Artificial Neural Networks in Manufacturing Concepts Applications and Perspectives-Hb3

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Artificial neural networks in manufacturing:

Concepts, applications, and perspectives
Article in IEEE Transactions on Components Packaging and Manufacturing Technology Part A July 1994
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A, VOL. 17, NO. 2, JUNE 1994
Artificial Neural Networks in Manufacturing:

Concepts, Applications, and Perspectives
Samuel H. Huang and Hong-Chao Zhang
Abstract- New approaches and techniques are continuously

and rapidly introduced and adopted in todays manufacturing environment. Recently, there is an explosion of interest in
applying artificial neural networks to manufacturing. Artificial
neural networks have several advantages that are desired in
manufacturing practice, including learning and adapting ability,
parallel distributed computation, robustness, etc. There is an
expectation that neural network techniques can lead to the
realization of truly intelligent manufacturing systems. This paper
introduces the basic concepts of neural networks and reviews the
current application of neural networks in manufacturing. The
problems with neural networks are also identified and some possible solutions are suggested. We hope that the material presented
in this paper can provide useful guidelines and references for the
research and implementation of artificial neural networks in the
field of manufacturing.
I. INTRODUCTION
ANUFACTURING is a set of correlated operations

and activities, which includes product design, material
selection, planning, production, inspection, management, and
marketing of the products, for the manufacturing industries
11. Computers are commonly used in modern manufacturing
practice. In the late 1960s, computers were first used for
the direct control of groups of machine tools. In the 1970s,
the concept of flexible manufacturing system (FMS) was
introduced. An FMS is a computer-controlled grouping of
semi-independent work stations linked by automated materialhandling systems [2]. Systems of this type are capable of
producing a variety of products automatically. They are now
widely used in the manufacturing industry. Currently, the
development of computer-aided manufacturing systems is advanced to the stage where computer integrated manufacturing
(CIM) systems are in a rapid, world-wide proliferation. A
CIM system results when the design effort includes the use
of computers to achieve an integrated flow of manufacturing
activities, based on integrated information flow that links
together all organizational activities [3]. It is becoming clear
that the next stage will be that of intelligent manufacturing
systems (IMS). The systems belonging to this stage may
be characterized by their ability to solve problems without
either a detailed, explicit algorithm available for each solution
procedure, or all the facts, mathematical relationships and
Manuscript received November 15, 1993; revised February
1994. This
paper was presented at the International Electronics Manufacturing Symposium, Santa Clara, CA, October
1993.
The authors are with the Department of Industrial Engineering, Texas Tech
University, Lubbock, TX 79409-3061 USA.
IEEE Log Number 9401776.
models available in perfect arrangement and complete form

for a deterministic (and unique) answer to be found [4].
Since the decision-making process in an advanced manufacturing system environment is becoming increasingly difficult
and overwhelming to humans, artificial intelligence (AI) is
widely adopted to assist human efforts. Artificial intelligence
is an unfortunate choice of title for an ill-defined technology
that may, in the long run, be the single most important and
most pervasive ingredient for the realization of true computerintegrated manufacturing (CIM) [5]. AI has provided several
techniques with applications in manufacturing. Knowledgebased expert systems are the most popular AI techniques in the
1980s. Recently, there is an explosion of interest in applying
artificial neural networks to manufacturing. Artificial neural
networks are a type of AI that have the potential of increasing
the product quality, reducing the reaction time of a manufacturing system, improving system reliability and enhancing
its intelligence [6]. Since the late 1980s, hundreds of papers
have been published pertaining to neural network applications
in manufacturing. Most of them are widely scattered over
many different disciplines and publications. This makes it
very difficult for one to locate all the information necessary
for using artificial neural networks in manufacturing. A paper
that can help researchers and practitioners in applying this
emerging technology is highly desired.
The objective of this paper is to present the concepts,
applications, and perspectives of artificial neural networks
in manufacturing, thus providing some useful guidelines and
references for the research and implementation. Section 2
of this paper reviews the development of neural network
techniques and introduces the basic concepts of artificial
neural networks. Section 3 gives a comprehensive survey
of neural network applications in manufacturing. Section 4
identifies the problems with artificial neural networks and
suggests that neural network techniques should be combined
with knowledge-based expert system techniques in order to
develop intelligent manufacturing systems. This is followed
by a conclusion section.
11. ARTIFICIALNEURALNETWORKS
A. Historical Overview
The development of artificial neural networks has an interesting history. In the 1940s, scientists found out that the
physiology of the brain was similar to the processing mode
used by electronic computing devices (computers). In both
cases, large amounts of data are manipulated. In computers, the
0162-8828/94$04.00 0 1994 IEEE
Authorized licensd use limted to: IE Xplore. Downlade on May 10,2 at 19:0537 UTC from IE Xplore. Restricon aply.
HUANG AND ZHANG: ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING
processing element is the bit, while in the brain, the processing

element is the neuron. This phenomenon suggests that research
in the design of brain-like processing might be interesting. In
1943, McCulloch and Pitts [7] outlined the first formal model
of an elementary computing neuron. Their neuron model
laid the groundwork for future development. In 1949, Hebb
[8] stated that information can be stored in connections and
proposed a learning scheme for updating a neurons connections. His learning rule (known as the Hebbian leaming rule)
made a primary contribution to the development of artificial
neural networks. In 1954, Farley and Clark [9] set up models
for adaptive stimulus-response relations in random networks.
Their theories were further elaborated by several researchers.
Rosenblatt 101 invented the perceptron, which is a trainable
machine capable of learning to classify certain patterns by
modifying connections to the threshold elements. Caianiello
[ l l ] outlined a theory for thinking machines. Widrow and
Hoff 121 introduced a device called ADALZNE (for ADAptive
LINEar combiner). A learning rule (the popular Widrow-Hoff
leaming rule) was then devised for neural networks with
multiple adaptive elements 131. Other early works include
Starks mode-seeking technique 141 and Steinbuchs Learning
Matrix [15]. A book on learning machines by Nilsson [16]
clearly summarizes many of these early developments. The
book also formulates inherent limitations of learning machines
with modifiable connections.
During the 1950s, the first neurocomputer was built and
tested 171. Many implementations of neural computers were
realized in the 1960s. However, the existing machine learning
theorems of that time were too weak to support more complex
computational problems. The computational resources available were also relatively modest at that time. As a result, neural
network research entered a stagnation phase. In 1969, Minsky
and Papert 181 criticized the existing neural network research
as being worthless in their book entitled Perceptrons. It has
been claimed that the pessimistic views presented in this book
discouraged further funding for neural network research for
several years. Instead, funding was diverted to further research
of knowledge-based expert systems, which Minsky and Papert
favored.
It is only after the mid-1980s that neural networks have
begun to make a strong comeback. The renaissance of neural
networks is the result of rigorous works by a handful of
researchers. In Japan, Amari [19], [20] studied the learning in
networks of threshold elements and the mathematical theory
of neural networks. Also in Japan, Fukushima [21], [22]
developed a class of neural network architectures known as
Cognitrons and Neocognitrons. In Finland, Kohonen [23],
[24], [25] pursued the research on associative memory. He
also developed unsupervised learning networks for feature
mapping into regular arrays of neurons [26]. Carpenter and
Grossberg [27], [28], [29], [30] introduced a number of neural
network architectures and theories and developed the Adaptive
Resonance Theory (ART). Hopfield [31], [32] developed a
recurrent neural network architecture for associative memories
in the early 1980s. More recently, Kosko [33] extended
some of the ideas of Hopfield and Grossberg to develop his
adaptive bidirectional associative memory (BAM) network.
Fig.
213
An artificial neuron.
Hinton [34], [35] developed a probabilistic neural network

