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Browse filesproject/
├── ai4i2020.csv # Dataset file
├── analysis.py # EDA analysis script
├── preprocessing.py # Data preprocessing module
├── model.py # Machine learning model
├── train_model.py # Script to train and save model
├── app.py # Streamlit web application
└── README.md # Project documentation
- README.md +215 -16
- ai4i2020.csv +0 -0
- analysis.py +431 -0
- app.py +989 -0
- model.py +235 -0
- preprocessing.py +205 -0
- requirements.txt +5 -3
- train_model.py +52 -0
README.md
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forums](https://discuss.streamlit.io).
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+
# Predictive Maintenance System - AI4I 2020 Dataset
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+
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+
## Project Overview
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+
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+
This project implements a comprehensive predictive maintenance system using machine learning to predict when industrial machinery needs maintenance. The system analyzes the AI4I 2020 Predictive Maintenance Dataset and provides interactive visualizations and real-time predictions through a Streamlit web application.
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+
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## Features
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| 8 |
+
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- **Comprehensive EDA**: 15+ different exploratory data analyses
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+
- **Machine Learning Model**: Random Forest Classifier for failure prediction
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| 11 |
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- **Real-time Predictions**: Interactive interface for runtime predictions
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+
- **Maintenance Scheduling**: Estimates time to failure and maintenance urgency
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+
- **Interactive Visualizations**: Dynamic charts and graphs using Plotly
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- **Batch Processing**: Upload CSV files for batch predictions
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+
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+
## Dataset
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The AI4I 2020 Predictive Maintenance Dataset contains:
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- **10,000 machine records**
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- **14 features** including temperature, rotational speed, torque, and tool wear
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+
- **Binary target**: Machine failure (0 = no failure, 1 = failure)
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- **5 failure types**: TWF, HDF, PWF, OSF, RNF
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+
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+
## Project Structure
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+
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+
```
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project/
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├── ai4i2020.csv # Dataset file
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├── analysis.py # EDA analysis script
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├── preprocessing.py # Data preprocessing module
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├── model.py # Machine learning model
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| 32 |
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├── train_model.py # Script to train and save model
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| 33 |
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├── app.py # Streamlit web application
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| 34 |
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└── README.md # Project documentation
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+
```
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+
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+
## Installation
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+
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+
1. **Clone or download the project**
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+
2. **Install dependencies** (requirements listed below):
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+
```bash
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+
pip install pandas==2.1.4 numpy==1.26.2 matplotlib==3.8.2 seaborn==0.13.0 scikit-learn==1.4.0 streamlit==1.29.0 plotly==5.18.0
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```
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3. **Ensure the dataset file (`ai4i2020.csv`) is in the project directory**
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## Usage
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### Option 1: Run Streamlit App Directly (Recommended)
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The app will train the model automatically on first run:
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```bash
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streamlit run app.py
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```
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### Option 2: Train Model First, Then Run App
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1. **Train the model**:
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```bash
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python train_model.py
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```
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2. **Run the Streamlit app**:
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```bash
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streamlit run app.py
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```
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### Option 3: Run EDA Analysis Only
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```bash
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python analysis.py
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```
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## Streamlit Application
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The web application includes four main sections:
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### 1. Introduction
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- Dataset overview and statistics
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- Project goals and features
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- Dataset preview
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| 82 |
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### 2. Exploratory Data Analysis
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Interactive visualizations including:
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- Summary statistics
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- Target distribution
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- Feature distributions
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- Correlation analysis
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- Failure analysis by machine type
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- Tool wear analysis
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- Temperature analysis
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- Outlier detection
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- Pairwise relationships
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- Failure type breakdown
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### 3. Model & Predictions
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- Model performance metrics
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- Feature importance visualization
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- **Runtime prediction**: Enter machine parameters to predict maintenance needs
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- **Batch prediction**: Upload CSV file for multiple predictions
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- Maintenance urgency assessment
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- Time-to-failure estimation
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### 4. Conclusion
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- Key findings and takeaways
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- Applications and future improvements
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## EDA Analyses Performed
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1. Summary statistics (mean, median, mode, etc.)
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2. Missing value analysis
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3. Data types and unique value counts
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4. Target variable distribution
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5. Correlation analysis
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6. Outlier detection (IQR method)
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7. Feature distribution analysis
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8. Failure analysis by machine type
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9. Tool wear analysis
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10. Temperature analysis
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11. Power and rotational speed analysis
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12. Pairwise feature relationships
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13. Detailed failure type analysis
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14. Time to failure estimation
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15. Grouped aggregations
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## Machine Learning Model
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- **Algorithm**: Random Forest Classifier
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- **Features**: 11 engineered features including:
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- Air temperature, Process temperature
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- Rotational speed, Torque
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- Tool wear
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- Temperature difference
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- Power
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- Machine type encoding
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- **Evaluation Metrics**:
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- Accuracy
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- Precision
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- Recall
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- F1-Score
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- ROC-AUC
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## Predictive Features
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The model predicts:
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1. **Machine Failure**: Binary prediction (Yes/No)
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2. **Failure Probability**: Probability score (0-1)
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3. **Time to Failure**: Estimated minutes until maintenance needed
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4. **Maintenance Status**: Current maintenance requirement status
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5. **Maintenance Urgency**: CRITICAL, HIGH, MEDIUM, or LOW
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## Runtime Prediction
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Users can input machine parameters:
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- Machine Type (L, M, H)
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- Air Temperature (K)
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- Process Temperature (K)
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- Rotational Speed (rpm)
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- Torque (Nm)
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- Tool Wear (minutes)
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The system provides:
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- Failure prediction
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- Maintenance urgency level
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- Estimated time to failure
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- Detailed recommendations
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| 168 |
+
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| 169 |
+
## Technical Stack
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| 170 |
+
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| 171 |
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- **Python 3.8+**
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- **Data Processing**: Pandas, NumPy
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| 173 |
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- **Visualization**: Matplotlib, Seaborn, Plotly
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- **Machine Learning**: Scikit-learn
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- **Web Framework**: Streamlit
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+
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## Key Insights
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1. **Tool wear** is the most critical indicator of machine health
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2. **Temperature difference** between process and air temperature correlates with failures
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| 181 |
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3. Machine **type affects failure rates** differently
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| 182 |
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4. Early detection can **prevent costly downtime**
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| 183 |
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5. Proactive maintenance scheduling can **optimize operations**
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+
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+
## Applications
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| 186 |
+
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| 187 |
+
- Industrial manufacturing
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+
- Equipment monitoring systems
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- Preventive maintenance scheduling
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| 190 |
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- Cost reduction through failure prevention
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| 191 |
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- Production optimization
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| 192 |
+
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| 193 |
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## Future Enhancements
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1. Real-time data streaming integration
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2. IoT sensor integration
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3. Advanced ensemble methods
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4. Time-series analysis
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5. Automated alert system
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6. Historical maintenance record integration
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+
## Author
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| 203 |
+
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| 204 |
+
Developed as part of the Introduction to Data Science course project.
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+
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+
## License
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| 207 |
+
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| 208 |
+
This project is for educational purposes.
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| 209 |
+
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+
## Acknowledgments
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| 211 |
+
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| 212 |
+
- AI4I 2020 Predictive Maintenance Dataset
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| 213 |
+
- Scikit-learn documentation
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| 214 |
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- Streamlit documentation
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| 215 |
+
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| 216 |
+
---
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**Note**: Make sure the `ai4i2020.csv` file is in the same directory as the scripts before running the application.
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ai4i2020.csv
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analysis.py
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| 1 |
+
"""
|
| 2 |
+
Comprehensive Exploratory Data Analysis (EDA) for AI4I 2020 Predictive Maintenance Dataset
|
| 3 |
+
This script performs 10-15 different analyses as required for the project.
|
| 4 |
+
"""
|
| 5 |
+
|
| 6 |
+
import pandas as pd
|
| 7 |
+
import numpy as np
|
| 8 |
+
import matplotlib.pyplot as plt
|
| 9 |
+
import seaborn as sns
|
| 10 |
+
import warnings
|
| 11 |
+
warnings.filterwarnings('ignore')
|
| 12 |
+
|
| 13 |
+
# Set style for better visualizations
|
| 14 |
+
sns.set_style("whitegrid")
|
| 15 |
+
plt.rcParams['figure.figsize'] = (12, 6)
|
| 16 |
+
|
| 17 |
+
class EDAAnalysis:
|
| 18 |
+
def __init__(self, data_path='ai4i2020.csv'):
|
| 19 |
+
"""Initialize the EDA analysis class"""
|
| 20 |
+
self.df = pd.read_csv(data_path)
|
| 21 |
+
self.prepare_data()
|
| 22 |
+
|
| 23 |
+
def prepare_data(self):
|
| 24 |
+
"""Prepare data for analysis"""
|
| 25 |
+
# Create a copy for analysis
|
| 26 |
+
self.df_clean = self.df.copy()
|
| 27 |
+
|
| 28 |
+
# Calculate temperature difference (important feature)
|
| 29 |
+
self.df_clean['Temperature difference [K]'] = (
|
| 30 |
+
self.df_clean['Process temperature [K]'] -
|
| 31 |
+
self.df_clean['Air temperature [K]']
|
| 32 |
+
)
|
| 33 |
+
|
| 34 |
+
# Calculate power (Rotational speed * Torque)
|
| 35 |
+
self.df_clean['Power [W]'] = (
|
| 36 |
+
self.df_clean['Rotational speed [rpm]'] *
|
| 37 |
+
self.df_clean['Torque [Nm]'] / 9.5488 # Conversion factor
|
| 38 |
+
)
|
| 39 |
+
|
| 40 |
+
# Failure type names
|
| 41 |
+
self.failure_types = {
|
| 42 |
+
'TWF': 'Tool Wear Failure',
|
| 43 |
+
'HDF': 'Heat Dissipation Failure',
|
| 44 |
+
'PWF': 'Power Failure',
|
| 45 |
+
'OSF': 'Overstrain Failure',
|
| 46 |
+
'RNF': 'Random Failure'
|
| 47 |
+
}
|
| 48 |
+
|
| 49 |
+
def analysis_1_summary_statistics(self):
|
| 50 |
+
"""Analysis 1: Summary statistics for numerical features"""
|
| 51 |
+
print("="*80)
|
| 52 |
+
print("ANALYSIS 1: SUMMARY STATISTICS")
|
| 53 |
+
print("="*80)
|
| 54 |
+
|
| 55 |
+
numerical_cols = [
|
| 56 |
+
'Air temperature [K]', 'Process temperature [K]',
|
| 57 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]',
|
| 58 |
+
'Temperature difference [K]', 'Power [W]'
|
| 59 |
+
]
|
| 60 |
+
|
| 61 |
+
summary = self.df_clean[numerical_cols].describe()
|
| 62 |
+
print(summary)
|
| 63 |
+
print("\n")
|
| 64 |
+
|
| 65 |
+
return summary
|
| 66 |
+
|
| 67 |
+
def analysis_2_missing_values(self):
|
| 68 |
+
"""Analysis 2: Missing value analysis"""
|
| 69 |
+
print("="*80)
|
| 70 |
+
print("ANALYSIS 2: MISSING VALUE ANALYSIS")
|
| 71 |
+
print("="*80)
|
| 72 |
+
|
| 73 |
+
missing = self.df_clean.isnull().sum()
|
| 74 |
+
missing_pct = (missing / len(self.df_clean)) * 100
|
| 75 |
+
|
| 76 |
+
missing_df = pd.DataFrame({
|
| 77 |
+
'Missing Count': missing,
|
| 78 |
+
'Missing Percentage': missing_pct
|
| 79 |
+
})
|
| 80 |
+
missing_df = missing_df[missing_df['Missing Count'] > 0]
|
| 81 |
+
|
| 82 |
+
if len(missing_df) == 0:
|
| 83 |
+
print("✓ No missing values found in the dataset!")
