Predictive Quality Defect Detection Using Machine Learning Algorithms: A Case Study from Automobile Industry

Industry 4.0 is generally defined as a development system that compels the digitalization of processes to create integrated and autonomous systems. The process tracking of parts is very important in terms of detecting missed faulty products. Some defects that escape from quality control directly affect the end-user. Machine learning algorithms have been used to predict changes in the quality control processes and defective products, toward real-time and effective data processing. Thus, the highest quality of the final product will be delivered to the customer and to reduce the defective production coming out of the manufacturing chain. In this article, the study aims to establish a predictive quality model that can detect defect-free approved but faulty products overlooked during the quality inspection operations. Machine learning methods are used to analyze the relationship between quality control data and customer complaints. For this purpose, we use the last quality stage data of an automobile manufacturer’s brake system from 2018 to 2020. Machine learning models are constructed using logistic regression, ridge regression, support vector machine, random forest classification tree, gradient boost, XGBoost, LightGBM, and CatBoost algorithms. The results of specificity and negative prediction value show that the Gradient Boost and CatBoost algorithms have the best classification benefit for detecting the rare events.