Kamran Paynabar

Upala Junaida Islam, Kamran Paynabar, George Runger et al.

Active learning provides a framework to adaptively query the most informative experiments towards learning an unknown black-box function. Various approaches of active learning have been proposed in the literature, however, they either focus on exploration or exploitation in the design space. Methods that do consider exploration-exploitation simultaneously employ fixed or ad-hoc measures to control the trade-off that may not be optimal. In this paper, we develop a Bayesian hierarchical approach, referred as BHEEM, to dynamically balance the exploration-exploitation trade-off as more data points are queried. To sample from the posterior distribution of the trade-off parameter, We subsequently formulate an approximate Bayesian computation approach based on the linear dependence of queried data in the feature space. Simulated and real-world examples show the proposed approach achieves at least 21% and 11% average improvement when compared to pure exploration and exploitation strategies respectively. More importantly, we note that by optimally balancing the trade-off between exploration and exploitation, BHEEM performs better or at least as well as either pure exploration or pure exploitation.

Shengzhe Chen, Mehrdad Moradi, Kamran Paynabar et al.

We propose Flow Mismatching, an unsupervised anomaly detection method that deliberately avoids reconstruction-based paradigms. Instead, we treat flow matching as geometric dynamics and leverage a key insight: anomalies occur at places where the learned normal flow disagrees with the geometric path toward a test image. Given a flow matching model trained only on normal images, we probe its learned velocity field along affine paths from Gaussian noise to a target image. Along each path, we compare the model-predicted velocity, which follows normal generative dynamics, with the geometric velocity toward the target, which includes any anomalous content. Anomalies induce strong local disagreement between these velocities. Aggregating the mismatch over different time steps and multiple paths yields pixel-wise heatmaps and image-level scores without test-time optimization, feature memories, or additional calibration. Our analysis shows that the population mismatch decomposes into an irreducible denoising term and a Fisher-divergence term between the test-path and normal-path score functions, which identifies the score-gap component that drives anomaly separation and explains the effectiveness of robust path aggregation. Extensive experiments on MVTec-AD and VisA demonstrate superior performance compared with SOTA reconstruction-based and recent flow matching-based approaches.

Mariafrancesca Patalano, Giovanna Capizzi, Kamran Paynabar

Advanced manufacturing technologies allow for the production of intricate parts featuring high shape complexity and spatially-varying material composition. Data fusion of point clouds with chromatic attributes provides 4D point clouds, a compact and informative representation that encodes both shape and material information. In this paper, we present a registration-free framework for Simultaneous Monitoring of shApe and Color (SMAC) via 4D point clouds. The proposed framework leverages Laplace-Beltrami operator spectral properties to capture and monitor geometric features and the relationship between shape and surface color. A combined monitoring scheme is proposed to effectively detect shape deformations and color anomalies, along with a spatially-aware post-signal diagnostic procedure to determine the source of change and localize color anomalies. Importantly, neither component relies on registration or mesh reconstruction, eliminating error-prone and computationally expensive preprocessing steps. A Monte Carlo simulation study and a case study on functionally graded materials demonstrate that SMAC achieves effective detection performance, particularly for subtle defects, while providing diagnostic capabilities to identify the source and location of anomalies.

Che-Yi Liao, Zheng Dong, Gian-Gabriel Garcia et al.

Multivariate time series imputation is often compromised by mismatch between the observed and true data distributions, a bias induced by the combined effects of time-series non-stationarity and systematic missingness. Standard methods that encourage point-wise reconstruction or direct distributional alignment may overfit these biased observations. We propose the Distributionally Robust Regularized Imputer Objective (DRIO), which jointly minimizes reconstruction error and the worst-case divergence between the imputer distribution and data distributions within a Wasserstein ambiguity set. We derive a tractable upper-bound surrogate that reduces infinite-dimensional optimization over measures to adversarial search over sample trajectories, and develop an alternating learning algorithm compatible with modern deep learning backbones. Comprehensive experiments on diverse real-world datasets show that DRIO consistently provides robust imputation and suggests improved downstream forecasting under various missingness scenarios.