model known as the Boltzmann Machine. Other significant
contributors include Anderson [36], Werbos [37], Rumelhart
[38], etc.
The overview provided above is by no means complete.
Readers who are interested in more details may refer to
[39], [40], [41]. One more thing worth mentioning here is
the publication of a two-volume set of books on parallel
distributed processing. It is believed that these two books,
edited by Rumelhart and McClelland [42], revitalized the
field of neural network research. Beginning in 1986-87, many
new research programs in neural networks were initiated. The
intensity of research in neural networks can be measured by a
quickly growing number of conferences and journals devoted
to this field.
B. Basic Concepts
Artificial neural networks have been defined by Kohonen as

massively parallel interconnected networks of simple (usually
adaptive) elements and their hierarchical organizations which
are intended to interact with the objects of the real world in
the same way as biological nervous system do 1431. Neural
networks attempt to achieve good performance via dense
mesh of computing nodes and connections. They also go by
many names such as connectionist models, parallel distributed
processing models, and neuromorphic systems. We will use
the term neural networks or simply networks in the following
discussion. Neural networks have the following main benefits
[61:
1) processing speed through massive parallelism;
2) learning and adapting ability by means of efficient
knowledge acquisition;
3) robustness with respect to fabrication defects and different failures;
4) compact processors for space- and power-constrained
applications, etc.
The basic components of a neural network are nodes (neurons) and weights (connections). The adjustable weights correspond to biological synapses. A positive weight represents
an excitatory connection. A negative weight represents an
inhibitory connection. The weighted inputs to a neuron are
accumulated and then passed to an activation function which
determines the neurons response. Fig. 1 shows an artificial
neuron with weighted connections.
IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY-PART A, VOL. 17, NO. 2, JUNE 1994
Fig. 2.
Neural networks:
Fig. 3.
a back-propagation network, (b) a Hopfield network, and (c) an ART network.
A taxonomy of neural network models.
The output of a neuron is given as

o
f(net)
in which
f ( n e t ) is referred to as an activation function. Typical activation functions used are

2
f ( n e t ) 1 e--X.net - 1
(3)
or
in which the parameter

0) is used to control the
steepness of the continuous function f ( n e t ) near n e t
0.
There are also other types of activation functions that can be
used. Readers may refer to [44],
for more details about
model neurons and activation rules.
A neural network is a collection of interconnected neurons
(Fig. 2). A neural network may be distinguished on the
basis of the directions in which signals flow. Basically, there
are two types of networks, i.e., feedforward networks and
recurrent networks. In a feedforward network (Fig. 2(a)),

signals propagate in only one direction from an input stage
through intermediate neurons to an output stage. While in a
recurrent network (Fig. 2(b) and (c)), signals may propagate
from the output of any neuron to the input of any neuron.
Neural networks are able to store experiential knowledge
through learning from examples. They can also be classified
in terms of the amount of guidance that the learning process
receives from an outside agent. An Unsupervised learning
network learns to classify the input into sets without being
told anything. A Supervised learning network adjusts weights
on the basis of the difference between the values of output
units and the desired values given by the teacher, given an
input pattern
C. Network Models
Today, more than a dozen neural network models have been
developed. For the purpose of study, analysis, understanding,
and utilization, it is necessary to provide an overview and
taxonomy of neural network models. Fig. 3 summarizes the
taxonomy of the most important network models.
Since this paper is focused on the application of neural
networks in manufacturing, we have no intention of discussing
every network model in detail. Instead, we will briefly in-
HUANG AND ZHANG. ARTIF'ICIAL NEURAL NETWORKS IN MANUFACTURING
troduce three types of network models that are very popular

in manufacturing applications. There are back-propagation
networks, Hopfield networks, and ART networks. Readers may
refer to [41],
for detailed information about different
network models and learning algorithms.
Back-propagation networks are multi-layered feedforward
neural networks that apply the error back-propagation procedure [38] for learning. The back-propagation procedure uses
a gradient descent method which adjusts the weight in its
original and simplest form by an amount proportional to the
partial derivative of the error function with respect to the given
weight. The formula used for the adjustment is
evolves to an equilibrium state. Therefore, one may design a

neural network for function minimization by associating variables in an optimization problem with variables in the energy
function. Hopfield and Tank illustrated the use of the energy
function to configure networks for several optimization applications including the traveling salesman problem [47], a signal
processing problem [48], and a linear programming problem
In manufacturing applications, Hopfield networks are
typically used for solving combinatorial optimization problems
such as scheduling problems.
ART networks are neural networks based on the Adaptive Resonance Theory (ART) provided by Carpenter and
Grossberg [29]. They belong to the class of unsupervised
8E
learning networks. An ART network selects its first input as
Wij(t
1) W i j ( t ) 7)8Wij
the exemplar for the first cluster. The next input is compared
in which 17 is a user-selected, positive constant called learning to the first cluster exemplar. It is clustered with the first if the
rate. The error back-propagation is a typical supervised learn- distance to the first cluster is less than a threshold. Otherwise
ing procedure. The learning procedure of a back-propagation it is the exemplar for a new cluster. This procedure is repeated
for all following inputs. If an input is clustered with the jth
network is as follows:
cluster, the weights of the network are updated according to
1) Initialize the weights of the network at small random
the following formulae
values.
2) Start the learning cycle by exposing the network to a
certain input pattern paired with the desired output.
(7)
3) Compute the network's output and compare it with the
Vij(t
1) X i V i j ( t )
desired output so that the error can be calculated.
4) Adjust the weights of the network using the error backpropagation algorithm so that a certain amount of the where i
1,
M. Carpenter and Grossberg's ART2
detected error is removed.
architecture, which works for analog and binary input pattern
Repeat step (2), (3), and (4) with all the input pat- as well, embodies solutions to a number of design principles
terns and their correspondent desired outputs (training such as the stability-plasticity tradeoff and the search-direct
examples), compute the cumulative error.
access tradeoff. ART networks use an unsupervised learning
6) If the cumulative error is within a tolerable range, procedure. They are stable because new input patterns do
terminate the training process; otherwise, go back to not wash away previously learned information. They are also
step (2).
adaptive because new information can be incorporated until
Back-propagation networks can be applied to almost all the full capacity of the architectures is utilized. ART networks
applications in the manufacturing domain. In fact, they are provide a fertile ground for gaining a new understanding of
the most popular neural network models in manufacturing biological intelligence. They also suggest novel computational
theories and real-time adaptive architectures with promising
applications.
Hopjield networks are recurrent networks introduced by properties for tackling some of the outstanding problems
Hopfield [31], [32]. The earliest Hopfield network, which in computer science and technology [29]. In manufacturing
employs two-state
neurons, is used for the design of applications, ART networks have been used in solving group
neural content-addressablememories [311. Hopfield later intro- technology (GT) and engineering design problems. It seems
duced a modified version of his earlier model that employed a the family of the ART networks can act as very valuable
continuous nonlinear function to describe the output behavior modules in intelligent manufacturing systems, where real-time
of the neurons. The neurons represent an approximation to classification abilities with self-learning and self-organizing
biological neurons in which a simplified set of important com- capabilities are required [6].
putational properties is retained. This neural network model,
which consists of nonlinear graded-response model neurons
organized into networks with effectively symmetric synaptic
111. MANUFACTURING
APPLICATIONS
connections, can be easily implemented with electronic devices
The development of computer-aided manufacturing systems
[46]. A Hopfield network can be characterized by its energy
has evolved to the phase of computer integrated manufacfunction, as shown below:
turing (CIh4). It has been proposed that the next phase will
be that of intelligent manufacturing systems (IMS). As a
I n
E
~ w i j v i v j kiivi g t i v i .
(6) trend, manufacturing systems are demanding more and more
i = l j=1
i=l
i=l
flexibility in product design, process planning, scheduling,
process control, and quality assurance. This may be achieved
The network will seek to minimize the energy function as it by building intelligent systems that can adapt to changes in
--r
IEEE TRANSACTIONS ON COMPONENTS. PACKAGING, AND MANUFACTURING TECHNOLOGY-PART A, VOL. 17, NO. 2, JUNE 1994
their environment. The first effort in this endeavor is the

