US 12,189,377 B2
Continous monitoring, advance alerts, and control of key performance indicator variables
Wesley M. Gifford, Ridgefield, CT (US); and Dharmashankar Subramanian, White Plains, NY (US)
Assigned to International Business Machines Corporation, Armonk, NY (US)
Filed by International Business Machines Corporation, Armonk, NY (US)
Filed on Feb. 17, 2021, as Appl. No. 17/177,434.
Prior Publication US 2022/0260977 A1, Aug. 18, 2022
Int. Cl. G05B 19/418 (2006.01); G01F 15/06 (2022.01); G01F 15/075 (2006.01)
CPC G05B 19/41875 (2013.01) [G01F 15/068 (2013.01); G01F 15/0755 (2013.01); G05B 19/4183 (2013.01); G05B 19/41865 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A computer-implemented method comprising:
collecting, by a computer system, sensor data of a manufacturing system, the sensor data being measured at a plurality of intervals smaller than a time interval “T” of a target measurement of the manufacturing system, wherein the sensor data is determined to have a relationship to the target measurement;
generating, by the computer system, a synthetic target measurement at a first interval of the plurality of intervals based on the relationship, the first interval being smaller than the time interval “T”, wherein the computer system employs a machine learning model to generate the synthetic target measurement, the machine learning model comprising a neural network trained on training data comprising historical sensor data and historical target measurement data, wherein training the machine learning model comprises fitting a regression model that relates the sensor data being measured at the plurality of intervals to the historical target measurement data at the time interval “T” through unknown intermediate quality results in which the historical target measurement data are based on equal volumes sampled uniformly over time;
automatically generating, by the computer system, an advance warning for the target measurement based on the synthetic target measurement within the interval smaller than the time interval; and
causing a control system of the manufacturing system to change operation of an actuator in response to the advance warning.