Using radial basis function neural networks to recognize shifts in correlated manufacturing process parameters

Traditional statistical process control (SPC) techniques of control charting are not applicable in many process industries because data from these facilities are autocorrelated. Therefore the reduction in process variability obtained through the use of SPC techniques has not been realized in process industries. Techniques are needed to serve the same function as SPC control charts, that is to identify process shifts, in correlated parameters. Radial basis function neural networks were developed to identify shifts in process parameter values from papermaking and viscosity data sets available in the literature. Time series residual control charts were also developed for the data sets. Networks were successful at separating data that were shifted 1.5 and 2 standard deviations from nonshifted data for both the papermaking and viscosity parameter values. The network developed on the basis of the papermaking data set was also able to separate shifts of 1 standard deviation from nonshifted data. The SPC control charts were not able to identify the same process shifts. The radial basis function neural networks can be used to identify shifts in process parameters, thus allowing improved process control in manufacturing processes that generate correlated process data.