application of knowledge-based expert systems. Since the late
1970s, knowledge-based systems have been used in various
manufacturing domains [49]. However, they are less effective
in the ever-changing, complex, and open system environment
of today's manufacturing systems [50]. On the other hand,
neural networks emerged as a revolutionary technology for
solving problems that are intractable or difficult for traditional
computation. Successful applications of this technology in
pattern matching and speech recognition generated enormous
interest in the manufacturing arena. Since the late 1980s, neural network applications in manufacturing have been reported.
The application area of neural networks in manufacturing is
surprisingly broad. It covers nearly all of the fields spreading
from the design phase through process planning, scheduling
and process monitoring to quality assurance. This section provides a comprehensive survey of neural network applications
in manufacturing.
A. Design
Retrieval of old product designs that meet current requirements on geometrical and/or technical information is a
problem that is often encountered in batch manufacturing
systems. Venugopal and Narendran [51] modeled the design
retrieval system as a human associative memory and used a
Hopfield network to develop a design retrieval system. The
system was verified with test cases on rotational as well as
non-rotational parts. The results show that neural network
methodology is a promising tool for the development of
practical design retrieval systems. The use of neural networks
for design data retrieval was also studied by Kamarthi et
al. [52]. Instead of Hopfield networks, a back-propagation
network was used. The result is also promising.
Kumara [53], [54] suggested an associative memory based
modeling procedure for conceptual design. The motivation for
their research stems from the following discussion [54]:
It is possible that the designer may be aware of the
structures that satisfy a particular set of functions. In
his memory the designer may have stored the representations of a number of physical devices (design solutions).
Given a (a set
functional requirement(s) the designer
will be able to identify a structure or a set of structures
that will satisfy the required function(s) and hence by
associating these structures with physical devices stored
in his memory, he can selectively retrieve those designs.
It must be noted that the physical devices could be from
different domains. After having retrieved the designs,
the designer mutates them to come up with new and
creative design solutions.
The author used a back-propagation network for modeling
the associative memory. A design model based on associative
memory is also proposed to capture the conceptual design
process (Fig. 4).
The application of neural networks in design also has
been studied by quite a few other researchers. Among them,
Coyne and Postmus [55] explored the application of neural
networks to simple spatial reasoning in computer-aided design.
I
Fig.
Design model based on associative memory
Arai and Iwata [56] suggested a four-layer neural network to

connect lower level items to upper level ones on the design
specification step of the conceptual design phase. Kim et
al. [57] applied a neural network approach for engineering
drawing with geometrical constraints. Dhingra and Rao [58]
examined a new conceptual framework for solving design
optimization problems based on a neural computing paradigm.
Another interesting study was conducted by Chovan and
Waldron [59]. The authors proposed a cognitive model of
the transformation from perceived form to function based
on findings from a behavioral study of expert mechanical
designers when they were reading two dimensional mechanical
drawings. The model was simulated using an ART network
and was exercised and compared with findings from the
behavioral study. The top-down and bottom-up reasonings
exhibited by the subjects can be easily represented in the
ART network. Their results show that ART networks might
be useful for representing the behavioral system. The evidence
demonstrated in their paper may provide useful information for
the application of neural networks as the research community
works toward the development of intelligent computer-aided
systems for engineering design.
B. Process Planning
The first attempt to use neural network techniques in process

planning might be that of Osakada et al. 1601, 1611, [621. The
authors applied neural network techniques to an expert system
for the process planning of cold forging in order to increase
the consultation speed and to provide more reliable results. A
three-layer neural network is constructed to relate the shapes
of rotationally symmetric products to their forming methods.
The shapes of the products are transformed into 16x 16 black
and white pixels and are given to the input layer of the
neural network. The back-propagation algorithm is employed.
After training, the network is able to determine the forming
methods for the products which are exactly the same or slightly
HUANG AND WANG: ARTIF'ICIAL NEURAL NETWORKS IN MANUFACTURING
different from those used as training examples. To exploit

the self-learning ability, the authors further applied neural
network techniques to the prediction of the most probable
number of forming steps by considering the shape complexity
and material property, the prediction of the die fracture and
surface defect in the formed product, and the generation of
rules from the knowledge acquired from an FEM (Finite
Element Modeling) simulation. It is found that the prediction
of the most probable number of forming steps can be made
successfully and the FEM results are represented better by the
neural network than by statistical methods.
Hwang and Henderson
applied a perceptron network
in feature recognition, which is the first step in automated
process planning (i.e., to interpret the design data from a
CAD model). The goal of feature recognition is to convert
a low-level representation such as face, edge, vertex to a
semantically higher feature-based model. The network training
is accomplished by manually presenting exemplars of features
the user considers important in an engineering analysis (for
example, manufacturing-relatedfeatures for process planning).
Their results show that the neural network approach took less
time in feature recognition than other traditional approaches.
Knapp and Wang
applied neural network
techniques for the automatic acquisition of process planning
knowledge. In their approach, two cooperating neural networks
are utilized. The primary network is a three-layer backpropagation network. The second fixed-weight network
utilizes the MAXNET architecture. Parts to be planned
are decomposed into machining features such as slots,
holes, and planes. Each feature type is associated with
a set of characterizing attributes such as dimensions and
tolerances. Each feature is represented by a vector whose
elements identify the feature type and its attribute values.
This vector forms the input pattern to the primary network.
The network responds to the presentation of a feature vector
by activating certain output nodes, corresponding to the
proposal of particular machining operations. The response
of the network is trained using example process plans and
the back-propagation learning algorithm. The second network
is used to force a decision between competing operation
alternatives. Its output is then fed back to the input layer of
the primary network to provide a context for deciding the next
operation in the machining sequence. The part is presented
to the neural network feature by feature, the network then
generates a sequence of operations for machining each feature
of the part independently (global sequencing of operations
across all features is not considered).
Process planning is knowledge-intensive in nature. Neural
networks, being a useful knowledge acquisition tool, are expected to play an important role in process planning. However,
process planning is a challenging task due to the interdependencies among the steps in a plan. It is not clear how neural
networks can reason about the causal relationships among the
entities in a process plan. Compared with symbolic systems
(e.g., knowledge-based expert systems), neural networks are
less effective in representing structured, contextual knowledge
Therefore, neural networks should be integrated with
symbolic systems in order to solve process planning problems.
C. Scheduling
Foo and Takefuji
developed the Integral Linear Programming Neural Network (ILPNN) and used it to solve jobshop scheduling problems. In a job-shop scheduling problem,
the resources are typically machines and the jobs are the basic
tasks that need to be accomplished using the machines. Each
task may consist of several subtasks related by certain precedence restrictions. This problem can be formulated as a linear
programming problem. The cost function to be minimized is
defined as a sum of the starting times of all jobs subject to
compliance with precedence constraints. The problem is solved
using a linear programming network.
Vaithyanathan and Ignizio
investigated the use of neural
networks for solving certain types of large-scale, resource
constrained scheduling problems. Their work was focused
on dynamic resource constrained scheduling problems. Such
problems, so characteristic of real world situations, involve
the determination of a schedule subject not only to limited
resources but also to sudden, unforeseen changes. They first
decomposed the problem to be solved into a series of multidimensional knapsack models and established an equivalent
neural network model for each particular representation. Then,
they developed an approach that ultimately served to solve the
original problem by extending the work of Hopfield and Tank
Their approach, to a great extent, avoided common neural
network difficulties such as instability and local minima.
In addition to Hopfield networks, feedforward backpropagation networks can also be used in solving scheduling
problems. Yih
al.
provided a hybrid method that
combines back-propagation neural network, simulation, and
semi-Markov optimization to solve the crane scheduling
problem. The crane scheduling problem occurs in a circuit
board production line where one overhead crane is used
to transport jobs through a line of sequential chemical
process tanks. Because chemical processes are involved in
this production system, any mistiming or misplacing will
result in defective jobs. The proposed method consists of
three phases: data collection, optimization, and generalization.
Training data are purified using an operations research method
(semi-Markov optimization). The neural network is used in the
building of the decision making model. The resulted system
performed better than the human scheduler from whom the
models were formulated.
Other neural network approaches to scheduling problems
reported in the literature include: time table scheduling
real-time scheduling
multiple-job scheduling
assembly scheduling
robot scheduling
a stochastic
neural network (Gaussian machine) for scheduling
and an
intelligent scheduling system (ISS) for flexible manufacturing
systems where neural networks and expert systems are used
to generate good schedule
The application of neural networks in scheduling has been
studied by many researchers. In some cases, the neural network approach holds significant advantages. In others, the
usefulness and effectiveness of the neural network approach is
debatable. However, at the very least, neural networks present
a legitimate alternative to the more conventional methods for
218
IEEE TRANSACTIONS ON COMPONENTS. PACKAGING, AND MANUFACTURING TECHNOLOGY-PART A, VOL. 17, NO. 2, JUNE 1994
Fig. 5. Incremental learning and synthesis approach for process modeling