Melika Baghi, Xiao Liu, Kamran Paynabar

High-fidelity simulations, such as computational fluid dynamics and finite element analysis, are essential for modeling complex engineering systems but are often prohibitively expensive for tasks including parametric studies, optimization, and real-time control. Projection-based reduced-order models (ROMs) alleviate this cost by projecting the governing dynamics onto low-dimensional subspaces. However, their performance can deteriorate under parameter variation, motivating the need for adaptive basis construction. In this work, we propose a constrained ensemble learning framework, termed Constrained Extreme Gradient Boosting (cXGBoost), for predicting Proper Orthogonal Decomposition (POD) bases as functions of system parameters. The approach leverages a geometric representation of subspaces on the Grassmann manifold, which are mapped to a Euclidean space to enable efficient regression using gradient boosting trees. A norm constraint is imposed during training to ensure the validity of the inverse mapping and preserve the geometric structure of the predicted subspaces. The proposed method is evaluated on four numerical examples, including fluid dynamics and wave propagation problems, demonstrating its ability to accurately predict parameter-dependent bases while maintaining robustness across nonlinear regimes. These results highlight the potential of combining geometric learning with constrained ensemble methods for scalable and reliable reduced-order modeling of high-dimensional parametric systems.

Mariafrancesca Patalano, Giovanna Capizzi, Kamran Paynabar

Modern sensing technologies have enabled the collection of unstructured point cloud data (PCD) of varying sizes, which are used to monitor the geometric accuracy of 3D objects. PCD are widely applied in advanced manufacturing processes, including additive, subtractive, and hybrid manufacturing. To ensure the consistency of analysis and avoid false alarms, preprocessing steps such as registration and mesh reconstruction are commonly applied prior to monitoring. However, these steps are error-prone, time-consuming and may introduce artifacts, potentially affecting monitoring outcomes. In this paper, we present a novel registration-free approach for monitoring PCD of complex shapes, eliminating the need for both registration and mesh reconstruction. Our proposal consists of two alternative feature learning methods and a common monitoring scheme. Feature learning methods leverage intrinsic geometric properties of the shape, captured via the Laplacian and geodesic distances. In the monitoring scheme, thresholding techniques are used to further select intrinsic features most indicative of potential out-of-control conditions. Numerical experiments and case studies highlight the effectiveness of the proposed approach in identifying different types of defects.

Qian Wang, Kamran Paynabar

Point cloud data are widely used in manufacturing applications for process inspection, modeling, monitoring and optimization. The state-of-art tensor regression techniques have effectively been used for analysis of structured point cloud data, where the measurements on a uniform grid can be formed into a tensor. However, these techniques are not capable of handling unstructured point cloud data that are often in the form of manifolds. In this paper, we propose a nonlinear dimension reduction approach named Maximum Covariance Unfolding Regression that is able to learn the low-dimensional (LD) manifold of point clouds with the highest correlation with explanatory covariates. This LD manifold is then used for regression modeling and process optimization based on process variables. The performance of the proposed method is subsequently evaluated and compared with benchmark methods through simulations and a case study of steel bracket manufacturing.

Qian Wang, Huanyi Shui, Thi Tu Trinh Tran et al.

In the automotive industry, the full cycle of managing in-use vehicle quality issues can take weeks to investigate. The process involves isolating root causes, defining and implementing appropriate treatments, and refining treatments if needed. The main pain-point is the lack of a systematic method to identify causal relationships, evaluate treatment effectiveness, and direct the next actionable treatment if the current treatment was deemed ineffective. This paper will show how we leverage causal Machine Learning (ML) to speed up such processes. A real-word data set collected from on-road vehicles will be used to demonstrate the proposed framework. Open challenges for vehicle quality applications will also be discussed.