|
| 84 |
+
else:
|
| 85 |
+
print(missing_df)
|
| 86 |
+
print("\n")
|
| 87 |
+
|
| 88 |
+
return missing_df
|
| 89 |
+
|
| 90 |
+
def analysis_3_data_types(self):
|
| 91 |
+
"""Analysis 3: Data types and unique value counts"""
|
| 92 |
+
print("="*80)
|
| 93 |
+
print("ANALYSIS 3: DATA TYPES AND UNIQUE VALUES")
|
| 94 |
+
print("="*80)
|
| 95 |
+
|
| 96 |
+
info_df = pd.DataFrame({
|
| 97 |
+
'Column': self.df_clean.columns,
|
| 98 |
+
'Data Type': self.df_clean.dtypes,
|
| 99 |
+
'Unique Values': [self.df_clean[col].nunique() for col in self.df_clean.columns],
|
| 100 |
+
'Non-Null Count': self.df_clean.count().values
|
| 101 |
+
})
|
| 102 |
+
|
| 103 |
+
print(info_df.to_string(index=False))
|
| 104 |
+
print("\n")
|
| 105 |
+
|
| 106 |
+
# Categorical value counts
|
| 107 |
+
print("Type Distribution:")
|
| 108 |
+
print(self.df_clean['Type'].value_counts())
|
| 109 |
+
print("\n")
|
| 110 |
+
|
| 111 |
+
return info_df
|
| 112 |
+
|
| 113 |
+
def analysis_4_target_distribution(self):
|
| 114 |
+
"""Analysis 4: Target variable (Machine failure) distribution"""
|
| 115 |
+
print("="*80)
|
| 116 |
+
print("ANALYSIS 4: TARGET VARIABLE DISTRIBUTION")
|
| 117 |
+
print("="*80)
|
| 118 |
+
|
| 119 |
+
failure_counts = self.df_clean['Machine failure'].value_counts()
|
| 120 |
+
failure_pct = self.df_clean['Machine failure'].value_counts(normalize=True) * 100
|
| 121 |
+
|
| 122 |
+
print("Machine Failure Distribution:")
|
| 123 |
+
print(f" No Failure (0): {failure_counts[0]} ({failure_pct[0]:.2f}%)")
|
| 124 |
+
print(f" Failure (1): {failure_counts[1]} ({failure_pct[1]:.2f}%)")
|
| 125 |
+
print("\n")
|
| 126 |
+
|
| 127 |
+
# Failure types breakdown
|
| 128 |
+
print("Failure Types Breakdown:")
|
| 129 |
+
for ft in ['TWF', 'HDF', 'PWF', 'OSF', 'RNF']:
|
| 130 |
+
count = self.df_clean[ft].sum()
|
| 131 |
+
pct = (count / len(self.df_clean)) * 100
|
| 132 |
+
print(f" {self.failure_types[ft]}: {count} ({pct:.2f}%)")
|
| 133 |
+
print("\n")
|
| 134 |
+
|
| 135 |
+
return failure_counts
|
| 136 |
+
|
| 137 |
+
def analysis_5_correlation_analysis(self):
|
| 138 |
+
"""Analysis 5: Correlation analysis"""
|
| 139 |
+
print("="*80)
|
| 140 |
+
print("ANALYSIS 5: CORRELATION ANALYSIS")
|
| 141 |
+
print("="*80)
|
| 142 |
+
|
| 143 |
+
numerical_cols = [
|
| 144 |
+
'Air temperature [K]', 'Process temperature [K]',
|
| 145 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]',
|
| 146 |
+
'Temperature difference [K]', 'Power [W]', 'Machine failure'
|
| 147 |
+
]
|
| 148 |
+
|
| 149 |
+
corr_matrix = self.df_clean[numerical_cols].corr()
|
| 150 |
+
|
| 151 |
+
print("Correlation with Machine Failure:")
|
| 152 |
+
failure_corr = corr_matrix['Machine failure'].sort_values(ascending=False)
|
| 153 |
+
print(failure_corr)
|
| 154 |
+
print("\n")
|
| 155 |
+
|
| 156 |
+
return corr_matrix
|
| 157 |
+
|
| 158 |
+
def analysis_6_outlier_detection(self):
|
| 159 |
+
"""Analysis 6: Outlier detection using IQR method"""
|
| 160 |
+
print("="*80)
|
| 161 |
+
print("ANALYSIS 6: OUTLIER DETECTION (IQR METHOD)")
|
| 162 |
+
print("="*80)
|
| 163 |
+
|
| 164 |
+
numerical_cols = [
|
| 165 |
+
'Air temperature [K]', 'Process temperature [K]',
|
| 166 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]'
|
| 167 |
+
]
|
| 168 |
+
|
| 169 |
+
outlier_summary = {}
|
| 170 |
+
|
| 171 |
+
for col in numerical_cols:
|
| 172 |
+
Q1 = self.df_clean[col].quantile(0.25)
|
| 173 |
+
Q3 = self.df_clean[col].quantile(0.75)
|
| 174 |
+
IQR = Q3 - Q1
|
| 175 |
+
lower_bound = Q1 - 1.5 * IQR
|
| 176 |
+
upper_bound = Q3 + 1.5 * IQR
|
| 177 |
+
|
| 178 |
+
outliers = self.df_clean[(self.df_clean[col] < lower_bound) |
|
| 179 |
+
(self.df_clean[col] > upper_bound)]
|
| 180 |
+
outlier_count = len(outliers)
|
| 181 |
+
outlier_pct = (outlier_count / len(self.df_clean)) * 100
|
| 182 |
+
|
| 183 |
+
outlier_summary[col] = {
|
| 184 |
+
'Lower Bound': lower_bound,
|
| 185 |
+
'Upper Bound': upper_bound,
|
| 186 |
+
'Outlier Count': outlier_count,
|
| 187 |
+
'Outlier Percentage': outlier_pct
|
| 188 |
+
}
|
| 189 |
+
|
| 190 |
+
print(f"{col}:")
|
| 191 |
+
print(f" Bounds: [{lower_bound:.2f}, {upper_bound:.2f}]")
|
| 192 |
+
print(f" Outliers: {outlier_count} ({outlier_pct:.2f}%)")
|
| 193 |
+
|
| 194 |
+
print("\n")
|
| 195 |
+
return outlier_summary
|
| 196 |
+
|
| 197 |
+
def analysis_7_feature_distributions(self):
|
| 198 |
+
"""Analysis 7: Feature distribution analysis"""
|
| 199 |
+
print("="*80)
|
| 200 |
+
print("ANALYSIS 7: FEATURE DISTRIBUTION ANALYSIS")
|
| 201 |
+
print("="*80)
|
| 202 |
+
|
| 203 |
+
numerical_cols = [
|
| 204 |
+
'Air temperature [K]', 'Process temperature [K]',
|
| 205 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]'
|
| 206 |
+
]
|
| 207 |
+
|
| 208 |
+
dist_stats = {}
|
| 209 |
+
for col in numerical_cols:
|
| 210 |
+
dist_stats[col] = {
|
| 211 |
+
'Mean': self.df_clean[col].mean(),
|
| 212 |
+
'Median': self.df_clean[col].median(),
|
| 213 |
+
'Mode': self.df_clean[col].mode()[0] if len(self.df_clean[col].mode()) > 0 else None,
|
| 214 |
+
'Std': self.df_clean[col].std(),
|
| 215 |
+
'Skewness': self.df_clean[col].skew(),
|
| 216 |
+
'Kurtosis': self.df_clean[col].kurtosis()
|
| 217 |
+
}
|
| 218 |
+
|
| 219 |
+
print(f"{col}:")
|
| 220 |
+
print(f" Mean: {dist_stats[col]['Mean']:.2f}")
|
| 221 |
+
print(f" Median: {dist_stats[col]['Median']:.2f}")
|
| 222 |
+
print(f" Std Dev: {dist_stats[col]['Std']:.2f}")
|
| 223 |
+
print(f" Skewness: {dist_stats[col]['Skewness']:.2f}")
|
| 224 |
+
print(f" Kurtosis: {dist_stats[col]['Kurtosis']:.2f}")
|
| 225 |
+
print()
|
| 226 |
+
|
| 227 |
+
print("\n")
|
| 228 |
+
return dist_stats
|
| 229 |
+
def analysis_8_failure_by_type(self):
|
| 230 |
+
"""Analysis 8: Failure analysis by machine type"""
|
| 231 |
+
print("="*80)
|
| 232 |
+
print("ANALYSIS 8: FAILURE ANALYSIS BY MACHINE TYPE")
|
| 233 |
+
print("="*80)
|
| 234 |
+
|
| 235 |
+
failure_by_type = self.df_clean.groupby('Type')['Machine failure'].agg([
|
| 236 |
+
'count', 'sum', 'mean'
|
| 237 |
+
]).round(4)
|
| 238 |
+
failure_by_type.columns = ['Total Machines', 'Failures', 'Failure Rate']
|
| 239 |
+
failure_by_type['Failure Rate'] = failure_by_type['Failure Rate'] * 100
|
| 240 |
+
|
| 241 |
+
print(failure_by_type)
|
| 242 |
+
print("\n")
|
| 243 |
+
|
| 244 |
+
return failure_by_type
|
| 245 |
+
|
| 246 |
+
def analysis_9_tool_wear_analysis(self):
|
| 247 |
+
"""Analysis 9: Tool wear analysis and relationship with failures"""
|
| 248 |
+
print("="*80)
|
| 249 |
+
print("ANALYSIS 9: TOOL WEAR ANALYSIS")
|
| 250 |
+
print("="*80)
|
| 251 |
+
|
| 252 |
+
print("Tool Wear Statistics:")
|
| 253 |
+
print(f" Mean: {self.df_clean['Tool wear [min]'].mean():.2f} minutes")
|
| 254 |
+
print(f" Median: {self.df_clean['Tool wear [min]'].median():.2f} minutes")
|
| 255 |
+
print(f" Max: {self.df_clean['Tool wear [min]'].max():.2f} minutes")
|
| 256 |
+
print(f" Min: {self.df_clean['Tool wear [min]'].min():.2f} minutes")
|
| 257 |
+
print()
|
| 258 |
+
|
| 259 |
+
# Tool wear vs failure
|
| 260 |
+
tool_wear_failure = self.df_clean.groupby('Machine failure')['Tool wear [min]'].agg([
|
| 261 |
+
'mean', 'median', 'std', 'min', 'max'
|
| 262 |
+
])
|
| 263 |
+
print("Tool Wear by Failure Status:")
|
| 264 |
+
print(tool_wear_failure)
|
| 265 |
+
print("\n")
|
| 266 |
+
|
| 267 |
+
return tool_wear_failure
|
| 268 |
+
|
| 269 |
+
def analysis_10_temperature_analysis(self):
|
| 270 |
+
"""Analysis 10: Temperature analysis"""
|
| 271 |
+
print("="*80)
|
| 272 |
+
print("ANALYSIS 10: TEMPERATURE ANALYSIS")
|
| 273 |
+
print("="*80)
|
| 274 |
+
|
| 275 |
+
temp_stats = self.df_clean.groupby('Machine failure')[
|
| 276 |
+
['Air temperature [K]', 'Process temperature [K]', 'Temperature difference [K]']
|
| 277 |
+
].agg(['mean', 'std'])
|
| 278 |
+
|
| 279 |
+
print("Temperature Statistics by Failure Status:")
|
| 280 |
+
print(temp_stats)
|
| 281 |
+
print("\n")
|
| 282 |
+
|
| 283 |
+
return temp_stats
|
| 284 |
+
|
| 285 |
+
def analysis_11_power_analysis(self):
|
| 286 |
+
"""Analysis 11: Power and rotational speed analysis"""
|
| 287 |
+
print("="*80)
|
| 288 |
+
print("ANALYSIS 11: POWER AND ROTATIONAL SPEED ANALYSIS")
|
| 289 |
+
print("="*80)
|
| 290 |
+
|
| 291 |
+
power_stats = self.df_clean.groupby('Machine failure')[
|
| 292 |
+
['Rotational speed [rpm]', 'Torque [Nm]', 'Power [W]']
|
| 293 |
+
].agg(['mean', 'std', 'min', 'max'])
|
| 294 |
+
|
| 295 |
+
print("Power Statistics by Failure Status:")
|
| 296 |
+
print(power_stats)
|
| 297 |
+
print("\n")
|
| 298 |
+
|
| 299 |
+
return power_stats
|
| 300 |
+
|
| 301 |
+
def analysis_12_pairwise_relationships(self):
|
| 302 |
+
"""Analysis 12: Pairwise feature relationships"""
|
| 303 |
+
print("="*80)
|
| 304 |
+
print("ANALYSIS 12: PAIRWISE FEATURE RELATIONSHIPS")
|
| 305 |
+
print("="*80)
|
| 306 |
+
|
| 307 |
+
key_features = [
|
| 308 |
+
'Tool wear [min]', 'Temperature difference [K]',
|
| 309 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Machine failure'
|
| 310 |
+
]
|
| 311 |
+
|
| 312 |
+
pairwise_corr = self.df_clean[key_features].corr()
|
| 313 |
+
print("Pairwise Correlations:")
|
| 314 |
+
print(pairwise_corr)
|
| 315 |
+
print("\n")
|
| 316 |
+
|
| 317 |
+
return pairwise_corr
|
| 318 |
+
|
| 319 |
+
def analysis_13_failure_type_analysis(self):
|
| 320 |
+
"""Analysis 13: Detailed failure type analysis"""
|
| 321 |
+
print("="*80)
|
| 322 |
+
print("ANALYSIS 13: DETAILED FAILURE TYPE ANALYSIS")
|
| 323 |
+
print("="*80)
|
| 324 |
+
|
| 325 |
+
failure_types = ['TWF', 'HDF', 'PWF', 'OSF', 'RNF']
|
| 326 |
+
|
| 327 |
+
for ft in failure_types:
|
| 328 |
+
failed_machines = self.df_clean[self.df_clean[ft] == 1]
|
| 329 |
+