and control
scheduling. Since the scheduling problem is one of immense

importance, it is certain that considerable efforts will continue
in applying neural networks in scheduling.
D. Process Modeling and Control
For the control of machining processes, perhaps the greatest

difficulty is that reliable models of the processes do not exist.
Rangwala and Dornfeld [78] suggested neural networks as
learning structures for intelligent controllers that can model
machining processes and use adaptive control. They also
proposed an incremental learning and synthesis approach as
shown in Fig. 5. This approach relies only on sensor data
generated by the manufacturing process and does not require
a priori process model. Training samples are composed from
the inputs and measured variables during operation and are
continually used to enhance the network performance; while
the knowledge embedded in the partially learned system is
used for the determination of the local optimum of the input
variables.
In the process industry, usually human operators rather than
mathematically based advanced algorithms are used to achieve
product control. Gingrich [79] discussed a methodology that
uses neural networks for capturing the knowledge of human
process operators. The results show that it is possible to
learn the control actions of a human operator using neural
networks, at least for simple systems. The neural network
approach is preferred over heuristic approaches for several
reasons including: (1) there is no need for the operator to
formulate his knowledge as rules, and (2) to train a neural
network is easier than to design, build, and maintain an expert
system.
Anderson et al. 1801,
applied the neural network approach in arc welding. Any arc welding process is controlled
by a number of parameters, and the ultimate objectives of the
process are specified in terms of numerous parameters as well.

As a result, any arc welding process can generally be viewed as
a multiple-inputlmultiple-output system. The lack of reliable,
general, and yet computationally fast physical models of this
multi-variable system, makes the design of a generalized realtime controller for arc welding nontrivial. One of the basic issues to be considered regarding the generalized control for arc
welding is to determine what is to be controlled and which parameters are accessible to enact control actions on the process.
The back-propagation networks were used for the modeling
and control of the Gas Tungsten Arc Welding (GTAW).
Various configurations, in terms of the number of layers and
the number of network nodes, were tested. For the application
presented, two-layer (not counting the input layer) networks
consisting of a single hidden layer and an output layer have
been proved to be adequate. Smartt et al. [82] also applied
the neural network approach in arc welding. Instead of using
neural network to model the arc welding processes, they developed a new approach to quantify conditional logic rules and
represent them in a neural network. The network was then used
in place of a PI controller for a gas metal arc welding process.
Process modeling and control are a manufacturing domain
where neural networks can play a very important role. Chryssolouris and Guillot 1831 combined process modeling and AI
techniques for the determination of the operational range of
the process parameters. The process models were determined
by neural network learning techniques. Jalel et al. 1841 applied neural networks in imitating a skilled process operator.
h g h [85] described the application of a neural network on
manufacturing process control. Levin et al. [86] discussed
the use of neural network architecture for adaptive system
modeling and control. Patrick 1871 reported the application
of a neural network to brownstock washer operations at a
pulp and paper mill. Karsai et al. [88] applied neural network
methods for the modeling and control of welding processes.
Guha [89] presented some neural network-based adaptive
control strategies that can be used for designing controllers for
continuous process control problems. Madey et al. 1901 used
neural networks and general-purpose simulation to model a
continuous improvement system.
The advantages of using neural network approaches in
process modeling and control are indicated by Chryssolouris
et al. [91]. The authors pointed out that while synthesis of
multiple sensor information would provide better result, neural
networks excelled in dealing with situations in which process
models do not adequately reflect the process complexity. A
neural networks ability to learn a control algorithm without
the benefit of a priori analysis or modeling can be of great
help for difficult, complex, and nonlinear control applications.
The same conclusion also can be found in 1921, in which
Bozich and Mackay applied a neurocontroller in vibration
cancellation.
E. Monitoring and Diagnosis
The first application of neural networks in monitoring

reported in the literature could be that of Govekar et al.
[93]. The authors applied a back-propagation network for
HUANG AND W A N G : ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING
b)
A
c)
Sensory inputs that include data from a variety

of sensors such as force, acoustic emission, accelerometers, etc.
The operator modifications to feed and cutting
speed.
Fig. 6.
Proposed monitoring scheme for machining processes
the monitoring of a drilling process. Their results show that

Acoustic Emission (AE) signals detected by a single sensor
are applicable to the recognition of operations like free run,
drilling at different positions, and drilling with a wom drill.
However, they also discovered that the recognition ability
was influenced not only by the neural network but also by
the properties of the detected system. Later applications [94],
[95] show that neural networks can advantageously be used
in real-time monitoring of manufacturing processes and other
technical prodesses.
Kamarthi et al. [96] investigated a new method for on-line
measurement of flank wear through the synergy of vibration
and force sensing. Their method used a Kohonens selforganizing feature map for correlating force and vibration
signals with the tool wear levels. In the particular experiment,
it was found that the trained feature map learned to detect
the tool wear levels with a reliability close to 95%. Thkr
results show that methods based on sensor data fusion using
neural networks have the potential to offer reliable and robust
methods for correlating tool wear levels with the signatures
from force, vibration, and acoustic emission sensors for a wide
range of process conditions.
Hou and Lin [97] designed a monitoring system for identifying both periodic and aperiodic process signals using
neural networks. First, digital signal processing techniques
are used to convert collected manufacturing signals into frequency domain. Then, a neural network based program is
used to identify the signals by examining their characteristic
frequencies. Two examples (periodic signals and aperiodic
signals) were presented to demonstrate the feasibility of the
monitoring system and its recognition ability. The results
are quite promising and show that the neural network based
system seems to have a good potential in monitoring automatic
manufacturing processes.
Masory [98] proposed a scheme for machining processes
monitoring using multi-sensor readings fused by neural networks. His scheme, shown in Fig. 6, functions in two modes
as the following:
1) Training Mode: In this mode a skilled operator is monitoring the process and the
is used to capture his
knowledge. The
is fed with three groups of data:
a)
Process inputs that include feed, cutting speed,

