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iStock/gorodenkoffThis blog is the first in a four-part series on the beginner's guide to Industrial Artificial Intelligence applications.
Welcome knowledge seeker! Do you feel dazzled and awed by the great potential of Artificial Intelligence aka AI? Perhaps hesitant or lost when words like 'convolution,' 'deep learning,' or 'autoencoder' are thrown around? Well, fear not, friend, for you have come to just the right place! You don't need to be a computer wizard or a super genius to understand how using AI can impact your system and, more importantly, if using it is worth the investment.
This is a multi-part series aimed at helping you practically evaluate each step of investing in and using an AI-enhanced system or tool in an industrial application. We will address the fundamentals of what an Industrial AI (IAI) is and how that makes it different from your everyday AI. We discuss its development, considerations in training and concepts for practical evaluation in a live or test-grade environment. We won't be covering everything you would need to know, but we will give you a good flavor of what, when, and why of assessing your IAI.
So come along with us as we look at the fundamentals of Industrial AI acumen!
Finding the best application for AI
Let's take a look at a few hypothetical scenarios where AI might be applied in industrial applications.
Sam is considering purchasing an AI-enabled part-tracking system that will cost hundreds of thousands of dollars to install and maintain. Is it worth it?
Robin wants to protect and monitor their high-value Computer Numerical Control (CNC) Milling Machine in their startup production facility. Should they buy the newer, more expensive model with AI Adaptric Proto Interegatrix ' Technology, or can they save some money and buy the older model with standard built-in audio monitoring?
Casey wants to use the latest Machine Learning (ML) technology to develop an AI-driven box that can determine the health of a planetary gearbox from observing 100+ hours of operations data. How can they sell this idea to their supervisor?
I have been in the fields of reliability engineering and AI analytics for nearly 20 years. In that time, I have seen some ingenious and inexplicable applications of AI to problems from the mundane to the bizarre. These have led me to create 10 basic questions that everyone should ask when considering or evaluating an AI-driven tool.
Why is AI needed for this problem?
Has this technology been proven on a (sufficiently) comparable system/problem?
Is the training data relevant to the task?
Does the training data provide sufficient coverage/characterization of the problem?
Is the model optimizing/training for the things you think it is?
Has the model had sufficient training?
Are any model/domain assumptions being violated?
Are the relationships being captured sensible?
Is this model overfitting data?
Are you looking at the appropriate performance metrics?
AI will be with us in the long run and that's not a bad thing! AI can make our lives simpler, easier, and more efficient in many ways. If we ascribe to the axiom that the simplest tool for the job is the best from the perspective of maintaining and using that tool, then any additional complexity added by an AI system should also have a proportional level of additional benefit.
While this axiom could be considered true in a broad sense, it becomes especially important when considering high-risk or high-value assets in industrial or economically high-stakes settings. In these settings, we must ask ourselves some rendition of the following questions:
How do we ensure that the AI is doing what we think it is?
How can we tell when the AI is worth the added price, complexity, or risk?
How do we know we need AI at all?
What is IAI?
IAI is the intersection of Rules-Based Decision Making, Machine Learning, and Human Insight. Importantly, IAI typically adheres to three fundamental principles:
IAI systems and models are made to solve a known problem or provide some explicit benefit.
Solutions that fulfill requirements and are easier to understand, verify, and maintain are preferred unless there is a known reason not to.
Justifications for modeling choices come from the greater context of the application.
These have some implications that will help determine what philosophical goals we should address.
Providing performance benefits
The first principle implies that any evaluations must be directed toward the desired outcome of the larger system. Simple accuracy or precision measures may not be enough to determine the true impact of an AI-enhanced product without the context of the system in which it is applied. The successful impact of using an AI-enhanced product should result in benefits in terms of system-level performance or financial measures.
Furthermore, solutions that worked last year may not meet today's needs. Problems can arise because the distribution of inputs to the AI model may change over time. For example, a model that estimates HVAC use from historical weather data may deteriorate if underlying weather patterns, sensing systems, or even if the usage patterns or internal environment change. Categorically, AI systems lose efficacy as the learned relationships between their inputs and outputs no longer produce the required results. The clear solution to this situation involves the evaluation of both the system and your AI tool as a continual or periodic process.