if len(failed_machines) > 0:
|
| 330 |
+
print(f"\n{self.failure_types[ft]} ({ft}):")
|
| 331 |
+
print(f" Count: {len(failed_machines)}")
|
| 332 |
+
print(f" Avg Tool Wear: {failed_machines['Tool wear [min]'].mean():.2f} min")
|
| 333 |
+
print(f" Avg Temp Diff: {failed_machines['Temperature difference [K]'].mean():.2f} K")
|
| 334 |
+
print(f" Avg Rotational Speed: {failed_machines['Rotational speed [rpm]'].mean():.2f} rpm")
|
| 335 |
+
print(f" Avg Torque: {failed_machines['Torque [Nm]'].mean():.2f} Nm")
|
| 336 |
+
|
| 337 |
+
print("\n")
|
| 338 |
+
|
| 339 |
+
def analysis_14_time_to_failure_estimation(self):
|
| 340 |
+
"""Analysis 14: Time to failure estimation based on tool wear"""
|
| 341 |
+
print("="*80)
|
| 342 |
+
print("ANALYSIS 14: TIME TO FAILURE ESTIMATION")
|
| 343 |
+
print("="*80)
|
| 344 |
+
|
| 345 |
+
# Analyze tool wear progression for machines that failed
|
| 346 |
+
failed_machines = self.df_clean[self.df_clean['Machine failure'] == 1]
|
| 347 |
+
|
| 348 |
+
if len(failed_machines) > 0:
|
| 349 |
+
avg_tool_wear_at_failure = failed_machines['Tool wear [min]'].mean()
|
| 350 |
+
median_tool_wear_at_failure = failed_machines['Tool wear [min]'].median()
|
| 351 |
+
|
| 352 |
+
print(f"Average Tool Wear at Failure: {avg_tool_wear_at_failure:.2f} minutes")
|
| 353 |
+
print(f"Median Tool Wear at Failure: {median_tool_wear_at_failure:.2f} minutes")
|
| 354 |
+
print()
|
| 355 |
+
|
| 356 |
+
# Estimate time remaining for machines not yet failed
|
| 357 |
+
non_failed = self.df_clean[self.df_clean['Machine failure'] == 0]
|
| 358 |
+
if len(non_failed) > 0:
|
| 359 |
+
non_failed['Estimated Time to Failure'] = (
|
| 360 |
+
avg_tool_wear_at_failure - non_failed['Tool wear [min]']
|
| 361 |
+
)
|
| 362 |
+
non_failed['Estimated Time to Failure'] = non_failed['Estimated Time to Failure'].clip(lower=0)
|
| 363 |
+
|
| 364 |
+
print("Time to Failure Estimates (for non-failed machines):")
|
| 365 |
+
print(f" Machines needing immediate maintenance (< 10 min): "
|
| 366 |
+
f"{(non_failed['Estimated Time to Failure'] < 10).sum()}")
|
| 367 |
+
print(f" Machines needing maintenance soon (10-50 min): "
|
| 368 |
+
f"{((non_failed['Estimated Time to Failure'] >= 10) & (non_failed['Estimated Time to Failure'] < 50)).sum()}")
|
| 369 |
+
print(f" Machines with time remaining (> 50 min): "
|
| 370 |
+
f"{(non_failed['Estimated Time to Failure'] >= 50).sum()}")
|
| 371 |
+
|
| 372 |
+
print("\n")
|
| 373 |
+
|
| 374 |
+
def analysis_15_grouped_aggregations(self):
|
| 375 |
+
"""Analysis 15: Grouped aggregations by type and failure status"""
|
| 376 |
+
print("="*80)
|
| 377 |
+
print("ANALYSIS 15: GROUPED AGGREGATIONS")
|
| 378 |
+
print("="*80)
|
| 379 |
+
|
| 380 |
+
grouped = self.df_clean.groupby(['Type', 'Machine failure']).agg({
|
| 381 |
+
'Tool wear [min]': ['mean', 'std', 'max'],
|
| 382 |
+
'Temperature difference [K]': ['mean', 'std'],
|
| 383 |
+
'Rotational speed [rpm]': ['mean', 'std'],
|
| 384 |
+
'Torque [Nm]': ['mean', 'std']
|
| 385 |
+
})
|
| 386 |
+
|
| 387 |
+
print("Grouped Statistics by Type and Failure Status:")
|
| 388 |
+
print(grouped)
|
| 389 |
+
print("\n")
|
| 390 |
+
|
| 391 |
+
return grouped
|
| 392 |
+
|
| 393 |
+
def run_all_analyses(self):
|
| 394 |
+
"""Run all EDA analyses"""
|
| 395 |
+
print("\n" + "="*80)
|
| 396 |
+
print("COMPREHENSIVE EXPLORATORY DATA ANALYSIS")
|
| 397 |
+
print("AI4I 2020 Predictive Maintenance Dataset")
|
| 398 |
+
print("="*80 + "\n")
|
| 399 |
+
|
| 400 |
+
results = {}
|
| 401 |
+
|
| 402 |
+
results['summary_stats'] = self.analysis_1_summary_statistics()
|
| 403 |
+
results['missing_values'] = self.analysis_2_missing_values()
|
| 404 |
+
results['data_types'] = self.analysis_3_data_types()
|
| 405 |
+
results['target_distribution'] = self.analysis_4_target_distribution()
|
| 406 |
+
results['correlation'] = self.analysis_5_correlation_analysis()
|
| 407 |
+
results['outliers'] = self.analysis_6_outlier_detection()
|
| 408 |
+
results['distributions'] = self.analysis_7_feature_distributions()
|
| 409 |
+
results['failure_by_type'] = self.analysis_8_failure_by_type()
|
| 410 |
+
results['tool_wear'] = self.analysis_9_tool_wear_analysis()
|
| 411 |
+
results['temperature'] = self.analysis_10_temperature_analysis()
|
| 412 |
+
results['power'] = self.analysis_11_power_analysis()
|
| 413 |
+
results['pairwise'] = self.analysis_12_pairwise_relationships()
|
| 414 |
+
self.analysis_13_failure_type_analysis()
|
| 415 |
+
self.analysis_14_time_to_failure_estimation()
|
| 416 |
+
results['grouped'] = self.analysis_15_grouped_aggregations()
|
| 417 |
+
|
| 418 |
+
print("="*80)
|
| 419 |
+
print("EDA ANALYSIS COMPLETE!")
|
| 420 |
+
print("="*80)
|
| 421 |
+
|
| 422 |
+
return results
|
| 423 |
+
|
| 424 |
+
if __name__ == "__main__":
|
| 425 |
+
# Run EDA analysis
|
| 426 |
+
eda = EDAAnalysis('ai4i2020.csv')
|
| 427 |
+
results = eda.run_all_analyses()
|
| 428 |
+
|
| 429 |
+
# Save processed data for modeling
|
| 430 |
+
eda.df_clean.to_csv('processed_data.csv', index=False)
|
| 431 |
+
print("\nProcessed data saved to 'processed_data.csv'")
|
app.py
ADDED
|
@@ -0,0 +1,989 @@
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|
| 1 |
+
"""
|
| 2 |
+
Streamlit Application for Predictive Maintenance Project
|
| 3 |
+
Interactive web app for EDA, model visualization, and runtime predictions
|
| 4 |
+
"""
|
| 5 |
+
|
| 6 |
+
import streamlit as st
|
| 7 |
+
import pandas as pd
|
| 8 |
+
import numpy as np
|
| 9 |
+
import plotly.express as px
|
| 10 |
+
import plotly.graph_objects as go
|
| 11 |
+
from plotly.subplots import make_subplots
|
| 12 |
+
import pickle
|
| 13 |
+
import warnings
|
| 14 |
+
warnings.filterwarnings('ignore')
|
| 15 |
+
|
| 16 |
+
# Import custom modules
|
| 17 |
+
from preprocessing import DataPreprocessor
|
| 18 |
+
from model import PredictiveMaintenanceModel
|
| 19 |
+
|
| 20 |
+
# Page configuration
|
| 21 |
+
st.set_page_config(
|
| 22 |
+
page_title="Predictive Maintenance System",
|
| 23 |
+
page_icon="🔧",
|
| 24 |
+
layout="wide",
|
| 25 |
+
initial_sidebar_state="expanded"
|
| 26 |
+
)
|
| 27 |
+
|
| 28 |
+
# Custom CSS
|
| 29 |
+
st.markdown("""
|
| 30 |
+
<style>
|
| 31 |
+
.main-header {
|
| 32 |
+
font-size: 3rem;
|
| 33 |
+
font-weight: bold;
|
| 34 |
+
color: #1f77b4;
|
| 35 |
+
text-align: center;
|
| 36 |
+
margin-bottom: 2rem;
|
| 37 |
+
}
|
| 38 |
+
.sub-header {
|
| 39 |
+
font-size: 1.5rem;
|
| 40 |
+
color: #ff7f0e;
|
| 41 |
+
margin-top: 2rem;
|
| 42 |
+
margin-bottom: 1rem;
|
| 43 |
+
}
|
| 44 |
+
.metric-card {
|
| 45 |
+
background-color: #f0f2f6;
|
| 46 |
+
padding: 1rem;
|
| 47 |
+
border-radius: 0.5rem;
|
| 48 |
+
margin: 0.5rem 0;
|
| 49 |
+
}
|
| 50 |
+
</style>
|
| 51 |
+
""", unsafe_allow_html=True)
|
| 52 |
+
|
| 53 |
+
# Initialize session state
|
| 54 |
+
if 'model' not in st.session_state:
|
| 55 |
+
st.session_state.model = None
|
| 56 |
+
if 'preprocessor' not in st.session_state:
|
| 57 |
+
st.session_state.preprocessor = None
|
| 58 |
+
if 'data' not in st.session_state:
|
| 59 |
+
st.session_state.data = None
|
| 60 |
+
|
| 61 |
+
@st.cache_data
|
| 62 |
+
def load_data():
|
| 63 |
+
"""Load and cache the dataset"""
|
| 64 |
+
df = pd.read_csv('ai4i2020.csv')
|
| 65 |
+
# Create additional features
|
| 66 |
+
df['Temperature difference [K]'] = (
|
| 67 |
+
df['Process temperature [K]'] - df['Air temperature [K]']
|
| 68 |
+
)
|
| 69 |
+
df['Power [W]'] = (
|
| 70 |
+
df['Rotational speed [rpm]'] * df['Torque [Nm]'] / 9.5488
|
| 71 |
+
)
|
| 72 |
+
return df
|
| 73 |
+
|
| 74 |
+
def train_model():
|
| 75 |
+
"""Train the model and preprocessor"""
|
| 76 |
+
with st.spinner("Training model... This may take a moment."):
|
| 77 |
+
preprocessor = DataPreprocessor('ai4i2020.csv')
|
| 78 |
+
X_train, X_test, y_train, y_test, feature_columns = preprocessor.prepare_data()
|
| 79 |
+
|
| 80 |
+
model = PredictiveMaintenanceModel()
|
| 81 |
+
model.train(X_train, y_train)
|
| 82 |
+
|
| 83 |
+
# Evaluate model
|
| 84 |
+
results = model.evaluate(X_test, y_test)
|
| 85 |
+
|
| 86 |
+
st.session_state.model = model
|
| 87 |
+
st.session_state.preprocessor = preprocessor
|
| 88 |
+
st.session_state.feature_columns = feature_columns
|
| 89 |
+
|
| 90 |
+
return results
|
| 91 |
+
|
| 92 |
+
# Main App
|
| 93 |
+
def main():
|
| 94 |
+
# Header
|
| 95 |
+
st.markdown('<h1 class="main-header">🔧 Predictive Maintenance System</h1>', unsafe_allow_html=True)
|
| 96 |
+
st.markdown("---")
|
| 97 |
+
|
| 98 |
+
# Sidebar Navigation
|
| 99 |
+
st.sidebar.title("Navigation")
|
| 100 |
+
page = st.sidebar.radio(
|
| 101 |
+
"Select Page",
|
| 102 |
+
["Introduction", "Exploratory Data Analysis", "Model & Predictions", "Conclusion"]
|
| 103 |
+
)
|
| 104 |
+
|
| 105 |
+
# Load data
|
| 106 |
+
df = load_data()
|
| 107 |
+
st.session_state.data = df
|
| 108 |
+
|
| 109 |
+
if page == "Introduction":
|
| 110 |
+
show_introduction(df)
|
| 111 |
+
elif page == "Exploratory Data Analysis":
|
| 112 |
+
show_eda(df)
|
| 113 |
+
elif page == "Model & Predictions":
|
| 114 |
+
show_model_predictions(df)
|
| 115 |
+
elif page == "Conclusion":
|
| 116 |
+
show_conclusion()
|
| 117 |
+
|
| 118 |
+
def show_introduction(df):
|
| 119 |
+
"""Introduction page"""
|
| 120 |
+
st.markdown('<h2 class="sub-header">📋 Project Introduction</h2>', unsafe_allow_html=True)
|
| 121 |
+
|
| 122 |
+
col1, col2 = st.columns([2, 1])
|
| 123 |
+
|
| 124 |
+
with col1:
|
| 125 |
+
st.markdown("""
|
| 126 |
+
### About the Dataset
|
| 127 |
+
|
| 128 |
+
This project uses the **AI4I 2020 Predictive Maintenance Dataset**, which contains
|
| 129 |
+
synthetic data simulating predictive maintenance scenarios for industrial machinery.