process geometry and workpiece/tool materials.
2) Operation Mode: Upon convergence, the network is fed

with the process and the sensory input and according to
the mapping (model) established during the training
session, it automatically modifies the cutting parameters.
Many research efforts have been dedicated to the application
of neural networks in monitoring and diagnosis. Sorsa et al.
[99] reported the use of neural networks in process fault
diagnosis. Burke and Rangwala [lo01 discussed a neural
network approach for tool condition monitoring in metal
cutting. Ray [loll reported on a project in an integrated
steel industry that applied neural network in engine fault
diagnosis. Bauer [lo21 reported on a study of unsupervised
neural network for tool failure detection in milling operations.
Elanayar and Shin 1031 applied neural network techniques to
estimate the evolution of flank and crater wears using feed
and cutting force measurements. Wasserman et al. [lo41 used
the neural network approach to detect and measure small
cracks in the shafts of rotating machines. Guillot and El Ouafi
[lo51 applied a three-layer feedforward neural network in the
identification of tool breakage in metal cutting processes. Wu
et al. [lo61 presented a neural network approach to diagnose
processing damages in injection molding. Lin et al. 1071 used
neural network techniques for sensor failure detection and
data recovery. Chow et al. [lo81 discussed a neural network
approach to real-time condition monitoring of induction motors. Knapp and Wang 1091 applied a back-propagation neural
network for machine fault diagnosis. Upadhyaya and Eryurek
[110] used neural networks for sensor validation and plant
monitoring. Murphy and Kagle 1 1 11 applied neural networks
for the recognition of electronic malfunctions. As a logical
consequence of these and similar investigations, some authors
reported on the development of neuro monitoring system
using accelerator cards for neural network computations [94],
[112], [113]. Other authors [97] argued that combining an
expert system with neural network based pattem recognition
might lead to potential applications in manufacturing process
monitoring and fault diagnosis.
F. Quality Assurance
Quality is the single most important factor in determining
market share [114]. There are two different approaches to
quality assurance, namely, reactive quality assurance and
proactive quality assurance. Reactive tools include sampling
plans, lot acceptance determination, scrap or rework analysis,
and so forth. Proactive strategy requires. an emphasis on
physical cause-effect knowledge, risk analysis, experience, and
judgment to justify action. Neural networks have been used for
both reactive and proactive quality assurances.
Reactive quality assurance is strongly related to monitoring
and diagnostics. Therefore, neural networks can also play an
important role in reactive quality assurance, especially where
high processing and classification capabilities are required.
Barschdorff 1 151 discussed the application of neural network

techniques for the quality control of electric drive motors.
Sixteen spectral features of the motors vibration were input
to a three-layer neural network. The network was able to
recognize production faults, such as unbalance of the rotor,
nonconducting winding connections, magnetic field failures,
failures on commutators or bearings, loose parts, etc. The
classifying ability of the network was compared with the
results obtained by different pattern recognition algorithms.
It was found that the performance of the neural network was
superior.
Smith 1161 reported the use of back-propagation neural
networks in quality control in an injection molding corporation
(Orscheln Industries, Moberly, Missouri). Injection molding is
a process with many variations in raw materials, machinery
conditions and ambient conditions. It also has a temporal
aspect where line conditions change during operation, affecting
the end product. Neural networks are especially applicable
when the data considered do not follow a known distribution or
pattern, and, hence, are well suited for the quality control of
injection molding. The results show that the neural network
approach is comparable to other quality control methods,
including control charts and statistical techniques, in goodness
of output for quality control. An advantage of the neural
network approach is the convenience of learning to establish
the relationships directly, rather than through analysis and
assumptions. Using a single network to monitor multiple
products and/or quality parameters is an additional advantage.
Neural network techniques also can be used in proactive
quality assurance. Schmerr et al. 1171 provided an innovative
approach for planning robust design experiments through the
use of neural networks. Robust design is a cost-effective
technique for achieving high quality and reliability. The basis
of the approach was to train a neural network on a set of
tuples where each tuple corresponds to a Taguchi experiment
along with its observed product response. Once trained, the
neural network can probe the entire parameter space of design
parameter settings, equivalent to performing a full factorial
experimental design. With this information, a designer can
identify alternative settings and search for optimal designs. The
neural network approach was compared with analytical modelbased approach. It was found that the neural network had
remarkable capabilities for generalization when trained on the
same sparse array of experiments as used in complementary
Taguchi analysis.
The research of neural networks for quality assurance has
actually be implemented in manufacturing practice. CTS Electronics of Texas has used a neural network system to detect
defective loudspeaker assembly lines 1181. Ford Motor Company used neural network techniques to check car paint
finishes [118]. Motorola Incorporated used artificial vision
based on neural network techniques for the quality inspection
of their chips 1 191.
G. Group Technology
Two engineering problems associated with implementing
GT are part classification and part family formation. Kaparthi
and Suresh [120] proposed a neural network system for

shape-based classification and coding of rotational parts. A
back-propagation neural network was trained to generate part
geometry-related digits of the Optiz code from the bitmaps of
part drawings. Their principal study shows that the network
can generate codes accurately and promises to be a useful tool
for the automatic generation of shape-based classes and codes.
The use of neural networks for part family formation was
studied by a couple of researchers [121], [122], [123]. In
their approach, a three-layer feedforward neural network was
trained with the back-propagation algorithm. Each input unit
of the network represents a part feature, and each output unit
represents a part family. An operator plays the role of a teacher
to the network by presenting each part in terms of part features,
and by telling which family it belongs to. The trained network
stores implicit discrimination rules through a set of connection
weights, and exhibits consistent classification practice. The
research demonstrates that the neural network approach is
capable of dealing with large part family formation problems
efficiently.
A problem in dealing with part classification and part family
formation is how to maintain consistency. The consistency
problem can be addressed most effectively if the classification
and formation are a single procedure rather than two separate
procedures. Kao and Moon [124] presented an approach for
using the learning ability of neural networks to automate the
process of part family formation during the part classification
process. They divided the task into four phases: ( 1 ) seeding
phase, (2) mapping phase, (3) training phase, and (4) assigning
phase. In the seeding phase, three to five apparently distinctive
parts are chosen from the part pool as part family representatives (seed parts). In the mapping phase, a code is assigned
to each seed part. A neural network is also constructed. The
number of input units is equivalent to the number of features
contained in a classification code system. In the training phase,
a set of training pattern pairs is presented to the network. The
network learns based on the back-propagation algorithm. In
the assigning phase, the network compares the presented part
to the training set. If the features of the part are similar to the
generalized features of any existing part family representative,
the output of the network will be the same part family number.
If there are no significant similarities between the part and any
of the part family representative, the output of the network will
not indicate any existing family code. That means a new part
family should be set up for this part.
Another GT problem is the machine-part cell formation
problem. The assignment of a group of similar parts to
a cell of machines having common processing characteristics greatly improves the efficiency of batch manufacturing.
However, approaches to the problem of machine-part cell
formation have been computationally inefficient for large
machine-part matrices. Dagli and Huggahalli 1251 applied the
binary ART network (ART-1) for machine-part cell formation.
The columns and rows of the machine-part matrix are binary
vectors that can be directly applied as inputs to an ART-1
network. Dagli and Huggahalli analyzed the performance of
the neural network classifier and found that direct application
of the basic ART-I network did not provide very satisfactory
HUANG AND ZHANG: ARTMCIAL NEURAL NETWORKS IN MANUFACTURING
result. They then reordered the input vectors derived from