Christian Capezza, Antonio Lepore, Kamran Paynabar

Statistical process monitoring (SPM) methods are essential tools in quality management to check the stability of industrial processes, i.e., to dynamically classify the process state as in control (IC), under normal operating conditions, or out of control (OC), otherwise. Traditional SPM methods are based on unsupervised approaches, which are popular because in most industrial applications the true OC states of the process are not explicitly known. This hampered the development of supervised methods that could instead take advantage of process data containing labels on the true process state, although they still need improvement in dealing with class imbalance, as OC states are rare in high-quality processes, and the dynamic recognition of unseen classes, e.g., the number of possible OC states. This article presents a novel stream-based active learning strategy for SPM that enhances partially hidden Markov models to deal with data streams. The ultimate goal is to optimize labeling resources constrained by a limited budget and dynamically update the possible OC states. The proposed method performance in classifying the true state of the process is assessed through a simulation and a case study on the SPM of a resistance spot welding process in the automotive industry, which motivated this research.

Pouya Ahadi, Blair Winograd, Camille Zaug et al.

Active Learning (AL) has garnered significant interest across various application domains where labeling training data is costly. AL provides a framework that helps practitioners query informative samples for annotation by oracles (labelers). However, these labels often contain noise due to varying levels of labeler accuracy. Additionally, uncertain samples are more prone to receiving incorrect labels because of their complexity. Learning from imperfectly labeled data leads to an inaccurate classifier. We propose a novel AL framework to construct a robust classification model by minimizing noise levels. Our approach includes an assignment model that optimally assigns query points to labelers, aiming to minimize the maximum possible noise within each cycle. Additionally, we introduce a new sampling method to identify the best query points, reducing the impact of label noise on classifier performance. Our experiments demonstrate that our approach significantly improves classification performance compared to several benchmark methods.

Qian Wang, Mohammad N. Bisheh, Kamran Paynabar

Modern sensing and metrology systems now stream terabytes of heterogeneous, high-dimensional (HD) data profiles, images, and dense point clouds, whose natural representation is multi-way tensors. Understanding such data requires regression models that preserve tensor geometry, yet remain expressive enough to capture the pronounced nonlinear interactions that dominate many industrial and mechanical processes. Existing tensor-based regressors meet the first requirement but remain essentially linear. Conversely, conventional neural networks offer nonlinearity only after flattening, thereby discarding spatial structure and incurring prohibitive parameter counts. This paper introduces a Tensor-on-Tensor Regression Neural Network (TRNN) that unifies these two paradigms.

Elif Konyar, Mostafa Reisi Gahrooei, Kamran Paynabar

Effective modeling of heterogeneous subpopulations presents a significant challenge due to variations in individual characteristics and behaviors. This paper proposes a novel approach to address this issue through multi-task learning (MTL) and low-rank tensor decomposition techniques. Our MTL approach aims to enhance personalized modeling by leveraging shared structures among similar tasks while accounting for distinct subpopulation-specific variations. We introduce a framework where low-rank decomposition decomposes the collection of task model parameters into a low-rank structure that captures commonalities and variations across tasks and subpopulations. This approach allows for efficient learning of personalized models by sharing knowledge between similar tasks while preserving the unique characteristics of each subpopulation. Experimental results in simulation and case study datasets demonstrate the superior performance of the proposed method compared to several benchmarks, particularly in scenarios with high variability among subpopulations. The proposed framework not only improves prediction accuracy but also enhances interpretability by revealing underlying patterns that contribute to the personalization of models.

Dan Li, Nagi Gebraeel, Kamran Paynabar et al.

Complex interconnections between information technology and digital control systems have significantly increased cybersecurity vulnerabilities in smart grids. Cyberattacks involving data integrity can be very disruptive because of their potential to compromise physical control by manipulating measurement data. This is especially true in large and complex electric networks that often rely on traditional intrusion detection systems focused on monitoring network traffic. In this paper, we develop an online detection algorithm to detect and localize covert attacks on smart grids. Using a network system model, we develop a theoretical framework by characterizing a covert attack on a generator bus in the network as sparse features in the state-estimation residuals. We leverage such sparsity via a regularized linear regression method to detect and localize covert attacks based on the regression coefficients. We conduct a comprehensive numerical study on both linear and nonlinear system models to validate our proposed method. The results show that our method outperforms conventional methods in both detection delay and localization accuracy.

