vi
TABLE OF CONTENTS
CHAPTER
CHAPTER 1
TITLE
PAGE
ACKNOWLEDGEMENTS
iii
ABSTRACT
iv
ABSTRAK
v
TABLE OF CONTENTS
vi
LIST OF TABLES
xii
LIST OF FIGURES
xv
LIST OF ABBREVIATIONS
xviii
LIST OF APPENDICES
xix
INTRODUCTION
1.1
Background of the Problem
1
1.2
Statement of the Problem
3
1.3
Purpose and Objective of the Study
4
1.4
Scope of the Study
4
1.5
Significance of the Study
5
1.6
Organization of the Thesis
5
vii
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
6
2.2
Process Variation and Statistical Process Control
7
2.3
Control Chart and Pattern Recognition
9
2.3.1
Control Chart
9
2.3.2
Control Chart Patterns Recognition (CCPR)
11
2.3.3
Existing Framework for Standalone CCPR
13
2.4
2.5
2.6
Web-based Manufacturing System
16
2.4.1
Application Area
17
2.4.2
Web-based Process Monitoring
20
Web-based Statistical Process Control System
21
2.5.1
Previous Researches
21
2.5.2
Commercial of the Shelf
25
Design Considerations in Development of Client-
29
Server based Application
2.7
2.6.1
Data Modeling
29
2.6.2
Network Security
30
2.6.3
Communication Standard
30
2.6.4
Load Balancing
32
2.6.5
Client and Server System Integration
33
Load Balancing and System Performance
33
Measurement
2.7.1
Application of Load Balancing
33
2.7.2
Performance Measurement
35
2.7.3
Summary of Performance Measurement
35
viii
2.8
2.9
Client and Server (CS) Architecture
36
2.8.1
Mainframe System and File Sharing System
37
2.8.2
Two – tier CS System
38
2.8.3
Three – tier CS System
39
2.8.4
N – tier CS System
40
2.8.5
Example of CS Architecture
41
2.8.6
User Requirement and CS Architecture
45
Tools and Techniques for Web-based System
46
Development
2.10
2.9.1
JSP Language
46
2.9.2
Apache Tomcat Server
47
2.9.3
My-SQL Database Server
48
2.9.4
The Mathworks Matlab
50
Summary
51
CHAPTER 3 RESEARCH METHODOLOGY
3.1
Introduction
52
3.2
Problem Situation and Solution Concept
52
3.3
Development Phases
55
3.3.1
57
Phase One –Analyze Existing
Standalone System
3.3.2
Phase Two – Determine a Suitable
57
Load Passing Procedure
3.3.3
Phase Three – Determine a Suitable
57
CS Architecture
3.3.4
Phase Four – Prototype System
Implementation & Evaluation
58
ix
3.4
3.5
Source of Data
58
3.4.1
Synthetic Data
58
3.4.2
Published Data
58
3.4.3
Industrial Data
59
Instruments and Equipments
59
3.5.1
Hardware Requirement
59
3.5.2
Software Requirement
60
3.6
Performance Measures
62
3.7
Summary
62
CHAPTER 4 CLIENT AND SERVER ARCHITECTURE
FOR CLIENT-SERVER BASED CCPR
SYSTEM
4.1
Introduction
63
4.2
Overview of Client and Server Architecture
63
4.3
Client and Server Architecture for Client-Server
64
based CCPR System
4.3.1
Standalone System
64
4.3.2
CS Design 1 – Load Passing Procedure and
66
Patterns Recognition at Engine Tier
4.3.3
CS Design 2 – Load Passing Procedure at
68
Server Tier and Patterns Recognition at
Engine Tier
4.4
Performance Comparison on the Candidate Designs
70
4.4.1
Engine Tier Performance
70
4.4.2
Web Server Tier Performance
75
4.4.3
Volume of Data
79
4.4.4
Intensity of Traffic
80
x
4.5
Selection of A Suitable Client and Server
82
Architecture
4.6
CHAPTER 5
Summary
84
LOAD PASSING PROCEDURE FOR
CONTROL CHART PROCESS
MONITORING
5.1
Introduction
85
5.2
Overview on the Load Passing Procedure
85
5.2.1
Nelson Run Rules Test
86
5.2.2
CUSUM Test
87
5.2.3
EWMA Test
88
5.3
Load Passing Procedure for Client-Server based
90
CCPR System
5.3.1
Procedure 1: Load Passing Using
97
Nelson Run Rules and CUSUM Test
5.3.2
Procedure 2: Load Passing Using
99
Nelson Run Rules and EWMA Test
5.3.3
Procedure 3: Load Passing Using
101
CUSUM and EWMA Test
5.4
Analysis and Comparison among the Load Passing
103
Procedures
5.4.1
Classification Accuracy
103
5.4.2
System Resources
105
5.4.3
Process Time
108
5.5
Selection of Suitable Load Passing Procedure
112
5.6
Summary
113
xi
CHAPTER 6 PROTOTYPE SYSTEM IMPLEMENTATION
AND VALIDATION
6.1
Introduction
114
6.2
Web-enabled Control Chart Patterns Recognition
115
System Operational Framework
6.2.1
System Management and Administration
115
Module
6.2.2
Operational Module
116
6.2.3
Client Module
117
6.3
Data Flow Diagram
118
6.4
Database Design
120
6.5
System Integration
121
6.6
Graphical User Interface
122
6.7
System Validation
124
6.8
6.7.1
White Box Testing
124
6.7.2
Black Box Testing
125
Guideline for Transforming the Standalone to
135
Client-Server based CCPR system.