the machine-part matrix, and modified the original ART1 paradigm. This produced drastic improvement over the
performance of the basic ART-1. The result obtained compared favorably with popular algorithms proposed in the
literature, such as the ROC2 algorithm provided by King
and Nakomchai [126]. The application of neural network
approaches in the design of cellular manufacturing systems,
which involves the machine-part family formation problem,
has been studied by MalavC and Ramachandran 1271 and Lee
et al. [128].
Back-propagation networks and ART networks both can be
used in solving GT problems. However, the learning results
of a back-propagation network depend on the frequency of
presenting a part. For example, if a network is trained three
more times with part A than with part B, the network becomes
biased toward part A [124]. This problem is not so obvious
when an ART network, which applies the unsupervised learning algorithm, is used. Since ART networks are both adaptive
and stable, they are more suitable for solving GT problems
than back-propagation networks. The use of ART networks
to solve GT problems is a research topic that is worthy of
further studies.
22 1
propagation networks and counter-propagationnetworks) have

the ability to mathematically solve the kinematic problem
within acceptable error rates.
Nguyen et al. [133] have designed several neural network
configurations for solving the forward kinematic problem for
robots with two degrees of freedom. Each of the networks
used for evaluation has two input nodes,
and
and two
output nodes, 2 and y. The network architectures studied
have 6een: 2-10-10-2 for the network trained with the error
back-propagation (BP), 2- 10-10-2 for the network trained
with the back-propagation algorithm but with output splitting
(BPOS), 2-8-2 for the functional link network (FL),and a
counter-propagationnetwork (CP) for trajectory mapping. The
networks were trained using a set of data (64 input/output
pairs) obtained from measurements taken in the robot work
area. The training of all four network architectures resulted in
quick learning convergence to the desired trajectory. The basic
BP network with two hidden layers gave a reasonably accurate
solution. The BPOS network, which involved considerably
fewer connections than the BP network, yielded comparable
accuracy. The best solution of the trajectory learning task was
achieved with the FL network. The CP network resulted in
a relatively fast approximation of the trajectorjr, but the endeffector position error was rather large and uneven. Therefore,
the CP network in this application can be recommended only
H. Robotics
if a short development time is required for low-precision
Robotics constitute the study of a finite number of rigid trajectory tracking.
Iberall 1341, 135J applied cooperativekompetitive neural
mechanical chains that represent a multi-variable non-linear
coupled system. The solution of this problem is difficult networks to compute the inverse kinematic solution for fingers
because even the simplest desired movement requires sophis- of a simulated robot hand during grasping. Guez and Ahmad
1361 investigated the inverse kinematics solution for twoticated and computationally intensive mathematics 1291. The
problem areas involved in robotics are kinematics, dynamics, and three-degrees-of-freedom manipulators using multiplelayer perceptrons. They suggested that neural networks might
trajectory planning, control, sensing, and intelligence.
Kinematics refers to the study of robot joint motions without be best for providing a good initial estimate for a manipulator
considering the causes of motion. Two distinct subproblems that required iterative methods for its solution, because of
are involved, namely, forward kinematics and inverse kine- the relative numerical accuracy of neural networks compared
[137] provided
matics. The forward kinematics problem involves a non-linear with the closed form solutions. Aylor et
matrix mapping from the joint space (a description in terms of proof that back-propagation neural networks can provide acjoint angles and positions) of the robot to its Cartesian space ceptable solutions to the inverse kinematic problem. The
(Cartesian coordinates of the robot end-effector). The forward authors developed a network that is capable of taking into
kinematic solution computes the Cartesian location of the end- account the unknown number of faults, errors, and limitations
effector given the joint space description. On the other hand, of the poorly constructed Fishertechnik robot and provides
the inverse kinematic solution computes the joint space coordi- solutions that are as accurate as the robots mechanical and
nates given the end-effector location in Cartesian coordinates. electrical systems can support. Also, they argued that backGiven the angular movement of each joint and the length of propagation neural networks were ready to leave the laboratory
each arm it is relatively easy to find the Cartesian location and enter the real working world to solve the inverse kinematic
(coordinates) of the end-effector, except that several non- problem.
Pa0 and Sobajic [138], and Sobajic et al. [139] studied
linear trigonometric and matrix multiplications are needed.
The inverse kinematics problem can yield multiple number of the use of neurocontrollers in robot arm movement with two
solutions when the robot has multiple degrees of freedom. It degrees of freedom and with a desired final end-effector posiis more computationally intensive than the forward kinematic tion. The results that were achieved demonstrated the unusual
problem and is the most difficult problem in robotics [130]. efficiency and potential of neurocontrollers for use in robot
Neural networks can be used to reduce the computational kinematics control systems. Albus [140], [141], 1421 precomplexity of the kinematic problem. The trade-off is that sented his Cerebellar Model Articulation Controller (CMAC)
the results yielded by the neural network approach may not for general robotic control. The basic idea of the CMAC
be as accurate as those yielded by the conventional analytic approach is to learn an approximation of the system characapproach. Hecht-Nielsen 1311, Josin 1301, and Saxon and teristics and then to use it to generate the appropriate control
Mukerjee 1321 have proven that neural networks (back- signal. The approximation of the system characteristics is
222
IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY-PART A, VOL. 17, NO. 2, JUNE
understood as gradual learning based on the observations of

the plant input-output data in real time [143], [144]. Miller et
al. 1451 used CMAC neural networks to control a robot whose
kinematics is unknown. After training, the neural network
controller performed very well. The average error was always
below the error of a fixed gain controller without learning.
The applications of neural networks in robot control have been
addressed by many authors. Readers may refer to the following
partial list of projects:
1) Multiple-layer perceptrons for an inverse Jacobian controller 1461.
2) The use of a proprietary neural network system, GLN
(Graded Learning Network), for controlling robots
movement and action [147].
3) A neural network based controller for a single degree
freedom robot arm [148].
4) A neural network based controller for tracking moving
objects with a two-joint robot arm [149].
5 ) Hierarchical neurocontroller for robotics manipulation
[150].
6) Learning optimization in robot positioning control 1511.
7) Visual control of robotics manipulator based on neural
networks [152].
8) Neural network compensator for uncertainties of
robotics manipulators 1531.
Neural networks have also been used for robot dynamics
due to their nonlinear mapping property. The basic idea is that
the neural network learns the inverse dynamical relationship
of the robot directly, which can be used as an inverse dynamic
controller. Kawato 1541 implemented a novel neural network
for inverse dynamics control based on neurophysiology.
The research of neural network approaches in trajectory
planning includes the following:
1) Eckmiller 1551 developed a novel neural network called
Neural Triangular Lattice (NTL) for storing and retrieving trajectories.
2 ) Jorgenson 1561 investigated the use of neural networks
for mobile robot path planning.
3) Tsutsumi and Matsumoto 1571 implemented obstacle
avoidance in an unknown environment using Hopfield
networks for multi-joint robots and truss structures.
4) Seshadri 1581 investigated the use of Hopfield networks
for mobile robot path planning.
5 ) Lee and Park [159] used a neural network approach for
collision-free path planning.
The objective of the research in neural network approaches
to robotics is to investigate the feasibility of creating an
intelligent robot control scheme in an unmanned working
environment. The research is quite diverse and rudimentary, leaving much room for improvement and new areas
for development. Much of the preliminary research discussed
here is quite promising. However, some of the works yield
poor performance relative to conventional techniques partially
because neural networks are not yet fully understood or
developed. Hopefully many of these problems will disappear as we develop and understand neural networks more
fully.
I. Other Applications
The ill-structured characteristics of manufacturing problems
provided fruitful grounds for neural network applications. Due
to the abundance and diversity of technical publications, we
cannot cover all the manufacturing applications in this paper.
The following is a list of specific applications that may be of
interest to the readers.
1) Multisensor fusion and integration 1601.
2) Sensing on the factory floor [161].
3) Maintenance management problem 1621.
4) Plant layout determination 1631.
5 ) Operational policy determination 1641.
6) Assembly system selection [165].
7) Sampling inspection plans determination 1661.
8) Design of manufacturing systems [167].
9) Design of assembly system [168].
10) General-purpose simulation 1691.
IV. PROBLEMS
WITH NEURALNETWORKS
AND
SUGGESTED
SOLUTIONS
Neural networks have several advantages over knowledgebased expert systems. Their learning ability and parallel distributed structure are very attractive to researchers who want
to develop intelligent systems. Currently, there is an explosion
of interests in neural networks. However, some of the scientific
and economic expectations on neural networks (e.g., replacing
conventional computers and eliminating programming) are
unreasonable 1701. This is because neural networks have the
following disadvantages:
1) A neural network cannot explain its results explicitly,
which implies that the user interface of a neural network
may not be as friendly or productive as that of an expert
system.
2 ) The knowledge representation of a neural network is
vague and not easily understood.
3) The configuration of a neural network is usually time
consuming, as one needs to use a trial-and-error method
to find the proper neural network architecture for a given
problem.
4) The current neural network learning algorithms are not
efficient enough and cannot guarantee network convergence.
5 ) How to derive some type of optimal training set for a
neural network application still remains a question.
Experience with expert systems has shown that the ability
to generate explanations is absolutely crucial for the user acceptance of AI systems [171]. However, neural networks have
no explicit, declarative knowledge representation and therefore
have considerable difficulty in explaining their results. In order
to solve this problem, Caudill [172] suggested that one can
construct an additional small rule-based system and use it
for explanation. The explanation system would be neither as
complete nor as detailed as a full-blown rule-based solution;
its function is solely to explain why an answer is correct.
Another solution to the problem is to introduce structure to
a neural network, e.g., the explicit encoding of relations and
modular network architectures [171].
HUANG AND ZHANG ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING
To build a neural network based system, one has to make

