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Real-Time Early Warning System for Sustainable and Intelligent Plastic Film Manufacturing

1
Division of Computer Science and Engineering, Sunmoon University, 70, Sunmoon-ro 221 beon-gil, Tangjeong-myeon, Asan-si 31460, Korea
2
Graduate School of Information, Yonsei University, 50, Yonsei-ro, Seodaemun-gu, Seoul 03722, Korea
*
Author to whom correspondence should be addressed.
Sustainability 2019, 11(5), 1490; https://doi.org/10.3390/su11051490
Received: 1 January 2019 / Revised: 5 March 2019 / Accepted: 7 March 2019 / Published: 12 March 2019
(This article belongs to the Special Issue Sustainable Intelligent Manufacturing Systems)
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Abstract

In this study, real-time preventive measures were formulated for a crusher process that is impossible to automate, due to the impossibility of installing sensors during the production of plastic films, and a real-time early warning system for semi-automated processes subsequently developed. First, the flow of a typical film process was ascertained. Second, a sustainable plan for real-time forecasting in a process that cannot be automated was developed using the semi-automation method flexible structure production control (FSPC). Third, statistical early selection of the process variables that are most probably responsible for failure was performed during data preprocessing. Then, a new, unified dataset was created using the link reordering method to transform the time sequence of the continuous process into one time zone. Fourth, a sustainable prediction algorithm was developed using the association rule method along with traditional statistical techniques, and verified using actual data. Finally, the overall developed logic was applied to new production process data to verify its prediction accuracy. The developed real-time early warning system for semi-automated processes contributes significantly to the smart manufacturing process both theoretically and practically. View Full-Text
Keywords: sustainable manufacturing; plastic film; semi-automation; flexible structure production control (FSPC); association rule; real-time early warning system sustainable manufacturing; plastic film; semi-automation; flexible structure production control (FSPC); association rule; real-time early warning system
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Kim, J.; Hwangbo, H. Real-Time Early Warning System for Sustainable and Intelligent Plastic Film Manufacturing. Sustainability 2019, 11, 1490.

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