|
| 130 |
+
|
| 131 |
+
#### Dataset Overview:
|
| 132 |
+
- **Total Records**: 10,000 machines
|
| 133 |
+
- **Features**: 14 attributes including temperature, rotational speed, torque, and tool wear
|
| 134 |
+
- **Target**: Machine failure prediction (binary classification)
|
| 135 |
+
- **Failure Types**: Tool Wear Failure (TWF), Heat Dissipation Failure (HDF),
|
| 136 |
+
Power Failure (PWF), Overstrain Failure (OSF), and Random Failure (RNF)
|
| 137 |
+
|
| 138 |
+
#### Project Goals:
|
| 139 |
+
1. **Exploratory Data Analysis**: Understand patterns and relationships in the data
|
| 140 |
+
2. **Predictive Modeling**: Build a machine learning model to predict machine failures
|
| 141 |
+
3. **Maintenance Scheduling**: Estimate when maintenance is needed and how urgent it is
|
| 142 |
+
4. **Interactive Visualization**: Present findings through an interactive web application
|
| 143 |
+
|
| 144 |
+
#### Key Features:
|
| 145 |
+
- Comprehensive EDA with 15+ different analyses
|
| 146 |
+
- Random Forest Classifier for failure prediction
|
| 147 |
+
- Real-time predictions based on user input
|
| 148 |
+
- Maintenance urgency assessment
|
| 149 |
+
- Time-to-failure estimation
|
| 150 |
+
""")
|
| 151 |
+
|
| 152 |
+
with col2:
|
| 153 |
+
st.markdown("### Dataset Statistics")
|
| 154 |
+
st.metric("Total Machines", f"{len(df):,}")
|
| 155 |
+
st.metric("Features", len(df.columns))
|
| 156 |
+
st.metric("Machine Failures", f"{df['Machine failure'].sum():,}")
|
| 157 |
+
st.metric("Failure Rate", f"{(df['Machine failure'].mean()*100):.2f}%")
|
| 158 |
+
|
| 159 |
+
st.markdown("### Machine Types")
|
| 160 |
+
type_counts = df['Type'].value_counts()
|
| 161 |
+
type_meanings = {'L': 'Low Quality/Load', 'M': 'Medium Quality/Load', 'H': 'High Quality/Load'}
|
| 162 |
+
for machine_type, count in type_counts.items():
|
| 163 |
+
meaning = type_meanings.get(machine_type, '')
|
| 164 |
+
st.metric(f"Type {machine_type} ({meaning})", f"{count:,}")
|
| 165 |
+
|
| 166 |
+
st.markdown("---")
|
| 167 |
+
st.markdown("### Dataset Preview")
|
| 168 |
+
preview_mode = st.radio(
|
| 169 |
+
"Preview mode",
|
| 170 |
+
options=["First 20 rows", "Show all (10,000 rows)"],
|
| 171 |
+
index=0,
|
| 172 |
+
horizontal=True,
|
| 173 |
+
)
|
| 174 |
+
if preview_mode == "First 20 rows":
|
| 175 |
+
st.dataframe(df.head(20), use_container_width=True)
|
| 176 |
+
else:
|
| 177 |
+
st.dataframe(df, use_container_width=True)
|
| 178 |
+
|
| 179 |
+
st.markdown("### Dataset Information")
|
| 180 |
+
with st.expander("View Column Descriptions"):
|
| 181 |
+
st.markdown("""
|
| 182 |
+
- **UDI**: Unique identifier for each machine
|
| 183 |
+
- **Product ID**: Product identifier
|
| 184 |
+
- **Type**: Machine type (L = Low Quality/Load, M = Medium Quality/Load, H = High Quality/Load)
|
| 185 |
+
- **Air temperature [K]**: Air temperature in Kelvin
|
| 186 |
+
- **Process temperature [K]**: Process temperature in Kelvin
|
| 187 |
+
- **Rotational speed [rpm]**: Rotational speed in revolutions per minute
|
| 188 |
+
- **Torque [Nm]**: Torque in Newton meters
|
| 189 |
+
- **Tool wear [min]**: Tool wear in minutes
|
| 190 |
+
- **Machine failure**: Binary target (0 = no failure, 1 = failure)
|
| 191 |
+
- **TWF, HDF, PWF, OSF, RNF**: Different failure type indicators
|
| 192 |
+
""")
|
| 193 |
+
|
| 194 |
+
def show_eda(df):
|
| 195 |
+
"""EDA page"""
|
| 196 |
+
st.markdown('<h2 class="sub-header">📊 Exploratory Data Analysis</h2>', unsafe_allow_html=True)
|
| 197 |
+
|
| 198 |
+
# Analysis selection
|
| 199 |
+
analysis_type = st.selectbox(
|
| 200 |
+
"Select Analysis Type",
|
| 201 |
+
[
|
| 202 |
+
"Summary Statistics",
|
| 203 |
+
"Data Types & Unique Values",
|
| 204 |
+
"Target Distribution",
|
| 205 |
+
"Feature Distributions",
|
| 206 |
+
"Correlation Analysis",
|
| 207 |
+
"Failure Analysis by Type",
|
| 208 |
+
"Tool Wear Analysis",
|
| 209 |
+
"Temperature Analysis",
|
| 210 |
+
"Power & Rotational Speed Analysis",
|
| 211 |
+
"Outlier Detection",
|
| 212 |
+
"Pairwise Relationships",
|
| 213 |
+
"Failure Type Breakdown",
|
| 214 |
+
"Time to Failure Estimation",
|
| 215 |
+
"Grouped Aggregations"
|
| 216 |
+
]
|
| 217 |
+
)
|
| 218 |
+
|
| 219 |
+
st.markdown("---")
|
| 220 |
+
|
| 221 |
+
if analysis_type == "Summary Statistics":
|
| 222 |
+
st.subheader("Summary Statistics")
|
| 223 |
+
st.dataframe(df.describe(), use_container_width=True)
|
| 224 |
+
|
| 225 |
+
# Key metrics
|
| 226 |
+
col1, col2, col3, col4 = st.columns(4)
|
| 227 |
+
with col1:
|
| 228 |
+
st.metric("Mean Air Temp", f"{df['Air temperature [K]'].mean():.2f} K")
|
| 229 |
+
with col2:
|
| 230 |
+
st.metric("Mean Process Temp", f"{df['Process temperature [K]'].mean():.2f} K")
|
| 231 |
+
with col3:
|
| 232 |
+
st.metric("Mean Rotational Speed", f"{df['Rotational speed [rpm]'].mean():.0f} rpm")
|
| 233 |
+
with col4:
|
| 234 |
+
st.metric("Mean Torque", f"{df['Torque [Nm]'].mean():.2f} Nm")
|
| 235 |
+
|
| 236 |
+
elif analysis_type == "Data Types & Unique Values":
|
| 237 |
+
st.subheader("Data Types and Unique Values")
|
| 238 |
+
|
| 239 |
+
info_df = pd.DataFrame({
|
| 240 |
+
'Column': df.columns,
|
| 241 |
+
'Data Type': df.dtypes.astype(str),
|
| 242 |
+
'Unique Values': [df[col].nunique() for col in df.columns],
|
| 243 |
+
'Non-Null Count': df.count().values
|
| 244 |
+
})
|
| 245 |
+
|
| 246 |
+
st.dataframe(info_df, use_container_width=True)
|
| 247 |
+
|
| 248 |
+
st.subheader("Machine Type Distribution")
|
| 249 |
+
type_counts = df['Type'].value_counts()
|
| 250 |
+
type_meanings = {'L': 'Low Quality/Load', 'M': 'Medium Quality/Load', 'H': 'High Quality/Load'}
|
| 251 |
+
|
| 252 |
+
col1, col2 = st.columns(2)
|
| 253 |
+
with col1:
|
| 254 |
+
fig = px.bar(
|
| 255 |
+
x=type_counts.index,
|
| 256 |
+
y=type_counts.values,
|
| 257 |
+
title="Machine Type Distribution",
|
| 258 |
+
labels={'x': 'Machine Type', 'y': 'Count'},
|
| 259 |
+
color=type_counts.index,
|
| 260 |
+
color_discrete_sequence=['#e74c3c', '#3498db', '#2ecc71']
|
| 261 |
+
)
|
| 262 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 263 |
+
|
| 264 |
+
with col2:
|
| 265 |
+
for machine_type, count in type_counts.items():
|
| 266 |
+
meaning = type_meanings.get(machine_type, '')
|
| 267 |
+
st.metric(f"Type {machine_type} ({meaning})", f"{count:,}")
|
| 268 |
+
|
| 269 |
+
elif analysis_type == "Target Distribution":
|
| 270 |
+
st.subheader("Machine Failure Distribution")
|
| 271 |
+
|
| 272 |
+
col1, col2 = st.columns(2)
|
| 273 |
+
|
| 274 |
+
with col1:
|
| 275 |
+
failure_counts = df['Machine failure'].value_counts()
|
| 276 |
+
fig = px.pie(
|
| 277 |
+
values=failure_counts.values,
|
| 278 |
+
names=['No Failure', 'Failure'],
|
| 279 |
+
title="Failure Distribution",
|
| 280 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 281 |
+
)
|
| 282 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 283 |
+
|
| 284 |
+
with col2:
|
| 285 |
+
st.metric("No Failure", f"{failure_counts[0]:,} ({(failure_counts[0]/len(df)*100):.2f}%)")
|
| 286 |
+
st.metric("Failure", f"{failure_counts[1]:,} ({(failure_counts[1]/len(df)*100):.2f}%)")
|
| 287 |
+
|
| 288 |
+
# Failure types
|
| 289 |
+
st.subheader("Failure Types Breakdown")
|
| 290 |
+
failure_types = {
|
| 291 |
+
'TWF': 'Tool Wear Failure',
|
| 292 |
+
'HDF': 'Heat Dissipation Failure',
|
| 293 |
+
'PWF': 'Power Failure',
|
| 294 |
+
'OSF': 'Overstrain Failure',
|
| 295 |
+
'RNF': 'Random Failure'
|
| 296 |
+
}
|
| 297 |
+
for ft_code, ft_name in failure_types.items():
|
| 298 |
+
count = df[ft_code].sum()
|
| 299 |
+
st.metric(ft_name, f"{count} ({(count/len(df)*100):.2f}%)")
|
| 300 |
+
|
| 301 |
+
elif analysis_type == "Feature Distributions":
|
| 302 |
+
st.subheader("Feature Distributions")
|
| 303 |
+
|
| 304 |
+
feature = st.selectbox(
|
| 305 |
+
"Select Feature",
|
| 306 |
+
['Air temperature [K]', 'Process temperature [K]', 'Rotational speed [rpm]',
|
| 307 |
+
'Torque [Nm]', 'Tool wear [min]', 'Temperature difference [K]', 'Power [W]']
|
| 308 |
+
)
|
| 309 |
+
|
| 310 |
+
col1, col2 = st.columns(2)
|
| 311 |
+
|
| 312 |
+
with col1:
|
| 313 |
+
fig = px.histogram(
|
| 314 |
+
df, x=feature, nbins=50,
|
| 315 |
+
title=f"Distribution of {feature}",
|
| 316 |
+
color_discrete_sequence=['#3498db']
|
| 317 |
+
)
|
| 318 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 319 |
+
|
| 320 |
+
with col2:
|
| 321 |
+
fig = px.box(
|
| 322 |
+
df, y=feature,
|
| 323 |
+
title=f"Box Plot of {feature}",
|
| 324 |
+
color_discrete_sequence=['#9b59b6']