decisions regarding the type of neural network to be used,
its architecture, topology, type of nonlinearity, and associated
parameters. However, there is still not an efficient method that
exists to make the decisions. Cios and Liu [173] proposed a
machine learning method to automatically generate a neural
network architecture for a given problem. Their approach
also allows interpretation of the knowledge embedded in the
generated connections and weights. However, neural networks
generated using the approach are usually more complicated
than those generated using the trial-and-error method.
While very large rule-based systems have been built, extremely large neural network based systems are not feasible
with todays technology [172]. Such networks can be constructed, but they cannot be effectively trained. The current
neural network learning algorithms available are heuristic in
nature. For small problems those algorithms are sufficient
enough. However, problems with moderate size usually require
long learning time; and network convergence is not guaranteed. One solution to this problem is to break big problems
into smaller pieces. This method also facilitates the selection
of a proper set of training examples.
One can expect that expert systems can help overcome the
problems inherent in existing neural networks and enable them
to do what they cannot accomplish alone in the following
[174]:
1) to deal with knowledge representation, symbolic reasoning, non-numerical operations, which conventional
neural networks cannot cope with;
2) to determine the number of nodes, number of layers,
connections, and initial weights of a neural network,
based on the degree of nonlinearity, complexity, and
other data that are available in the design process;
3) to improve the learning ability of neural networks
by controlling on-line the minimal number of nodes,
weights, and layers (i.e., determine the optimal network
architecture while training); and
4) to help train neural networks using the key data classified
by expert systems from a great number of the collected
data.
Quite a few researchers are interested in building hybrid
systems that merge the structures and functions of expert
systems with those of neural networks. There are some manufacturing applications that exemplify the functionality and
power of combining expert systems and neural networks. We
will provide a brief review in the following.
In order to overcome the knowledge acquisition bottleneck
in the building of expert systems, neural networks have
been used as a learning mechanism to transfer engineering experience into formulated knowledge. Yeh et al. [175]
employed a neural network to build an expert system for
debugging FEM program input data. The back-propagation
learning algorithm was used to train the network for extracting
knowledge from training examples. The authors examined the
influences of various control parameters including learning
rate and momentum factor, and various network architecture
factors (e.g., the number of hidden nodes and the number of
223
hidden layers). To apply the knowledge in the trained network,

a reasoning strategy that hybridizes forward-reasoning and
backward-reasoning schemes was proposed to realize the
inference mechanism. The results proved that neural networks
can work sufficiently for classification problem-related expert
systems.
Ben-David and Pao [176] presented an architecture, which
is based upon a hybrid of neural networks and rule-based
models, for the design of self-improving expert systems. The
architecture was tested on an expert system which assists users
during the planning stage of a chemical product that has given
properties and composition. In the application, 15 chemical
substances are components that will be mixed and processed
in order to produce a product that exhibits certain required
properties. The designers goal is to find a composition that
meets these properties. A neural network can be used to predict
a composition given the required properties. Any prediction
is naturally susceptible to errors. Laboratory tests must be
carried out in order to verify the actual properties before any
mass production takes place. The results of the laboratory
tests (i.e., the actual properties) can be stored for further
network training. When a prediction is not accurate, the system
invokes another source of knowledge, a rule-based component
that iteratively suggests possible modifications to the current
formula. All the suggestions made by the rule-base are fed into
a second neural network. The network estimates the effects of
each suggestion before resorting to a costly laboratory test. The
designer then selects a plan based on the estimation provided
by the network for laboratory testing. The results are fed back
into the system for further training of the neural network. At
intervals, all the neural networks are trained using feedbacks.
The rule-based component, on the other hand, is static. It can
only be modified explicitly. The consultation process repeats
iteratively until an acceptable formula is found.
AI Ware has developed a commercial Integrated Technology
Platform [177], [178], [179], [180]. The workstation-based
software platform combines neural networks, expert systems,
and optimization. The platform system attempts to provide
all the capabilities of the individual technologies, while minimizing the limitations of each. The individual technologies
within the platform are essentially transparent to the user. This
leaves the user free to concentrate on the problem to be solved.
The user does not need to address the application issues and
technical quirks typically associated with each technology. AI
expertise is not mandatory when using the platform system.
Therefore, domain experts can both develop and apply systems
based on the platform.
The platform has been incorporated in a new applicationspecific product designed for chemical engineers. The product,
called CAD/Chem Custom Formulation System, helps designers rapidly optimize the formulation and processing of
products such as plastics, rubber, alloys, composite materials,
and pharmaceuticals [177], 1781, [179]. The functionalities
of CAD/Chem and the underlying Integrated Technology Platform include Best Match, Estimate, and Optimize. Best
Match enables a product designer find in the database the
current or past product that best meets a given set of new
product requirements. This capability is based on a neural
224
networks pattern matching ability. The Estimate capability

