Computer-Implemented Method for Detecting Deviations in a Production Process

A computer-implemented method for detecting deviations in a production process with process parameters, a computing device with a memory being provided, the method comprising:

• a) providing reference process data from a reference production process, which comprises reference parameters for the production process, to the computing device;
• b) generating and training a process model with model nodes and assigning model weights based on an autoencoder utilizing the reference process data;
• c) at least partially assigning model nodes of the process model to process parameters of the production process;
• d) providing current process data from a current production process, which comprises current parameters of the production process, to the computing device;
• e) ascertaining process deviations of the current process data utilizing the process model by determining a reconstruction error and outputting the model weights of the model nodes, as well as ascertaining individual contributions of model nodes to the process deviations and determining at least one individual contribution which lies outside a predetermined value range for the respective contribution;
• f) estimating a future course of the reconstruction error from the currently determined production error and at least one previously determined reconstruction error for a predetermined duration and storing the reconstruction error in the memory as at least one previously determined reconstruction error for a subsequent estimate;
• and
• g) performing a check to determine whether the estimated future course of the reconstruction error for the predetermined duration lies within a predetermined value range and, if the estimated future course of the reconstruction error for the predetermined duration lies within the predetermined value range, continuing with step d), otherwise outputting an alarm and transmitting the at least one individual contribution ascertained in step e) to the reference production process and utilizing the at least one individual contribution ascertained in step e) in a subsequent production process in step d).

A computing device for detecting deviations in a production process with process parameters comprising:

• a memory;
• wherein the computing device is configured to:
• a) receive reference process data from a reference production process, which comprises reference parameters for the production process;
• b) generate and train a process model with model nodes and assig model weights based on an autoencoder utilizing the reference process data;
• c) at least partially assign model nodes of the process model to process parameters of the production process;
• d) receive current process data from a current production process, which comprises current parameters of the production process;
• e) ascertain process deviations of the current process data utilizing the process model by determining a reconstruction error and output the model weights of the model nodes, as well as ascertain individual contributions of model nodes to the process deviations and determine at least one individual contribution which lies outside a predetermined value range for the respective contribution;
• f) estimate a future course of the reconstruction error from the currently determined production error and at least one previously determined reconstruction error for a predetermined duration and store the reconstruction error in the memory as at least one previously determined reconstruction error for a subsequent estimate;
• and
• g) perform a check to determine whether the estimated future course of the reconstruction error for the predetermined duration lies within a predetermined value range and, if the estimated future course of the reconstruction error for the predetermined duration lies within the predetermined value range, continue with step d), otherwise output an alarm and transmit the at least one individual contribution ascertained in step e) to the reference production process and utilize the at least one individual contribution ascertained in step e) in a subsequent production process in step d).

A non-transitory electronically readable data carrier with readable control information stored thereon, which comprises at least a computer program which, when executed by a computer of a computing facility, causes detection of deviations in a production process with process parameters, the computer program comprising:

• a) program instructions for providing reference process data from a reference production process, which comprises reference parameters for the production process, to a computing device;
• b) program instructions for generating and training a process model with model nodes and assigning model weights based on an autoencoder utilizing the reference process data;
• c) program instructions for at least partially assigning model nodes of the process model to process parameters of the production process;
• d) program instructions for providing current process data from a current production process, which comprises current parameters of the production process, to the computing device;
• e) program instructions for ascertaining process deviations of the current process data utilizing the process model by determining a reconstruction error and outputting the model weights of the model nodes, as well as ascertaining individual contributions of model nodes to the process deviations and determining at least one individual contribution which lies outside a predetermined value range for the respective contribution;
• f) program instructions for estimating a future course of the reconstruction error from the currently determined production error and at least one previously determined reconstruction error for a predetermined duration and storing the reconstruction error in memory as at least one previously determined reconstruction error for a subsequent estimate;
• and
• g) program instructions for performing a check to determine whether the estimated future course of the reconstruction error for the predetermined duration lies within a predetermined value range and, if the estimated future course of the reconstruction error for the predetermined duration lies within the predetermined value range, continuing with step d), otherwise outputting an alarm and transmitting the at least one individual contribution ascertained in step e) to the reference production process and utilizing the at least one individual contribution ascertained in step e) in a subsequent production process in step d).