Knowledge-enhanced spatiotemporal analysis for anomaly detection in process manufacturing

Effective fault detection and diagnosis (FDD) is crucial for proactively identifying irregular states that could jeopardize operator well-being and process integrity. In the era of Industry 4.0, data-driven FDD techniques have received particular attention, driven by the proliferation of stored manufacturing sensor data. While these methods have proven adept at categorizing established process fault scenarios, there remains an imperative to identify and explain anomalies stemming from uncharted faults or the interplay of consecutive anomalies. To address this we present a knowledge-enhanced FDD approach that integrates well-defined chemical engineering knowledge with cutting-edge deep learning techniques. We apply our methodology, named Knowledge-Enhanced Spatiotemporal Analysis (KESA), to identify abnormal process conditions that may be a precursor to failure. Furthermore, we utilize the knowledge of the fundamental relationships governing the process to explain why this fault case has occurred. This type of in-depth fault analysis is only possible through leveraging domain expertise and marks a step forward in FDD technology in comparison to current literature. Using the benchmark Tennessee Eastman process dataset, we establish superiority in the accuracy and efficiency of our KESA model against state-of-the-art FDD algorithms. This work highlights the importance of a knowledge-enhanced approach to deep learning in complex environments, emphasizing the critical role of timely and interpretable fault detection. By providing explanations for model results, our KESA framework not only aids in effective decision-making but also has the potential to significantly reduce the time between fault detection and the implementation of proactive mitigation actions. This capability is paramount for improving overall safety, minimizing downtime, and ultimately contributing to substantial cost savings in industrial processes.