basically is also a neural network function. It tells the user
what product properties to be expected for a given change in
formulation. This estimation capability is based on a system
model that is automatically learned by the neural network. An
automatic neural network configuration capability is provided
by an expert system embedded in the platform. The rules
in the expert system are used to select an initial network
configuration and a set of parameters, based on the nature and
dimension of the task. Additional rules adjust the configuration
and parameters in real-time, as required, to enhance the
learning rate of the neural network. The Optimize function
finds the best way to formulate or process a product.
The platform system has also been applied to tasks such as
quality control, product design, process control, power system
security monitoring, material selection, and finite element
modeling. A Functional Link Network (FLN) Combustion
Optimizer, which is also built upon the Integrated Technology
Platform, as discussed in 1SO].
Other significant applications reported in the literature include the following. Holden and Suddarth [181] used neural
networkhowledge-based hybrid systems for large scale dynamic control. Bulsari et al. 1821, 1831 applied the so-called
productive neural networks for continuous steel casting
diagnosis. Hall and Lu [184] used a hybrid methodology to
develop an adaptive controller for optimizing the operation of
a harvester. Spelt el al. [185] presented a hybrid architecture
for the diagnosis and decision-making in manufacturing.
When we are dealing with a manufacturing problem, most
often we have a certain amount of apriori knowledge about the
problem domain. However, the a priori knowledge is neither
complete nor necessarily accurate. While expert systems can
handle a priori knowledge easily, neural networks can be used
to refine the knowledge base. Due to the recent successes of
connectionism, one may argue that the a priori knowledge
can also be learned by neural networks. This is possible but
may be inappropriate. First, the task may not be well suited
to inductive learning. For example, in his connectionist model
of beam-balance physics, McClelland 1861 suggested that the
highest level of knowledge, i.e., using the concept of torque
to predict which way the beam will fall, cannot be learned
from examples and required explicit transfer of knowledge.
Second, many learning algorithms are often designed to extract
previously unknown regularities from their environment. Thus
the representations they developed may not be comprehensible
to the user. Third, it makes little sense to train a neural network
when the a priori knowledge can be explicitly embedded in
the system architecture. Therefore, it is desirable to build a
hybrid system which consists of expert system as well as
neural network components.
Although hybrid systems can exploit the advantages and
neutralize the disadvantages of their components, they also
bring some new problems. Hybrid systems face two problems
not found (or found to a lesser extent) in their single-paradigm
counterparts 1871. First, the expert system and neural network
components in a hybrid system must be able to communicate.
Second, if learning is to be supported, credit must be assigned
to each component. The communication problem arises be-
cause the two paradigms (expert systems and neural networks)

use different representations. One solution to this problem is
to subdivide the problem, delegating one set of tasks to each
component. However, this approach restricts the effectiveness
of the hybrid system; the components cannot benefit from each
others information when solving their individual tasks. An
alternative is to convert the representations of each component
into a common language, or simply use one of the original
representations (e.g., connectionist representation). The credit
assignment problem also can be largely solved by using a
homogeneous representation and adjusting all learning parameters with a single mechanism. This approach seems to be a
better solution. It is a very interesting research topic which
requires tremendous amounts of effort.
V. CONCLUSIONS
The idea of building manufacturing systems that can function automatically has attracted a lot of attention and created
continuous research activities. Recently, artificial neural networks have emerged as a revolutionary AI approach and
generated enormous interests in the manufacturing arena.
This paper introduces the basic concepts of neural networks
and reviews the current application of neural networks in
manufacturing. The problems with neural networks are also
identified and some possible solutions are suggested. We
hope that the materials presented in this paper can provide
some useful guidelines and references for the research and
implementation. Our conclusions are summarized as follows:
1) There is an intense research interest in applying neural
network techniques in manufacturing.
2) Some manufacturing problems have attracted more research attention than others.
3) Many of the applications reported in the literature are either laboratory experiments or preliminary applications.
4) While Hopfield networks are used in solving optimization problems and ART networks are used in group
technology, back-propagation networks have been applied in a variety of problems (including optimization
and group technology).
5 ) Some of the theoretical claims of neural network abilities
have been tested in real manufacturing practices and
found to be true.
6) Most of the applications are simulated in conventional
computers rather than implemented in hardware.
7) The development of VLSI (Very-Large Scale Integrated)
neural chips will further accelerate the computation
speed of neural networks.
8) The development of a generalized neural network for
solving different types of large-scale problems is desired.
9) There is a trend to integrate neural network and expert
system techniques to solve manufacturing problems.
Artificial neural network techniques are still very new and
are developing quickly. We are witnessing fast expansion of
neural network-based intelligent machines. Neural networks
are an enhancing rather than replacing technology. As most
researchers agree, artificial neural networks are not going to
replace conventional computer and eliminate programming.
AND
ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING
Instead, they Will be integrated with conventional computing techniques and other AI schemes (e.g., knowledge-based
expert systems) in order to develop truly intelligent manufacturing systems. Hopefully, the era of Intelligent Manufacturing
Systems will soon be realized via the help of artificial neural
networks.
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Denmark in 1989 and the M.Sc. degree in mechan[I761 A. Ben-David and Y.-H. Pao, Self-improving expert systems: An
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[I771 W. H. VerDuin, Neural network software assists expert system,
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University, Lubbock, TX. His research and teaching
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of journals and conferences. One of his recent books, titled Computerized
1811
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Recognition, vol. 5, no. 4, pp. 503-522, 1991.

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IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY-PART

A, VOL. 17, NO. 2, JUNE 1994

Artificial Neural Networks in Manufacturing:

Abstract- New approaches and techniques are continuously

ANUFACTURING is a set of correlated operations

models available in perfect arrangement and complete form

0162-8828/94$04.00 0 1994 IEEE

HUANG AND ZHANG: ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING

processing element is the bit, while in the brain, the processing

Hinton [34], [35] developed a probabilistic neural network

Artificial neural networks have been defined by Kohonen as

a back-propagation network, (b) a Hopfield network, and (c) an ART network.

A taxonomy of neural network models.

The output of a neuron is given as

f ( n e t ) is referred to as an activation function. Typical activation functions used are

in which the parameter

recurrent networks. In a feedforward network (Fig. 2(a)),

HUANG AND ZHANG. ARTIF'ICIAL NEURAL NETWORKS IN MANUFACTURING

troduce three types of network models that are very popular

evolves to an equilibrium state. Therefore, one may design a

their environment. The first effort in this endeavor is the

Design model based on associative memory

Arai and Iwata [56] suggested a four-layer neural network to

The first attempt to use neural network techniques in process

HUANG AND WANG: ARTIF'ICIAL NEURAL NETWORKS IN MANUFACTURING

different from those used as training examples. To exploit

Fig. 5. Incremental learning and synthesis approach for process modeling

scheduling. Since the scheduling problem is one of immense

For the control of machining processes, perhaps the greatest

process are specified in terms of numerous parameters as well.

The first application of neural networks in monitoring

HUANG AND W A N G : ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING

Sensory inputs that include data from a variety

Proposed monitoring scheme for machining processes

the monitoring of a drilling process. Their results show that

Process inputs that include feed, cutting speed,

2) Operation Mode: Upon convergence, the network is fed

Barschdorff 1 151 discussed the application of neural network

and Suresh [120] proposed a neural network system for

HUANG AND ZHANG: ARTMCIAL NEURAL NETWORKS IN MANUFACTURING

result. They then reordered the input vectors derived from

propagation networks and counter-propagationnetworks) have

understood as gradual learning based on the observations of

HUANG AND ZHANG ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING

To build a neural network based system, one has to make

hidden layers). To apply the knowledge in the trained network,

networks pattern matching ability. The Estimate capability

cause the two paradigms (expert systems and neural networks)

1281 G. A. Carpenter and S. Grossberg, ART 2: Self-organization of stable

[56] E. Arai and K. Iwata, CAD with design specification decomposition

[82] H. B. Smartt, J. A. Johnson, C. J. Einerson, and G. A. Cordes,

HUANG AND W A N G ARTIFICIAL NEURAL NETWORKS IN MANUFACTURING

detection and data recovery, in Intelligent Engineering Systems Through

[135] T. Iberall, A neural network for planning hand shapes in human

A, VOL. 17, NO. 2, JUNE 1994

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