6.9
Summary
137
CHAPTER 7 DISCUSSION AND CONCLUSION
7.1
Introduction
138
7.2
Research Achievement and Contribution
138
7.3
Comparison with Previous Research
140
7.4
Research Limitation
143
7.5
Research Implication and Practically
144
7.6
Recommendation for Future Works
144
7.7
Closing Note
145
REFERENCES
146
APPENDICES
160
xii
LIST OF TABLES
TABLE NO.
TITLE
PAGE
2.1
Application of ANN in Control Chart Patterns
ecognition
12
2.2
Conventional and Future Manufacturing (Jay, 2003)
17
2.3
Researchers’ Contributions in Web-based SPC System
25
2.4
Web-based SPC System and Provided Features
28
2.5
Summary of Load Balancing Performance
Measurement Methods
35
3.1
System Performance Measurement
62
4.1
Standalone system Engine Tier Performance
71
4.2
System Performance for Engine Tier
71
4.3
ANOVA Analysis for Engine Tier Performance
73
4.4
Result for Web Server Tier Performance
75
4.5
ANOVA Analysis for Engine Tier Performance
77
4.6
Process Time for Different Volume of Data (second)
79
4.7
Process Time for the Experiment on Intensity of Traffic
(second)
81
4.8
Overall Ranking on Engine Tier and Server Tier
Performance
82
4.9
Overall Ranking on Volume of Data and Intensity of
Traffic
83
5.1
Suitable λ and L value for EWMA chart with ARL ≈
500 (Montgomery,2004)
89
5.2
Example of calculation to determine the process
priority at time, t = 0
92
xiii
5.3
Example of calculation to determine the process
priority at time, t =100ms
93
5.4
Load passing Algorithm
94
5.5
Sample of clients being scheduled and waiting for
process
95
5.6
Classification of Stable and Unstable Process Procedure 1
97
5.7
System Resource Usage - Procedure 1
98
5.8
Process Time for Procedure 1 (millisecond)
99
5.9
Classification of Stable and Unstable Process Procedure 2
99
5.10
System Resource Usage - Procedure 2
100
5.11
Process Time for Procedure 2
100
5.12
Classification of Stable and Unstable Process Procedure 3
101
5.13
System Resource Usage - Procedure 3
102
5.14
Process Time for Procedure 3
102
5.15
Summary of Classification Accuracy for Candidate
Procedures
104
5.16
Summary of System Resources Usage
106
5.17
Summary of Process Time for Candidate Procedure
108
5.18
Comparison among the Candidate Procedure
110
5.19
Summary of Process Time in term of Different Delay
Time
111
5.20
Comparison among the Different Delay Time
112
5.21
Overall Ranking for the Candidate Load Passing
Procedures
112
6.1
System Validation Result for the Published Dataset 1
127
6.2
System Validation Result for the Published Dataset 2
128
6.3
System Validation Result for the Industrial Dataset 1
130
xiv
6.4
System Validation Result for the Industrial Dataset 2
131
6.5
Calculation for dataset 3 to determine the process
priority (t=a)
132
6.6
Calculation for dataset 3 to determine the process
priority (t=a+100ms)
133
6.7
Sample of measurement data schedule by load passing
procedure
134
6.8
Guideline for converting the standalone to Client-server
based system
135
7.1
Comparison between standalone and the proposed
system.
140
7.2
Comparison between the Previous and Author’s
Research
141
xv
LIST OF FIGURES
FIGURE NO.