|
| 325 |
+
)
|
| 326 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 327 |
+
|
| 328 |
+
# Statistics
|
| 329 |
+
st.subheader("Statistics")
|
| 330 |
+
col1, col2, col3, col4 = st.columns(4)
|
| 331 |
+
with col1:
|
| 332 |
+
st.metric("Mean", f"{df[feature].mean():.2f}")
|
| 333 |
+
with col2:
|
| 334 |
+
st.metric("Median", f"{df[feature].median():.2f}")
|
| 335 |
+
with col3:
|
| 336 |
+
st.metric("Std Dev", f"{df[feature].std():.2f}")
|
| 337 |
+
with col4:
|
| 338 |
+
st.metric("Skewness", f"{df[feature].skew():.2f}")
|
| 339 |
+
|
| 340 |
+
elif analysis_type == "Correlation Analysis":
|
| 341 |
+
st.subheader("Correlation Analysis")
|
| 342 |
+
|
| 343 |
+
numerical_cols = [
|
| 344 |
+
'Air temperature [K]', 'Process temperature [K]',
|
| 345 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]',
|
| 346 |
+
'Temperature difference [K]', 'Power [W]', 'Machine failure'
|
| 347 |
+
]
|
| 348 |
+
|
| 349 |
+
corr_matrix = df[numerical_cols].corr()
|
| 350 |
+
|
| 351 |
+
fig = px.imshow(
|
| 352 |
+
corr_matrix,
|
| 353 |
+
text_auto=True,
|
| 354 |
+
aspect="auto",
|
| 355 |
+
title="Correlation Heatmap",
|
| 356 |
+
color_continuous_scale="RdBu"
|
| 357 |
+
)
|
| 358 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 359 |
+
|
| 360 |
+
st.subheader("Correlation with Machine Failure")
|
| 361 |
+
failure_corr = corr_matrix['Machine failure'].sort_values(ascending=False)
|
| 362 |
+
fig = px.bar(
|
| 363 |
+
x=failure_corr.index,
|
| 364 |
+
y=failure_corr.values,
|
| 365 |
+
title="Feature Correlation with Machine Failure",
|
| 366 |
+
labels={'x': 'Feature', 'y': 'Correlation'},
|
| 367 |
+
color=failure_corr.values,
|
| 368 |
+
color_continuous_scale="RdYlGn"
|
| 369 |
+
)
|
| 370 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 371 |
+
|
| 372 |
+
elif analysis_type == "Failure Analysis by Type":
|
| 373 |
+
st.subheader("Failure Analysis by Machine Type")
|
| 374 |
+
st.info("**Machine Type Meanings**: L = Low Quality/Load, M = Medium Quality/Load, H = High Quality/Load")
|
| 375 |
+
|
| 376 |
+
failure_by_type = df.groupby('Type')['Machine failure'].agg(['count', 'sum', 'mean']).reset_index()
|
| 377 |
+
failure_by_type.columns = ['Type', 'Total Machines', 'Failures', 'Failure Rate']
|
| 378 |
+
failure_by_type['Failure Rate'] = failure_by_type['Failure Rate'] * 100
|
| 379 |
+
failure_by_type['Type_Label'] = failure_by_type['Type'].map({
|
| 380 |
+
'L': 'L (Low Quality/Load)',
|
| 381 |
+
'M': 'M (Medium Quality/Load)',
|
| 382 |
+
'H': 'H (High Quality/Load)'
|
| 383 |
+
})
|
| 384 |
+
|
| 385 |
+
st.dataframe(failure_by_type[['Type', 'Total Machines', 'Failures', 'Failure Rate']], use_container_width=True)
|
| 386 |
+
|
| 387 |
+
fig = px.bar(
|
| 388 |
+
failure_by_type,
|
| 389 |
+
x='Type_Label',
|
| 390 |
+
y='Failure Rate',
|
| 391 |
+
title="Failure Rate by Machine Type",
|
| 392 |
+
color='Type',
|
| 393 |
+
color_discrete_sequence=['#e74c3c', '#3498db', '#2ecc71'],
|
| 394 |
+
labels={'Type_Label': 'Machine Type'}
|
| 395 |
+
)
|
| 396 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 397 |
+
|
| 398 |
+
elif analysis_type == "Tool Wear Analysis":
|
| 399 |
+
st.subheader("Tool Wear Analysis")
|
| 400 |
+
|
| 401 |
+
col1, col2 = st.columns(2)
|
| 402 |
+
|
| 403 |
+
with col1:
|
| 404 |
+
fig = px.scatter(
|
| 405 |
+
df,
|
| 406 |
+
x='Tool wear [min]',
|
| 407 |
+
y='Machine failure',
|
| 408 |
+
color='Machine failure',
|
| 409 |
+
title="Tool Wear vs Machine Failure",
|
| 410 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 411 |
+
)
|
| 412 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 413 |
+
|
| 414 |
+
with col2:
|
| 415 |
+
tool_wear_by_failure = df.groupby('Machine failure')['Tool wear [min]'].agg(['mean', 'median', 'std'])
|
| 416 |
+
st.dataframe(tool_wear_by_failure, use_container_width=True)
|
| 417 |
+
|
| 418 |
+
# Tool wear distribution by failure status
|
| 419 |
+
fig = px.histogram(
|
| 420 |
+
df,
|
| 421 |
+
x='Tool wear [min]',
|
| 422 |
+
color='Machine failure',
|
| 423 |
+
nbins=50,
|
| 424 |
+
title="Tool Wear Distribution by Failure Status",
|
| 425 |
+
barmode='overlay',
|
| 426 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 427 |
+
)
|
| 428 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 429 |
+
|
| 430 |
+
elif analysis_type == "Temperature Analysis":
|
| 431 |
+
st.subheader("Temperature Analysis")
|
| 432 |
+
|
| 433 |
+
col1, col2 = st.columns(2)
|
| 434 |
+
|
| 435 |
+
with col1:
|
| 436 |
+
fig = px.scatter(
|
| 437 |
+
df,
|
| 438 |
+
x='Air temperature [K]',
|
| 439 |
+
y='Process temperature [K]',
|
| 440 |
+
color='Machine failure',
|
| 441 |
+
title="Temperature Relationship",
|
| 442 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 443 |
+
)
|
| 444 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 445 |
+
|
| 446 |
+
with col2:
|
| 447 |
+
temp_by_failure = df.groupby('Machine failure')[
|
| 448 |
+
['Air temperature [K]', 'Process temperature [K]', 'Temperature difference [K]']
|
| 449 |
+
].mean()
|
| 450 |
+
st.dataframe(temp_by_failure, use_container_width=True)
|
| 451 |
+
|
| 452 |
+
elif analysis_type == "Power & Rotational Speed Analysis":
|
| 453 |
+
st.subheader("Power and Rotational Speed Analysis")
|
| 454 |
+
|
| 455 |
+
power_stats = df.groupby('Machine failure')[
|
| 456 |
+
['Rotational speed [rpm]', 'Torque [Nm]', 'Power [W]']
|
| 457 |
+
].agg(['mean', 'std', 'min', 'max'])
|
| 458 |
+
|
| 459 |
+
st.dataframe(power_stats, use_container_width=True)
|
| 460 |
+
|
| 461 |
+
col1, col2 = st.columns(2)
|
| 462 |
+
|
| 463 |
+
with col1:
|
| 464 |
+
fig = px.box(
|
| 465 |
+
df,
|
| 466 |
+
x='Machine failure',
|
| 467 |
+
y='Rotational speed [rpm]',
|
| 468 |
+
title="Rotational Speed by Failure Status",
|
| 469 |
+
color='Machine failure',
|
| 470 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 471 |
+
)
|
| 472 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 473 |
+
|
| 474 |
+
with col2:
|
| 475 |
+
fig = px.box(
|
| 476 |
+
df,
|
| 477 |
+
x='Machine failure',
|
| 478 |
+
y='Power [W]',
|
| 479 |
+
title="Power by Failure Status",
|
| 480 |
+
color='Machine failure',
|
| 481 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 482 |
+
)
|
| 483 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 484 |
+
|
| 485 |
+
# Scatter plot: Power vs Rotational Speed
|
| 486 |
+
fig = px.scatter(
|
| 487 |
+
df,
|
| 488 |
+
x='Rotational speed [rpm]',
|
| 489 |
+
y='Power [W]',
|
| 490 |
+
color='Machine failure',
|
| 491 |
+
title="Power vs Rotational Speed",
|
| 492 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 493 |
+
)
|
| 494 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 495 |
+
|
| 496 |
+
elif analysis_type == "Outlier Detection":
|
| 497 |
+
st.subheader("Outlier Detection")
|
| 498 |
+
|
| 499 |
+
feature = st.selectbox(
|
| 500 |
+
"Select Feature for Outlier Detection",
|
| 501 |
+
['Air temperature [K]', 'Process temperature [K]', 'Rotational speed [rpm]',
|
| 502 |
+
'Torque [Nm]', 'Tool wear [min]']
|
| 503 |
+
)
|
| 504 |
+
|
| 505 |
+
method = st.radio(
|
| 506 |
+
"Detection method",
|
| 507 |
+
options=["IQR (robust, default)", "Z-score"],
|
| 508 |
+
index=0,
|
| 509 |
+
horizontal=True,
|
| 510 |
+
help="IQR is robust to skew; Z-score highlights extreme standardized values."
|
| 511 |
+
)
|
| 512 |
+
|
| 513 |
+
if method == "IQR (robust, default)":
|
| 514 |
+
iqr_mult = st.slider("IQR multiplier", 0.5, 3.0, 1.5, 0.1,
|
| 515 |
+
help="Lower the multiplier to surface milder outliers.")
|
| 516 |
+
Q1 = df[feature].quantile(0.25)
|
| 517 |
+
Q3 = df[feature].quantile(0.75)
|
| 518 |
+
IQR = Q3 - Q1
|
| 519 |
+
lower_bound = Q1 - iqr_mult * IQR
|
| 520 |
+
upper_bound = Q3 + iqr_mult * IQR
|
| 521 |
+
|
| 522 |
+
outliers = df[(df[feature] < lower_bound) | (df[feature] > upper_bound)]
|
| 523 |
+
|
| 524 |
+
col1, col2 = st.columns(2)
|
| 525 |
+
with col1:
|
| 526 |
+
st.metric("Lower Bound", f"{lower_bound:.2f}")
|
| 527 |
+
st.metric("Upper Bound", f"{upper_bound:.2f}")
|
| 528 |
+
with col2:
|
| 529 |
+
st.metric("Outlier Count", len(outliers))
|
| 530 |
+
st.metric("Outlier Percentage", f"{(len(outliers)/len(df)*100):.2f}%")
|
| 531 |
+
|
| 532 |
+
fig = px.box(df, y=feature, title=f"Box Plot with Outliers - {feature}")
|
| 533 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 534 |
+
|
| 535 |
+
else:
|
| 536 |
+
z_thresh = st.slider("Z-score threshold", 2.0, 5.0, 3.0, 0.1,
|
| 537 |
+
help="Lower threshold to surface more anomalies.")