Dan Li, Paritosh Ramanan, Nagi Gebraeel et al.

Cybersecurity of Industrial Control Systems (ICS) is drawing significant concerns as data communication increasingly leverages wireless networks. A lot of data-driven methods were developed for detecting cyberattacks, but few are focused on distinguishing them from equipment faults. In this paper, we develop a data-driven framework that can be used to detect, diagnose, and localize a type of cyberattack called covert attacks on smart grids. The framework has a hybrid design that combines an autoencoder, a recurrent neural network (RNN) with a Long-Short-Term-Memory (LSTM) layer, and a Deep Neural Network (DNN). This data-driven framework considers the temporal behavior of a generic physical system that extracts features from the time series of the sensor measurements that can be used for detecting covert attacks, distinguishing them from equipment faults, as well as localize the attack/fault. We evaluate the performance of the proposed method through a realistic simulation study on the IEEE 14-bus model as a typical example of ICS. We compare the performance of the proposed method with the traditional model-based method to show its applicability and efficacy.

Hao Yan, Marco Grasso, Kamran Paynabar et al.

The use of video-imaging data for in-line process monitoring applications has become more and more popular in the industry. In this framework, spatio-temporal statistical process monitoring methods are needed to capture the relevant information content and signal possible out-of-control states. Video-imaging data are characterized by a spatio-temporal variability structure that depends on the underlying phenomenon, and typical out-of-control patterns are related to the events that are localized both in time and space. In this paper, we propose an integrated spatio-temporal decomposition and regression approach for anomaly detection in video-imaging data. Out-of-control events are typically sparse spatially clustered and temporally consistent. Therefore, the goal is to not only detect the anomaly as quickly as possible ("when") but also locate it ("where"). The proposed approach works by decomposing the original spatio-temporal data into random natural events, sparse spatially clustered and temporally consistent anomalous events, and random noise. Recursive estimation procedures for spatio-temporal regression are presented to enable the real-time implementation of the proposed methodology. Finally, a likelihood ratio test procedure is proposed to detect when and where the hotspot happens. The proposed approach was applied to the analysis of video-imaging data to detect and locate local over-heating phenomena ("hotspots") during the layer-wise process in a metal additive manufacturing process.

Hao Yan, Kamran Paynabar, Jianjun Shi

In point-based sensing systems such as coordinate measuring machines (CMM) and laser ultrasonics where complete sensing is impractical due to the high sensing time and cost, adaptive sensing through a systematic exploration is vital for online inspection and anomaly quantification. Most of the existing sequential sampling methodologies focus on reducing the overall fitting error for the entire sampling space. However, in many anomaly quantification applications, the main goal is to estimate sparse anomalous regions in the pixel-level accurately. In this paper, we develop a novel framework named Adaptive Kernelized Maximum-Minimum Distance AKM$^2$D to speed up the inspection and anomaly detection process through an intelligent sequential sampling scheme integrated with fast estimation and detection. The proposed method balances the sampling efforts between the space-filling sampling (exploration) and focused sampling near the anomalous region (exploitation). The proposed methodology is validated by conducting simulations and a case study of anomaly detection in composite sheets using a guided wave test.

Samaneh Ebrahimi, Chitta Ranjan, Kamran Paynabar

The high-dimensionality and volume of large scale multistream data has inhibited significant research progress in developing an integrated monitoring and diagnostics (M&D) approach. This data, also categorized as big data, is becoming common in manufacturing plants. In this paper, we propose an integrated M\&D approach for large scale streaming data. We developed a novel monitoring method named Adaptive Principal Component monitoring (APC) which adaptively chooses PCs that are most likely to vary due to the change for early detection. Importantly, we integrate a novel diagnostic approach, Principal Component Signal Recovery (PCSR), to enable a streamlined SPC. This diagnostics approach draws inspiration from Compressed Sensing and uses Adaptive Lasso for identifying the sparse change in the process. We theoretically motivate our approaches and do a performance evaluation of our integrated M&D method through simulations and case studies.

