describes the overall treatment effect on the spectra and a vector of effect $\boldsymbol{\delta}$ that describes the degree of modification. $\mathbf g$ and $\boldsymbol{\delta}$ are solved by another optimization problem. They have explicit engineering interpretations and provide useful information on how the treatment effect change the surface chemical components. The effectiveness of the proposed method is first validated in a simulation. In a real case study, it's used to investigate how the plasma exposure applied at various heights affects the FTIR signal which indicates the change of the chemical composition on the composite material. The vector of effects indicates the range of effective plasma height, and the pattern of modification matches existing engineering knowledge well., Comment: \{copyright} 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works

We investigate two important properties of M-estimator, namely, robustness and tractability, in linear regression setting, when the observations are contaminated by some arbitrary outliers. Specifically, robustness means the statistical property that the estimator should always be close to the underlying true parameters {\em regardless of the distribution of the outliers}, and tractability indicates the computational property that the estimator can be computed efficiently, even if the objective function of the M-estimator is {\em non-convex}. In this article, by learning the landscape of the empirical risk, we show that under mild conditions, many M-estimators enjoy nice robustness and tractability properties simultaneously, when the percentage of outliers is small. We further extend our analysis to the high-dimensional setting, where the number of parameters is greater than the number of samples, $p \gg n$, and prove that when the proportion of outliers is small, the penalized M-estimators with {\em $L_1$} penalty will enjoy robustness and tractability simultaneously. Our research provides an analytic approach to see the effects of outliers and tuning parameters on the robustness and tractability for some families of M-estimators. Simulation and case study are presented to illustrate the usefulness of our theoretical results for M-estimators under Welsch's exponential squared loss.

Robust change-point detection for large-scale data streams has many real-world applications in industrial quality control, signal detection, biosurveillance. Unfortunately, it is highly non-trivial to develop efficient schemes due to three challenges: (1) the unknown sparse subset of affected data streams, (2) the unexpected outliers, and (3) computational scalability for real-time monitoring and detection. In this article, we develop a family of efficient real-time robust detection schemes for monitoring large-scale independent data streams. For each data stream, we propose to construct a new local robust detection statistic called $L_{\alpha}$-CUSUM statistic that can reduce the effect of outliers by using the Box-Cox transformation of the likelihood function. Then the global scheme will raise an alarm based upon the sum of the shrinkage transformation of these local $L_{\alpha}$-CUSUM statistics so as to filter out unaffected data streams. In addition, we propose a new concept called {\em false alarm breakdown point} to measure the robustness of online monitoring schemes and propose a worst-case detection efficiency score to measure the detection efficiency when the data contain outliers. We then characterize the breakdown point and the efficiency score of our proposed schemes. Asymptotic analysis and numerical simulations are conducted to illustrate the robustness and efficiency of our proposed schemes.

High dimensional data has introduced challenges that are difficult to address when attempting to implement classical approaches of statistical process control. This has made it a topic of interest for research due in recent years. However, in many cases, data sets have underlying structures, such as in advanced manufacturing systems. If extracted correctly, efficient methods for process control can be developed. This paper proposes a robust sparse dimensionality reduction approach for correlated high-dimensional process monitoring to address the aforementioned issues. The developed monitoring technique uses robust sparse probabilistic PCA to reduce the dimensionality of the data stream while retaining interpretability. The proposed methodology utilizes Bayesian variational inference to obtain the estimates of a probabilistic representation of PCA. Simulation studies were conducted to verify the efficacy of the proposed methodology. Furthermore, we conducted a case study for change detection for in-line Raman spectroscopy to validate the efficiency of our proposed method in a practical scenario.