|
| 538 |
+
mean = df[feature].mean()
|
| 539 |
+
std = df[feature].std()
|
| 540 |
+
if std == 0:
|
| 541 |
+
outliers = df.iloc[0:0]
|
| 542 |
+
zscores = pd.Series([0]*len(df), index=df.index)
|
| 543 |
+
else:
|
| 544 |
+
zscores = (df[feature] - mean) / std
|
| 545 |
+
outliers = df[zscores.abs() > z_thresh]
|
| 546 |
+
|
| 547 |
+
col1, col2 = st.columns(2)
|
| 548 |
+
with col1:
|
| 549 |
+
st.metric("Mean", f"{mean:.2f}")
|
| 550 |
+
st.metric("Std Dev", f"{std:.2f}")
|
| 551 |
+
with col2:
|
| 552 |
+
st.metric("Outlier Count", len(outliers))
|
| 553 |
+
st.metric("Outlier Percentage", f"{(len(outliers)/len(df)*100):.2f}%")
|
| 554 |
+
|
| 555 |
+
fig = px.histogram(df, x=feature, nbins=60, opacity=0.7,
|
| 556 |
+
title=f"{feature} with Z-score Threshold (>|{z_thresh}|)")
|
| 557 |
+
# Overlay threshold lines
|
| 558 |
+
fig.add_vline(x=mean + z_thresh*std, line_dash="dash", line_color="red")
|
| 559 |
+
fig.add_vline(x=mean - z_thresh*std, line_dash="dash", line_color="red")
|
| 560 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 561 |
+
|
| 562 |
+
elif analysis_type == "Pairwise Relationships":
|
| 563 |
+
st.subheader("Pairwise Feature Relationships")
|
| 564 |
+
|
| 565 |
+
feature1 = st.selectbox("Select First Feature",
|
| 566 |
+
['Tool wear [min]', 'Temperature difference [K]',
|
| 567 |
+
'Rotational speed [rpm]', 'Torque [Nm]'])
|
| 568 |
+
feature2 = st.selectbox("Select Second Feature",
|
| 569 |
+
['Tool wear [min]', 'Temperature difference [K]',
|
| 570 |
+
'Rotational speed [rpm]', 'Torque [Nm]'])
|
| 571 |
+
|
| 572 |
+
if feature1 != feature2:
|
| 573 |
+
fig = px.scatter(
|
| 574 |
+
df,
|
| 575 |
+
x=feature1,
|
| 576 |
+
y=feature2,
|
| 577 |
+
color='Machine failure',
|
| 578 |
+
title=f"{feature1} vs {feature2}",
|
| 579 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 580 |
+
)
|
| 581 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 582 |
+
|
| 583 |
+
correlation = df[feature1].corr(df[feature2])
|
| 584 |
+
st.metric("Correlation", f"{correlation:.4f}")
|
| 585 |
+
|
| 586 |
+
elif analysis_type == "Failure Type Breakdown":
|
| 587 |
+
st.subheader("Detailed Failure Type Analysis")
|
| 588 |
+
|
| 589 |
+
failure_types = {
|
| 590 |
+
'TWF': 'Tool Wear Failure',
|
| 591 |
+
'HDF': 'Heat Dissipation Failure',
|
| 592 |
+
'PWF': 'Power Failure',
|
| 593 |
+
'OSF': 'Overstrain Failure',
|
| 594 |
+
'RNF': 'Random Failure'
|
| 595 |
+
}
|
| 596 |
+
|
| 597 |
+
for ft_code, ft_name in failure_types.items():
|
| 598 |
+
with st.expander(f"{ft_name} ({ft_code})"):
|
| 599 |
+
failed_machines = df[df[ft_code] == 1]
|
| 600 |
+
if len(failed_machines) > 0:
|
| 601 |
+
st.metric("Count", len(failed_machines))
|
| 602 |
+
col1, col2, col3 = st.columns(3)
|
| 603 |
+
with col1:
|
| 604 |
+
st.metric("Avg Tool Wear", f"{failed_machines['Tool wear [min]'].mean():.2f} min")
|
| 605 |
+
with col2:
|
| 606 |
+
st.metric("Avg Temp Diff", f"{failed_machines['Temperature difference [K]'].mean():.2f} K")
|
| 607 |
+
with col3:
|
| 608 |
+
st.metric("Avg Rotational Speed", f"{failed_machines['Rotational speed [rpm]'].mean():.0f} rpm")
|
| 609 |
+
|
| 610 |
+
elif analysis_type == "Time to Failure Estimation":
|
| 611 |
+
st.subheader("Time to Failure Estimation")
|
| 612 |
+
|
| 613 |
+
# Analyze tool wear progression for machines that failed
|
| 614 |
+
failed_machines = df[df['Machine failure'] == 1]
|
| 615 |
+
|
| 616 |
+
if len(failed_machines) > 0:
|
| 617 |
+
avg_tool_wear_at_failure = failed_machines['Tool wear [min]'].mean()
|
| 618 |
+
median_tool_wear_at_failure = failed_machines['Tool wear [min]'].median()
|
| 619 |
+
|
| 620 |
+
col1, col2 = st.columns(2)
|
| 621 |
+
with col1:
|
| 622 |
+
st.metric("Average Tool Wear at Failure", f"{avg_tool_wear_at_failure:.2f} minutes")
|
| 623 |
+
with col2:
|
| 624 |
+
st.metric("Median Tool Wear at Failure", f"{median_tool_wear_at_failure:.2f} minutes")
|
| 625 |
+
|
| 626 |
+
# Estimate time remaining for machines not yet failed
|
| 627 |
+
non_failed = df[df['Machine failure'] == 0].copy()
|
| 628 |
+
if len(non_failed) > 0:
|
| 629 |
+
non_failed['Estimated Time to Failure'] = (
|
| 630 |
+
avg_tool_wear_at_failure - non_failed['Tool wear [min]']
|
| 631 |
+
)
|
| 632 |
+
non_failed['Estimated Time to Failure'] = non_failed['Estimated Time to Failure'].clip(lower=0)
|
| 633 |
+
|
| 634 |
+
st.subheader("Time to Failure Estimates (for non-failed machines)")
|
| 635 |
+
|
| 636 |
+
immediate = (non_failed['Estimated Time to Failure'] < 10).sum()
|
| 637 |
+
soon = ((non_failed['Estimated Time to Failure'] >= 10) &
|
| 638 |
+
(non_failed['Estimated Time to Failure'] < 50)).sum()
|
| 639 |
+
remaining = (non_failed['Estimated Time to Failure'] >= 50).sum()
|
| 640 |
+
|
| 641 |
+
col1, col2, col3 = st.columns(3)
|
| 642 |
+
with col1:
|
| 643 |
+
st.metric("Immediate Maintenance (< 10 min)", f"{immediate:,}")
|
| 644 |
+
with col2:
|
| 645 |
+
st.metric("Maintenance Soon (10-50 min)", f"{soon:,}")
|
| 646 |
+
with col3:
|
| 647 |
+
st.metric("Time Remaining (> 50 min)", f"{remaining:,}")
|
| 648 |
+
|
| 649 |
+
# Distribution chart
|
| 650 |
+
fig = px.histogram(
|
| 651 |
+
non_failed,
|
| 652 |
+
x='Estimated Time to Failure',
|
| 653 |
+
nbins=50,
|
| 654 |
+
title="Distribution of Estimated Time to Failure",
|
| 655 |
+
color_discrete_sequence=['#3498db']
|
| 656 |
+
)
|
| 657 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 658 |
+
|
| 659 |
+
elif analysis_type == "Grouped Aggregations":
|
| 660 |
+
st.subheader("Grouped Aggregations by Type and Failure Status")
|
| 661 |
+
|
| 662 |
+
grouped = df.groupby(['Type', 'Machine failure']).agg({
|
| 663 |
+
'Tool wear [min]': ['mean', 'std', 'max'],
|
| 664 |
+
'Temperature difference [K]': ['mean', 'std'],
|
| 665 |
+
'Rotational speed [rpm]': ['mean', 'std'],
|
| 666 |
+
'Torque [Nm]': ['mean', 'std']
|
| 667 |
+
})
|
| 668 |
+
|
| 669 |
+
st.dataframe(grouped, use_container_width=True)
|
| 670 |
+
|
| 671 |
+
# Visualizations
|
| 672 |
+
st.subheader("Tool Wear by Type and Failure Status")
|
| 673 |
+
fig = px.box(
|
| 674 |
+
df,
|
| 675 |
+
x='Type',
|
| 676 |
+
y='Tool wear [min]',
|
| 677 |
+
color='Machine failure',
|
| 678 |
+
title="Tool Wear Distribution by Type and Failure Status",
|
| 679 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 680 |
+
)
|
| 681 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 682 |
+
|
| 683 |
+
st.subheader("Temperature Difference by Type and Failure Status")
|
| 684 |
+
fig = px.box(
|
| 685 |
+
df,
|
| 686 |
+
x='Type',
|
| 687 |
+
y='Temperature difference [K]',
|
| 688 |
+
color='Machine failure',
|
| 689 |
+
title="Temperature Difference by Type and Failure Status",
|
| 690 |
+
color_discrete_sequence=['#2ecc71', '#e74c3c']
|
| 691 |
+
)
|
| 692 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 693 |
+
|
| 694 |
+
def show_model_predictions(df):
|
| 695 |
+
"""Model and predictions page"""
|
| 696 |
+
st.markdown('<h2 class="sub-header">🤖 Machine Learning Model & Predictions</h2>', unsafe_allow_html=True)
|
| 697 |
+
|
| 698 |
+
# Train model section
|
| 699 |
+
if st.session_state.model is None:
|
| 700 |
+
st.info("⚠️ Model not trained yet. Click the button below to train the model.")
|
| 701 |
+
if st.button("Train Model", type="primary"):
|
| 702 |
+
results = train_model()
|
| 703 |
+
st.success("✅ Model trained successfully!")
|
| 704 |
+
st.session_state.model_results = results
|
| 705 |
+
|
| 706 |
+
if st.session_state.model is not None:
|
| 707 |
+
model = st.session_state.model
|
| 708 |
+
preprocessor = st.session_state.preprocessor
|
| 709 |
+
|
| 710 |
+
# Model performance section
|
| 711 |
+
st.subheader("Model Performance")
|
| 712 |
+
|
| 713 |
+
if 'model_results' in st.session_state:
|
| 714 |
+
results = st.session_state.model_results
|
| 715 |
+
col1, col2, col3, col4 = st.columns(4)
|
| 716 |
+
with col1:
|
| 717 |
+
st.metric("Accuracy", f"{results['accuracy']:.4f}")
|
| 718 |
+
with col2:
|
| 719 |
+
st.metric("Precision", f"{results['precision']:.4f}")
|
| 720 |
+
with col3:
|
| 721 |
+
st.metric("Recall", f"{results['recall']:.4f}")
|
| 722 |
+
with col4:
|
| 723 |
+
st.metric("F1-Score", f"{results['f1_score']:.4f}")
|
| 724 |
+
|
| 725 |
+
# Feature importance
|
| 726 |
+
st.subheader("Feature Importance")
|
| 727 |
+
feature_importance = model.get_feature_importance()
|
| 728 |
+
fig = px.bar(
|
| 729 |
+
feature_importance,
|
| 730 |
+
x='importance',
|
| 731 |
+
y='feature',
|
| 732 |
+
orientation='h',
|
| 733 |
+
title="Feature Importance",
|
| 734 |
+
color='importance',
|
| 735 |
+
color_continuous_scale="Viridis"
|
| 736 |
+
)
|
| 737 |
+
st.plotly_chart(fig, use_container_width=True)
|
| 738 |
+
|
| 739 |
+
st.markdown("---")
|
| 740 |
+
|
| 741 |
+
# Runtime prediction section
|
| 742 |
+
st.subheader("🔮 Runtime Prediction - Predict Maintenance Needs")
|
| 743 |
+
st.markdown("Enter machine parameters below to predict if maintenance is needed:")
|
| 744 |
+
|
| 745 |
+
col1, col2 = st.columns(2)
|
| 746 |
+
|
| 747 |
+
with col1:
|
| 748 |
+
machine_type = st.selectbox(
|
| 749 |
+
"Machine Type",
|
| 750 |
+
['L', 'M', 'H'],
|
| 751 |
+
format_func=lambda x: f"{x} ({'Low Quality/Load' if x == 'L' else 'Medium Quality/Load' if x == 'M' else 'High Quality/Load'})"
|
| 752 |
+
)
|
| 753 |
+
air_temp = st.slider("Air Temperature (K)",
|
| 754 |
+
min_value=295.0, max_value=305.0, value=298.0, step=0.1)
|
| 755 |
+
process_temp = st.slider("Process Temperature (K)",
|
| 756 |
+
min_value=305.0, max_value=315.0, value=309.0, step=0.1)
|
| 757 |
+
|
| 758 |
+
with col2:
|
| 759 |
+
rotational_speed = st.slider("Rotational Speed (rpm)",
|
| 760 |
+
min_value=1000, max_value=3000, value=1500, step=10)
|
| 761 |
+
torque = st.slider("Torque (Nm)",
|
| 762 |
+
min_value=10.0, max_value=80.0, value=40.0, step=0.1)
|
| 763 |
+
tool_wear = st.slider("Tool Wear (minutes)",
|
| 764 |
+
min_value=0, max_value=300, value=50, step=1)
|
| 765 |
+
|
| 766 |
+
if st.button("Predict Maintenance Status", type="primary"):
|
| 767 |
+
# Create input data
|
| 768 |
+
input_data = pd.DataFrame({
|
| 769 |
+
'Type': [machine_type],
|
| 770 |
+
'Air temperature [K]': [air_temp],
|
| 771 |
+
'Process temperature [K]': [process_temp],
|
| 772 |
+
'Rotational speed [rpm]': [rotational_speed],
|
| 773 |
+
'Torque [Nm]': [torque],
|
| 774 |
+
'Tool wear [min]': [tool_wear]
|
| 775 |
+
})
|
| 776 |
+
|
| 777 |
+
# Preprocess
|
| 778 |
+
X_new = preprocessor.preprocess_new_data(input_data)
|
| 779 |
+
|
| 780 |
+
# Predict
|
| 781 |
+
maintenance_pred = model.predict_maintenance(X_new, tool_wear_values=[tool_wear])
|
| 782 |
+
|
| 783 |
+
# Display results
|
| 784 |
+
st.markdown("### Prediction Results")
|
| 785 |
+
|
| 786 |
+
failure_prob = maintenance_pred['Failure_Probability'].iloc[0]
|
| 787 |
+
time_to_failure = maintenance_pred['Time_to_Failure_Minutes'].iloc[0]
|
| 788 |
+
status = maintenance_pred['Maintenance_Status'].iloc[0]
|
| 789 |
+
urgency = maintenance_pred['Maintenance_Urgency'].iloc[0]
|
| 790 |
+
|
| 791 |
+
# Color coding
|
| 792 |
+
if urgency == "CRITICAL":
|
| 793 |
+
st.error(f"🚨 **{status}**")
|
| 794 |
+
elif urgency == "HIGH":
|
| 795 |
+
st.warning(f"⚠️ **{status}**")
|
| 796 |
+
elif urgency == "MEDIUM":
|
| 797 |
+
st.info(f"ℹ️ **{status}**")
|
| 798 |
+
else:
|
| 799 |
+
st.success(f"✅ **{status}**")
|
| 800 |
+
|
| 801 |
+
col1, col2, col3 = st.columns(3)
|
| 802 |
+
with col1:
|
| 803 |
+
st.metric("Failure Probability", f"{failure_prob:.2%}")
|
| 804 |
+
with col2:
|
| 805 |
+
st.metric("Estimated Time to Maintenance", f"{time_to_failure:.1f} minutes")
|
| 806 |
+
if time_to_failure > 0:
|
| 807 |
+
st.caption(f"Based on historical data: avg failure at 120 min tool wear")
|
| 808 |
+
else:
|
| 809 |
+
st.caption("Tool wear exceeded average failure threshold (120 min)")
|
| 810 |
+
with col3:
|
| 811 |
+
st.metric("Maintenance Urgency", urgency)
|
| 812 |
+
|
| 813 |
+
# Detailed information
|
| 814 |
+
with st.expander("View Detailed Information"):
|
| 815 |
+
st.markdown(f"""
|
| 816 |
+
**Machine Parameters:**
|
| 817 |
+
- Type: {machine_type} ({'Low Quality/Load' if machine_type == 'L' else 'Medium Quality/Load' if machine_type == 'M' else 'High Quality/Load'})
|
| 818 |
+
- Air Temperature: {air_temp} K
|
| 819 |
+
- Process Temperature: {process_temp} K
|
| 820 |
+
- Rotational Speed: {rotational_speed} rpm
|
| 821 |
+
- Torque: {torque} Nm
|
| 822 |
+
- Tool Wear: {tool_wear} minutes
|
| 823 |
+
|
| 824 |
+
**Prediction Details:**
|
| 825 |
+
- Failure Predicted: {'Yes' if maintenance_pred['Failure_Predicted'].iloc[0] == 1 else 'No'}
|
| 826 |
+
- Failure Probability: {failure_prob:.2%}
|
| 827 |
+
- Estimated Time to Maintenance: {time_to_failure:.1f} minutes
|
| 828 |
+
*Based on historical analysis: Machines in this dataset typically require maintenance when tool wear reaches approximately 120 minutes.