Chitta Ranjan, Mahendranath Reddy, Markku Mustonen et al.

A real-world dataset is provided from a pulp-and-paper manufacturing industry. The dataset comes from a multivariate time series process. The data contains a rare event of paper break that commonly occurs in the industry. The data contains sensor readings at regular time-intervals (x's) and the event label (y). The primary purpose of the data is thought to be building a classification model for early prediction of the rare event. However, it can also be used for multivariate time series data exploration and building other supervised and unsupervised models.

Hao Yan, Kamran Paynabar, Massimo Pacella

Advanced 3D metrology technologies such as Coordinate Measuring Machine (CMM) and laser 3D scanners have facilitated the collection of massive point cloud data, beneficial for process monitoring, control and optimization. However, due to their high dimensionality and structure complexity, modeling and analysis of point clouds are still a challenge. In this paper, we utilize multilinear algebra techniques and propose a set of tensor regression approaches to model the variational patterns of point clouds and to link them to process variables. The performance of the proposed methods is evaluated through simulations and a real case study of turning process optimization.

Chitta Ranjan, Samaneh Ebrahimi, Kamran Paynabar

In this paper, we develop a new sequential regression modeling approach for data streams. Data streams are commonly found around us, e.g in a retail enterprise sales data is continuously collected every day. A demand forecasting model is an important outcome from the data that needs to be continuously updated with the new incoming data. The main challenge in such modeling arises when there is a) high dimensional and sparsity, b) need for an adaptive use of prior knowledge, and/or c) structural changes in the system. The proposed approach addresses these challenges by incorporating an adaptive L1-penalty and inertia terms in the loss function, and thus called Inertial Regularization and Selection (IRS). The former term performs model selection to handle the first challenge while the latter is shown to address the last two challenges. A recursive estimation algorithm is developed, and shown to outperform the commonly used state-space models, such as Kalman Filters, in experimental studies and real data.

Chitta Ranjan, Samaneh Ebrahimi, Kamran Paynabar

Sequence feature embedding is a challenging task due to the unstructuredness of sequence, i.e., arbitrary strings of arbitrary length. Existing methods are efficient in extracting short-term dependencies but typically suffer from computation issues for the long-term. Sequence Graph Transform (SGT), a feature embedding function, that can extract a varying amount of short- to long-term dependencies without increasing the computation is proposed. SGT's properties are analytically proved for interpretation under normal and uniform distribution assumptions. SGT features yield significantly superior results in sequence clustering and classification with higher accuracy and lower computation as compared to the existing methods, including the state-of-the-art sequence/string Kernels and LSTM.

Chitta Ranjan, Kamran Paynabar, Jonathan E. Helm et al.

The ability to accurately forecast and control inpatient census, and thereby workloads, is a critical and longstanding problem in hospital management. Majority of current literature focuses on optimal scheduling of inpatients, but largely ignores the process of accurate estimation of the trajectory of patients throughout the treatment and recovery process. The result is that current scheduling models are optimizing based on inaccurate input data. We developed a Clustering and Scheduling Integrated (CSI) approach to capture patient flows through a network of hospital services. CSI functions by clustering patients into groups based on similarity of trajectory using a novel Semi-Markov model (SMM)-based clustering scheme proposed in this paper, as opposed to clustering by admit type or condition as in previous literature. The methodology is validated by simulation and then applied to real patient data from a partner hospital where we see it outperforms current methods. Further, we demonstrate that extant optimization methods achieve significantly better results on key hospital performance measures under CSI, compared with traditional estimation approaches, increasing elective admissions by 97% and utilization by 22% compared to 30% and 8% using traditional estimation techniques. From a theoretical standpoint, the SMM-clustering is a novel approach applicable to any temporal-spatial stochastic data that is prevalent in many industries and application areas.