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This thesis evaluates the feasibility of conducting visual inspection tests on power industry constructions using object detection techniques. The introduction provides an overview of this field’s state-of-the-art technologies and approaches. For the implementation, a case study is then conducted, which is done in collaboration with the partner company OMICRON Electronics GmbH, focusing on power transformers as an example. The objective is to develop an inspection test using photographs to identify power transformers and their subcomponents and detect existing rust spots and oil leaks within these components. Three object detection models are trained: one for power transformers and sub-components, one for rust detection, and one for oil leak detection. The training process utilizes the implementation of the YOLOv5 algorithm on a Linux-based workstation with an NVIDIA Quadro RTX 4000 GPU. The power transformer model is trained on a dataset provided by the partner company, while open-source datasets are used for rust and oil leak detection. The study highlights the need for a more powerful GPU to enhance training experiments and utilizes an Azure DevOps Pipeline to optimize the workflow. The performance of the power transformer detection model is satisfactory but influenced by image angles and an imbalance of certain sub-components in the dataset. Multi-angle video footage is a proposed solution for the inspection test to address this limitation and increase the size of the dataset, focusing on reducing the imbalance. The models trained on open-source datasets demonstrate the potential for rust and oil leak detection but lack accuracy due to their generic nature. Therefore, the datasets must be adjusted with case-specific data to achieve the desired accuracy for reliable visual inspection tests. The results of the case study have been well-received by the partner company’s management, indicating future development opportunities. This case study will likely be a foundation for implementing visual inspection tests as a product.
The usage of data gathered for Industry 4.0 and smart factory scenarios continues to be a problem for companies of all sizes. This is often the case because they aim to start with complicated and time-intensive Machine Learning scenarios. This work evaluates the Process Capability Analysis (PCA) as a pragmatic, easy and quick way of leveraging the gathered machine data from the production process. The area of application considered is injection molding. After describing all the required domain knowledge, the paper presents an approach for a continuous analysis of all parts produced. Applying PCA results in multiple key performance indicators that allow for fast and comprehensible process monitoring. The corresponding visualizations provide the quality department with a tool to efficiently choose where and when quality checks need to be performed. The presented case study indicates the benefit of analyzing whole process data instead of considering only selected production samples. The use of machine data enables additional insights to be drawn about process stability and the associated product quality.