|
| 829 |
+
This estimate projects when your machine will reach that threshold based on current tool wear level.*
|
| 830 |
+
- Maintenance Status: {status}
|
| 831 |
+
- Urgency Level: {urgency}
|
| 832 |
+
|
| 833 |
+
**Recommendation:**
|
| 834 |
+
{get_maintenance_recommendation(urgency, time_to_failure, failure_prob)}
|
| 835 |
+
""")
|
| 836 |
+
|
| 837 |
+
st.markdown("---")
|
| 838 |
+
|
| 839 |
+
# Batch prediction section
|
| 840 |
+
st.subheader("Batch Prediction")
|
| 841 |
+
st.markdown("Upload a CSV file with machine data for batch predictions:")
|
| 842 |
+
|
| 843 |
+
uploaded_file = st.file_uploader("Choose a CSV file", type="csv")
|
| 844 |
+
|
| 845 |
+
if uploaded_file is not None:
|
| 846 |
+
try:
|
| 847 |
+
batch_data = pd.read_csv(uploaded_file)
|
| 848 |
+
st.dataframe(batch_data.head(), use_container_width=True)
|
| 849 |
+
|
| 850 |
+
if st.button("Predict for Batch", type="primary"):
|
| 851 |
+
# Check required columns
|
| 852 |
+
required_cols = ['Type', 'Air temperature [K]', 'Process temperature [K]',
|
| 853 |
+
'Rotational speed [rpm]', 'Torque [Nm]', 'Tool wear [min]']
|
| 854 |
+
|
| 855 |
+
if all(col in batch_data.columns for col in required_cols):
|
| 856 |
+
X_batch = preprocessor.preprocess_new_data(batch_data)
|
| 857 |
+
tool_wear_batch = batch_data['Tool wear [min]'].values
|
| 858 |
+
batch_predictions = model.predict_maintenance(X_batch, tool_wear_batch)
|
| 859 |
+
|
| 860 |
+
# Combine with original data
|
| 861 |
+
results_df = pd.concat([batch_data, batch_predictions], axis=1)
|
| 862 |
+
|
| 863 |
+
st.success("✅ Batch prediction complete!")
|
| 864 |
+
st.dataframe(results_df, use_container_width=True)
|
| 865 |
+
|
| 866 |
+
# Summary statistics
|
| 867 |
+
st.subheader("Batch Prediction Summary")
|
| 868 |
+
col1, col2, col3, col4 = st.columns(4)
|
| 869 |
+
with col1:
|
| 870 |
+
st.metric("Total Machines", len(batch_data))
|
| 871 |
+
with col2:
|
| 872 |
+
st.metric("Critical Maintenance",
|
| 873 |
+
(batch_predictions['Maintenance_Urgency'] == 'CRITICAL').sum())
|
| 874 |
+
with col3:
|
| 875 |
+
st.metric("High Priority",
|
| 876 |
+
(batch_predictions['Maintenance_Urgency'] == 'HIGH').sum())
|
| 877 |
+
with col4:
|
| 878 |
+
st.metric("Average Time to Failure",
|
| 879 |
+
f"{batch_predictions['Time_to_Failure_Minutes'].mean():.1f} min")
|
| 880 |
+
else:
|
| 881 |
+
st.error(f"CSV must contain these columns: {', '.join(required_cols)}")
|
| 882 |
+
except Exception as e:
|
| 883 |
+
st.error(f"Error processing file: {str(e)}")
|
| 884 |
+
|
| 885 |
+
def get_maintenance_recommendation(urgency, time_to_failure, failure_prob):
|
| 886 |
+
"""Get maintenance recommendation based on prediction"""
|
| 887 |
+
if urgency == "CRITICAL":
|
| 888 |
+
return "**IMMEDIATE ACTION REQUIRED**: Stop the machine immediately and perform maintenance. Failure is imminent."
|
| 889 |
+
elif urgency == "HIGH":
|
| 890 |
+
if time_to_failure < 60:
|
| 891 |
+
return f"**URGENT**: Schedule maintenance within {int(time_to_failure/60)} hour(s) or immediately if possible. The machine shows high risk of failure."
|
| 892 |
+
else:
|
| 893 |
+
return f"**Schedule maintenance within {int(time_to_failure/60)} hours**. The machine shows high risk of failure."
|
| 894 |
+
elif urgency == "MEDIUM":
|
| 895 |
+
if time_to_failure < 20:
|
| 896 |
+
return f"**Schedule maintenance within the next 20-30 minutes**. Monitor the machine very closely. Estimated time to maintenance: {time_to_failure:.0f} minutes."
|
| 897 |
+
elif time_to_failure < 60:
|
| 898 |
+
return f"**Schedule maintenance within the next hour**. Monitor the machine closely. Estimated time to maintenance: {time_to_failure:.0f} minutes."
|
| 899 |
+
elif time_to_failure < 120:
|
| 900 |
+
return f"**Plan maintenance within the next 2 hours**. Monitor the machine closely. Estimated time to maintenance: {int(time_to_failure/60)} hours."
|
| 901 |
+
else:
|
| 902 |
+
return f"**Plan maintenance within the next few days**. Monitor the machine regularly. Estimated time to maintenance: {int(time_to_failure/60)} hours."
|
| 903 |
+
else:
|
| 904 |
+
if time_to_failure < 120:
|
| 905 |
+
return f"**Monitor regularly**. No immediate action needed, but plan maintenance soon. Estimated time to maintenance: {int(time_to_failure/60)} hours."
|
| 906 |
+
else:
|
| 907 |
+
return f"**No immediate action needed**. Continue regular monitoring. Estimated time to maintenance: {int(time_to_failure/60)} hours."
|
| 908 |
+
|
| 909 |
+
def show_conclusion():
|
| 910 |
+
"""Conclusion page"""
|
| 911 |
+
st.markdown('<h2 class="sub-header">📝 Conclusion & Key Takeaways</h2>', unsafe_allow_html=True)
|
| 912 |
+
|
| 913 |
+
st.markdown("""
|
| 914 |
+
### Project Summary
|
| 915 |
+
|
| 916 |
+
This predictive maintenance project successfully analyzed the AI4I 2020 dataset and built
|
| 917 |
+
a machine learning model to predict machine failures and estimate maintenance needs.
|
| 918 |
+
|
| 919 |
+
### Key Findings
|
| 920 |
+
|
| 921 |
+
1. **Dataset Characteristics**:
|
| 922 |
+
- The dataset contains 10,000 machine records with 14 features
|
| 923 |
+
- Machine failure rate is approximately 3.39% (imbalanced dataset)
|
| 924 |
+
- Five different failure types were identified: TWF, HDF, PWF, OSF, and RNF
|
| 925 |
+
|
| 926 |
+
2. **Important Features**:
|
| 927 |
+
- Tool wear is a critical indicator of machine health
|
| 928 |
+
- Temperature difference between process and air temperature correlates with failures
|
| 929 |
+
- Machine type (L = Low Quality/Load, M = Medium Quality/Load, H = High Quality/Load) affects failure rates differently
|
| 930 |
+
- Rotational speed and torque relationships are important predictors
|
| 931 |
+
|
| 932 |
+
3. **Model Performance**:
|
| 933 |
+
- Random Forest Classifier achieved good performance on the imbalanced dataset
|
| 934 |
+
- The model can effectively predict machine failures
|
| 935 |
+
- Feature importance analysis revealed tool wear and temperature as key predictors
|
| 936 |
+
|
| 937 |
+
4. **Maintenance Insights**:
|
| 938 |
+
- Machines with tool wear > 100 minutes are at higher risk
|
| 939 |
+
- Temperature differences > 10K indicate potential heat dissipation issues
|
| 940 |
+
- Early detection can prevent costly downtime
|
| 941 |
+
|
| 942 |
+
### Applications
|
| 943 |
+
|
| 944 |
+
This system can be used in real-world industrial settings to:
|
| 945 |
+
- **Prevent unexpected failures** by predicting maintenance needs
|
| 946 |
+
- **Optimize maintenance schedules** based on actual machine conditions
|
| 947 |
+
- **Reduce downtime** through proactive maintenance
|
| 948 |
+
- **Save costs** by avoiding catastrophic failures
|
| 949 |
+
|
| 950 |
+
### Future Improvements
|
| 951 |
+
|
| 952 |
+
1. **Model Enhancement**:
|
| 953 |
+
- Try ensemble methods (XGBoost, LightGBM)
|
| 954 |
+
- Implement time-series analysis for sequential data
|
| 955 |
+
- Add anomaly detection algorithms
|
| 956 |
+
|
| 957 |
+
2. **Feature Engineering**:
|
| 958 |
+
- Create more domain-specific features
|
| 959 |
+
- Include historical maintenance records
|
| 960 |
+
- Add environmental factors
|
| 961 |
+
|
| 962 |
+
3. **System Integration**:
|
| 963 |
+
- Real-time data streaming
|
| 964 |
+
- Integration with IoT sensors
|
| 965 |
+
- Automated alert system
|
| 966 |
+
|
| 967 |
+
### Technical Stack
|
| 968 |
+
|
| 969 |
+
- **Data Analysis**: Pandas, NumPy
|
| 970 |
+
- **Visualization**: Matplotlib, Seaborn, Plotly
|
| 971 |
+
- **Machine Learning**: Scikit-learn (Random Forest)
|
| 972 |
+
- **Web Application**: Streamlit
|
| 973 |
+
- **Preprocessing**: StandardScaler, LabelEncoder
|
| 974 |
+
|
| 975 |
+
### Acknowledgments
|
| 976 |
+
|
| 977 |
+
Dataset: AI4I 2020 Predictive Maintenance Dataset
|
| 978 |
+
|
| 979 |
+
---
|
| 980 |
+
|
| 981 |
+
**Project completed for Introduction to Data Science Course (IDS F24)**
|
| 982 |
+
""")
|
| 983 |
+
|
| 984 |
+
st.markdown("---")
|
| 985 |
+
st.markdown("### Thank you for using the Predictive Maintenance System! 🔧")
|
| 986 |
+
|
| 987 |
+
if __name__ == "__main__":
|
| 988 |
+
main()
|
| 989 |
+
|
model.py
ADDED
|
@@ -0,0 +1,235 @@
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|
|
|
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|
|
|
|
|
|
|
|
|
| 1 |
+
"""
|
| 2 |
+
Machine Learning Model for Predictive Maintenance
|
| 3 |
+
Uses Random Forest Classifier for failure prediction
|
| 4 |
+
"""
|
| 5 |
+
|
| 6 |
+
import pandas as pd
|
| 7 |
+
import numpy as np
|
| 8 |
+
import pickle
|
| 9 |
+
from sklearn.ensemble import RandomForestClassifier
|
| 10 |
+
from sklearn.metrics import (
|
| 11 |
+
accuracy_score, precision_score, recall_score, f1_score,
|
| 12 |
+
confusion_matrix, classification_report, roc_auc_score
|
| 13 |
+
)
|
| 14 |
+
import warnings
|
| 15 |
+
warnings.filterwarnings('ignore')
|
| 16 |
+
|
| 17 |
+
class PredictiveMaintenanceModel:
|
| 18 |
+
def __init__(self):
|
| 19 |
+
"""Initialize the model"""
|
| 20 |
+
self.model = RandomForestClassifier(
|
| 21 |
+
n_estimators=100,
|
| 22 |
+
max_depth=10,
|
| 23 |
+
min_samples_split=5,
|
| 24 |
+
min_samples_leaf=2,
|
| 25 |
+
random_state=42,
|
| 26 |
+
class_weight='balanced' # Handle class imbalance
|
| 27 |
+
)
|
| 28 |
+
self.is_trained = False
|
| 29 |
+
self.feature_importance_ = None
|
| 30 |
+
|
| 31 |
+
def train(self, X_train, y_train):
|
| 32 |
+
"""Train the model"""
|
| 33 |
+
print("Training Random Forest Classifier...")
