Statistical Process Monitoring of Isolated and Persistent Defects in Complex Geometrical Shapes

Traditional Statistical Process Control methodologies face several challenges when monitoring defects in complex geometries, such as those of products obtained via Additive Manufacturing techniques. Many approaches cannot be applied in these settings due to the high dimensionality of the data and the lack of parametric and distributional assumptions on the object shapes. Motivated by a case study involving the monitoring of egg-shaped trabecular structures, we investigate two recently-proposed methodologies to detect deviations from the nominal IC model caused by excess or lack of material. Our study focuses on the detection of both isolated large changes in the geometric structure, as well as persistent small deviations. We compare the approach of Scimone et al. (2022) with Zhao and del Castillo (2021) for monitoring defects in a small Phase I sample of 3D-printed objects. While the former control chart is able to detect large defects, the latter allows the detection of nonconforming objects with persistent small defects. Furthermore, we address the fundamental issue of selecting the number of eigenvalues to be monitored in Zhao and del Castillo's method by proposing a dimensionality reduction technique based on kernel principal components. This approach is shown to provide a good detection capability even when considering a large number of eigenvalues. By leveraging the sensitivity of the two monitoring schemes to different magnitudes of nonconformities, we also propose a novel joint monitoring scheme that is capable of identifying both types of defects in the considered case study. Computer code in R and Matlab that implements these methods and replicates the results is available as part of the supplementary material.