TITLE
PAGE
2.1
Example of Control Chart
10
2.2
Control Chart Zones
10
2.3
Control Chart Patterns (Wani and Pham, 1999)
11
2.4
Flow Chart for Online Recognition of Developing
Control Chart Patterns (Adnan, 2002)
14
2.5
Application Areas of Web-based Manufacturing
18
2.6
Research Issues in Development of the ClientServer based Application
29
2.7
Web Services for Different Platform Integration
31
2.8
Separation of Public and Private Network (Tony,
2001)
32
2.9
Simple Client / Server Computing Architecture
37
2.10
Two – tier Client and Server Architecture
39
2.11
Three- Tier Client and Server Architecture
40
2.12
N-Tier Client and Server Architecture
41
2.13
Design for Client – Server based Mobile Robot
Control
42
2.14
CS Architecture for Distributed Multimedia
Environment
42
2.15
Diagram for CS Telemedical system
43
2.16
Structure of an Http-based Remote Controlled
Laboratory
44
2.17
CS and Ad-Hoc Communication Platform
44
xvi
2.18
Example of Tomcat Web Application Manager
48
2.19
Interface of MySQL Control Center
49
2.20
MATLAB Interface Example
50
3.1
Enhancement from Standalone into a Client-Server
based CCPR System
53
3.2
Proposed Operation Framework for Web-enabled
CCPR System
54
3.3
Client-Server based CCPR System Architecture
Development Phases
56
4.1
Operational Framework for Standalone System
64
4.2
Logical Flow Chart for Standalone System
65
4.3
Operational Framework for CS Design 1
66
4.4
Logical Flow Chart for CS Design1
67
4.5
Operational Framework for CS Design 2
68
4.6
Logical Flow Chart for CS Design 2
69
4.7
Comparison Chart for the Engine Tier Performance
72
4.8
Radar Chart for Engine Tier Performance
74
4.9
Comparison Chart for the Web Server Tier
Performance
76
4.10
Radar Chart for Web Server Tier Performance
78
4.11
Line Chart for the Experiment on Volume of Data
80
4.12
Line Chart for the Experiment on Intensity of
Traffic
81
5.1
Nelson Run Rules
86
5.2
Sample of CUSUM Chart
87
5.3
Sample of EWMA Control Chart (Montgomery,
2004)
90
5.4
Client-Server based CCPR system with Multiple
Clients Access
91
xvii
5.5
Basic Architecture for CS based CCPR System
96
5.6
Summarize of Classification Accuracy using Bar
Chart.
104
5.7
Radar Chart for Classification Accuracy
105
5.8
Summarize of System Performance using Bar Chart
106
5.9
Radar Chart for System Performance
107
5.10
Summary of Process Time for Candidate Procedure
109
5.11
Radar Chart for Candidate Procedures Process Time
109
6.1
Functions provided for Administration Module
116
6.2
Functions for Operational Module
117
6.3
User Functions provided at Client Side
118
6.4
Context Diagram for Web-enabled CCPR System
118
6.5
Data Flow Diagram for Web-enabled CCPR System
119
6.6
Web-enabled CCPR System Database Structure
120
6.7
System Integration for the Web-enabled CCPR
122
6.8
Client Module Interface: Manufacturing Process
Listing
123
6.9
Operational Module Interface: Adding
Manufacturing Process Data
123
6.10
Administration Module: Display the Control Chart
Information
124
6.11
White Box Testing for User Authentication
125
6.12
Web-enabled CCPR System Validation Framework
using Published and Industrial Dataset
126
6.13
Control Chart Plotting for Published Dataset 1
127
6.14
Control Chart Plotting for Published Dataset 2
128
6.15
Control Chart Plotting for Industrial Dataset 1
130
6.16
Control Chart Plotting for Industrial Dataset 2
131
7.1
An Architecture for the Development of a ClientServer based CCPR System
139
xviii
LIST OF ABBREVIATIONS
AI
Artificial Intelligent
AFL
Average Frame Length
ANOVA
Analysis of Variance
CCPR
Control Chart Patterns Recognition
CPU
Centra Processing Unit
CS
Client and Server
CUSUM
Cumulative Sum
DBMS
Database Management System
DNS
Domain Name Service
EWMA
Exponentially Weighted Moving Average
I/O
Input and Output
JSP
Java Server Page
JVM
Java Virtual Machine
LCL
Lower Control Limit
MIB
Management Information Base
NA
Not Applicable
P2P
Peer to Peer
PDM
Product Data Management
PLC
Programmable Logic Control
SCM
Supply Chain Management
SNMP
Simple Network Management Protocol
SPC
Statistical Process Control
UCL
Upper Control Limit
XML
eXtensible Markup Language
WWW
World Wide Web
xix
LIST OF APPENDICES
APPENDIX
TITLE
PAGE
A
Factor for computing control limits for x-bar chart
160
B
Database Scheme
161
C
Measurement Result for Engine and Server Tier
Performance
163
D
Measurement on Silicon Wafer Width in the
Semiconductor Processing
168
E
Measurement on the Metallic Film Thickness
169
F
Measurement on PCB Solder Height
170
G
Measurement on Edge Wave Using Taper Gauge
171
H
Tin Plating Process
173