Solutions that fulfill requirements
The second principle provides us with the perspective that practical use for the end user is the highest priority. A solution may be technically correct, but if it does not perform the task the user wants, when and how they want it, it could fail to engage the user and be worthless. Instead, the task should be performed in a manner the user understands and feels confident that they can guide. Providing a simple solution to understand, maintain, and operate is the most time-tested and reliable way to ensure the end user is willing and able to use the AI.
Justifying model choices
Our last principle highlights that solutions are not applied in a void. This means they must not correspondingly be developed or evaluated in a way agnostic to the domain and specific application. The application or use case dictates so much about the inputs, assets, and requirements for an AI tool that it seems misguided to try to ignore that information when developing or assessing tools for it.
10 common pitfalls of IAI development
Without assessment and evaluation against these philosophical waypoints, many IAI applications fail in their task or design. Time and again, I have encountered ten elementary mistakes that ultimately contribute to some failure of the IAI, everything from adding unnecessary complexity to a well-understood problem to unreasonable expectations in performance. More insidious and subtle are the occasions where nothing seems wrong, but the application spits out nonsensical or trivial output.
The ten most common pitfalls in IAI applications can be summarized as:
Creating an AI System that is
technically
correct, but
functionally
useless
or unnecessarily complex
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Not learning long enough
Basing expectations on cases that are not
sufficiently
comparable to the target environment
Every model has assumptions, if you don't know your assumptions, keep asking
Learning from the wrong information
Egregious anomalies are not the only bad actors in data
Learning in too small a space
Claims of 100% accuracy 100% of the time are 100% inaccurate, 100% of the time
Learning to solve the wrong problem
No single number can tell a complete story
Ask about the key elements of your IAI system
Knowing the key elements of your system can lead to a simple breakdown of any model or tool that performs a function.
The need for the tool: What is the task or goal?
What the tool uses: What are the inputs?
How the tool works: Are the internal parts doing something you can understand?
What the tool does: What outputs does it give and how reasonable are they?
If we treat this evaluation as an assessment of a closed box (also known as a black box), we can examine it in three stages.
What is going into the box? You will need to know the characteristics of the training data, what preprocessing has been/needs to be done, and what (if any) parameters/hyperparameters the model needs.
What is inside the box? You will need to know the model assumptions, what type of inputs the model is looking for, how the model trains, and what types of relationships the model is capturing/recreating.
What is the box giving back? You will need to know the model's reliable input range, the units being reported, and the scenarios that can cause it to fail.
As we progress through this blog series, we will address each of these stages to examine the risks and benefits of an IAI application and provide a practical philosophy for assessing any IAI tool you may come across. This will lead us through the working philosophy of understanding when an IAI system is appropriate and adds value to the situation. Many of the ideas and concepts prompted here apply beyond AI or Machine Learning applications, but our focus will be on any tool that ingests data or information and outputs some form of decision support or control action.
Equipped with the appropriate information and tools, you will be in a better position to make the best decisions about adding IAI to your operations.
Robots, robotics and automation are used almost interchangeably but have different meanings. Robots are the actual robot arms you see in a factory setting, and robotics is the technology that involves conception, design, construction, and operation of robots in manufacturing. Automation is defined as a technology that uses mechanical, electronic, and computer-based systems in operation and control of production. An automated robot system uses many components to autonomously complete a task.
Take the following items into account:
A robot needs additional equipment to be operational and to carry out tasks. Here are a few examples:
Every robot manufacturer uses its own programming language, however ours is an engineer's best friend. Kawasaki Robotics' programming platform is comprised of three powerful, intuitive, and flexible programming languages for the most basic to complex applications ' we don't limit your potential.
Industrial robot arms are ideal for tasks that aren't ideal for humans. Here's a list of criteria:
For the right application, robotic systems provide a wealth of benefits for the end user. A robot can run non-stop at a defined speed without supervision, which provides you the opportunity to increase production volumes.
Another benefit of robotic automation is consistency. Robots run with high repeatability and accuracy, and that is reflected in improved part quality. And by allowing robots to handle non-human-friendly tasks, employers can re-skill their workforce to more fulfilling work in a safer environment.
When transitioning from a manual to automated process, you may have to make some changes to your part design, tooling, and fixtures to make sure it's suited for automation. This investment will be justified in the cost savings you see once your cell is up and running.
It's important to select a system integrator that will supply the robot system from the get-go. You want to partner with tenured experts that have expertise in concepting, designing, constructing, and commissioning the robot system. But don't forget you're the expert in manufacturing your product ' it's the combination of your expertise and their experience that results in successful applications.
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