|
| 34 |
+
self.model.fit(X_train, y_train)
|
| 35 |
+
self.is_trained = True
|
| 36 |
+
|
| 37 |
+
# Get feature importance
|
| 38 |
+
self.feature_importance_ = pd.DataFrame({
|
| 39 |
+
'feature': X_train.columns,
|
| 40 |
+
'importance': self.model.feature_importances_
|
| 41 |
+
}).sort_values('importance', ascending=False)
|
| 42 |
+
|
| 43 |
+
print("Model training complete!")
|
| 44 |
+
return self
|
| 45 |
+
|
| 46 |
+
def predict(self, X):
|
| 47 |
+
"""Make predictions"""
|
| 48 |
+
if not self.is_trained:
|
| 49 |
+
raise ValueError("Model must be trained first!")
|
| 50 |
+
return self.model.predict(X)
|
| 51 |
+
|
| 52 |
+
def predict_proba(self, X):
|
| 53 |
+
"""Get prediction probabilities"""
|
| 54 |
+
if not self.is_trained:
|
| 55 |
+
raise ValueError("Model must be trained first!")
|
| 56 |
+
return self.model.predict_proba(X)
|
| 57 |
+
|
| 58 |
+
def evaluate(self, X_test, y_test):
|
| 59 |
+
"""Evaluate the model"""
|
| 60 |
+
if not self.is_trained:
|
| 61 |
+
raise ValueError("Model must be trained first!")
|
| 62 |
+
|
| 63 |
+
# Predictions
|
| 64 |
+
y_pred = self.predict(X_test)
|
| 65 |
+
y_pred_proba = self.predict_proba(X_test)[:, 1]
|
| 66 |
+
|
| 67 |
+
# Metrics
|
| 68 |
+
accuracy = accuracy_score(y_test, y_pred)
|
| 69 |
+
precision = precision_score(y_test, y_pred, zero_division=0)
|
| 70 |
+
recall = recall_score(y_test, y_pred, zero_division=0)
|
| 71 |
+
f1 = f1_score(y_test, y_pred, zero_division=0)
|
| 72 |
+
roc_auc = roc_auc_score(y_test, y_pred_proba)
|
| 73 |
+
|
| 74 |
+
# Confusion matrix
|
| 75 |
+
cm = confusion_matrix(y_test, y_pred)
|
| 76 |
+
|
| 77 |
+
# Classification report
|
| 78 |
+
report = classification_report(y_test, y_pred, zero_division=0)
|
| 79 |
+
|
| 80 |
+
results = {
|
| 81 |
+
'accuracy': accuracy,
|
| 82 |
+
'precision': precision,
|
| 83 |
+
'recall': recall,
|
| 84 |
+
'f1_score': f1,
|
| 85 |
+
'roc_auc': roc_auc,
|
| 86 |
+
'confusion_matrix': cm,
|
| 87 |
+
'classification_report': report,
|
| 88 |
+
'y_pred': y_pred,
|
| 89 |
+
'y_pred_proba': y_pred_proba
|
| 90 |
+
}
|
| 91 |
+
|
| 92 |
+
print("="*60)
|
| 93 |
+
print("MODEL EVALUATION RESULTS")
|
| 94 |
+
print("="*60)
|
| 95 |
+
print(f"Accuracy: {accuracy:.4f}")
|
| 96 |
+
print(f"Precision: {precision:.4f}")
|
| 97 |
+
print(f"Recall: {recall:.4f}")
|
| 98 |
+
print(f"F1-Score: {f1:.4f}")
|
| 99 |
+
print(f"ROC-AUC: {roc_auc:.4f}")
|
| 100 |
+
print("\nConfusion Matrix:")
|
| 101 |
+
print(cm)
|
| 102 |
+
print("\nClassification Report:")
|
| 103 |
+
print(report)
|
| 104 |
+
|
| 105 |
+
return results
|
| 106 |
+
|
| 107 |
+
def predict_maintenance(self, X, tool_wear_values=None):
|
| 108 |
+
"""
|
| 109 |
+
Predict maintenance needs and time to failure
|
| 110 |
+
|
| 111 |
+
Args:
|
| 112 |
+
X: Feature matrix
|
| 113 |
+
tool_wear_values: Array of tool wear values (optional)
|
| 114 |
+
|
| 115 |
+
Returns:
|
| 116 |
+
DataFrame with predictions and maintenance recommendations
|
| 117 |
+
"""
|
| 118 |
+
if not self.is_trained:
|
| 119 |
+
raise ValueError("Model must be trained first!")
|
| 120 |
+
|
| 121 |
+
# Get failure predictions
|
| 122 |
+
failure_pred = self.predict(X)
|
| 123 |
+
failure_proba = self.predict_proba(X)[:, 1]
|
| 124 |
+
|
| 125 |
+
# Estimate time to failure based on tool wear
|
| 126 |
+
# Average tool wear at failure is around 100-150 minutes based on EDA
|
| 127 |
+
avg_tool_wear_at_failure = 120 # minutes
|
| 128 |
+
|
| 129 |
+
if tool_wear_values is None:
|
| 130 |
+
# Try to get tool wear from features if available
|
| 131 |
+
if 'Tool wear [min]' in X.columns:
|
| 132 |
+
tool_wear_values = X['Tool wear [min]'].values
|
| 133 |
+
else:
|
| 134 |
+
tool_wear_values = np.zeros(len(X))
|
| 135 |
+
else:
|
| 136 |
+
# Convert to numpy array if it's a list or scalar
|
| 137 |
+
tool_wear_values = np.array(tool_wear_values)
|
| 138 |
+
# If it's a scalar, make it an array
|
| 139 |
+
if tool_wear_values.ndim == 0:
|
| 140 |
+
tool_wear_values = np.array([tool_wear_values])
|
| 141 |
+
|
| 142 |
+
# Ensure tool_wear_values is 1D array with same length as predictions
|
| 143 |
+
if len(tool_wear_values) != len(failure_pred):
|
| 144 |
+
# If single value provided, repeat it for all predictions
|
| 145 |
+
if len(tool_wear_values) == 1:
|
| 146 |
+
tool_wear_values = np.repeat(tool_wear_values, len(failure_pred))
|
| 147 |
+
else:
|
| 148 |
+
raise ValueError(f"tool_wear_values length ({len(tool_wear_values)}) doesn't match predictions length ({len(failure_pred)})")
|
| 149 |
+
|
| 150 |
+
# Calculate estimated time to failure
|
| 151 |
+
time_to_failure = np.maximum(0, avg_tool_wear_at_failure - tool_wear_values)
|
| 152 |
+
|
| 153 |
+
# Determine maintenance urgency
|
| 154 |
+
maintenance_status = []
|
| 155 |
+
maintenance_urgency = []
|
| 156 |
+
|
| 157 |
+
for i in range(len(failure_pred)):
|
| 158 |
+
# Check if tool wear has exceeded the average failure threshold
|
| 159 |
+
tool_wear_exceeded = tool_wear_values[i] >= avg_tool_wear_at_failure
|
| 160 |
+
tool_wear_severely_exceeded = tool_wear_values[i] >= (avg_tool_wear_at_failure * 1.5) # 150% of threshold (180 min)
|
| 161 |
+
|
| 162 |
+
# Combined risk assessment: consider both ML prediction AND tool wear
|
| 163 |
+
if failure_pred[i] == 1:
|
| 164 |
+
# Model predicts failure - highest priority
|
| 165 |
+
maintenance_status.append("IMMEDIATE MAINTENANCE REQUIRED")
|
| 166 |
+
maintenance_urgency.append("CRITICAL")
|
| 167 |
+
elif tool_wear_severely_exceeded and failure_proba[i] > 0.2:
|
| 168 |
+
# Severely exceeded tool wear AND significant failure probability
|
| 169 |
+
maintenance_status.append("IMMEDIATE MAINTENANCE REQUIRED - Tool wear severely exceeded threshold")
|
| 170 |
+
maintenance_urgency.append("CRITICAL")
|
| 171 |
+
elif tool_wear_severely_exceeded:
|
| 172 |
+
# Severely exceeded tool wear but low failure probability - still HIGH priority
|
| 173 |
+
maintenance_status.append("URGENT MAINTENANCE NEEDED - Tool wear severely exceeded (monitor closely)")
|
| 174 |
+
maintenance_urgency.append("HIGH")
|
| 175 |
+
elif tool_wear_exceeded and failure_proba[i] > 0.3:
|
| 176 |
+
# Tool wear exceeded AND moderate failure probability
|
| 177 |
+
maintenance_status.append("IMMEDIATE MAINTENANCE REQUIRED - Tool wear exceeded threshold")
|
| 178 |
+
maintenance_urgency.append("CRITICAL")
|
| 179 |
+
elif tool_wear_exceeded:
|
| 180 |
+
# Tool wear exceeded but low failure probability - HIGH priority
|
| 181 |
+
maintenance_status.append("URGENT MAINTENANCE NEEDED - Tool wear exceeded threshold")
|
| 182 |
+
maintenance_urgency.append("HIGH")
|
| 183 |
+
elif failure_proba[i] > 0.7:
|
| 184 |
+
# High failure probability regardless of tool wear
|
| 185 |
+
maintenance_status.append("Maintenance needed soon")
|
| 186 |
+
maintenance_urgency.append("HIGH")
|
| 187 |
+
elif failure_proba[i] > 0.4:
|
| 188 |
+
# Moderate failure probability
|
| 189 |
+
maintenance_status.append("Schedule maintenance")
|
| 190 |
+
maintenance_urgency.append("MEDIUM")
|
| 191 |
+
elif time_to_failure[i] < 20:
|
| 192 |
+
# Less than 20 minutes remaining
|
| 193 |
+
maintenance_status.append("Monitor closely - Maintenance needed within 20 minutes")
|
| 194 |
+
maintenance_urgency.append("MEDIUM")
|
| 195 |
+
elif time_to_failure[i] < 60:
|
| 196 |
+
# Less than 1 hour remaining
|
| 197 |
+
maintenance_status.append("Monitor closely - Maintenance needed within 1 hour")
|
| 198 |
+
maintenance_urgency.append("MEDIUM")
|
| 199 |
+
else:
|
| 200 |
+
# Low risk
|
| 201 |
+
maintenance_status.append("No immediate maintenance needed")
|
| 202 |
+
maintenance_urgency.append("LOW")
|
| 203 |
+
|
| 204 |
+
results_df = pd.DataFrame({
|
| 205 |
+
'Failure_Predicted': failure_pred,
|
| 206 |
+
'Failure_Probability': failure_proba,
|
| 207 |
+
'Time_to_Failure_Minutes': time_to_failure,
|
| 208 |
+
'Maintenance_Status': maintenance_status,
|
| 209 |
+
'Maintenance_Urgency': maintenance_urgency
|
| 210 |
+
})
|
| 211 |
+
|
| 212 |
+
return results_df
|
| 213 |
+
|
| 214 |
+
|
| 215 |
+
def get_feature_importance(self):
|
| 216 |
+
"""Get feature importance"""
|
| 217 |
+
if self.feature_importance_ is None:
|
| 218 |
+
raise ValueError("Model must be trained first!")
|
| 219 |
+
return self.feature_importance_
|
| 220 |
+
|
| 221 |
+
def save_model(self, filepath='predictive_maintenance_model.pkl'):
|
| 222 |
+
"""Save the trained model"""
|
| 223 |
+
if not self.is_trained:
|
| 224 |
+
raise ValueError("Model must be trained first!")
|
| 225 |
+
|
| 226 |
+
with open(filepath, 'wb') as f:
|
| 227 |
+
pickle.dump(self.model, f)
|
| 228 |
+
print(f"Model saved to {filepath}")
|
| 229 |
+
|
| 230 |
+
def load_model(self, filepath='predictive_maintenance_model.pkl'):
|
| 231 |
+
"""Load a trained model"""
|
| 232 |
+
with open(filepath, 'rb') as f:
|
| 233 |
+
self.model = pickle.load(f)
|
| 234 |
+
self.is_trained = True
|
| 235 |
+
print(f"Model loaded from {filepath}")
|
preprocessing.py
ADDED
|
@@ -0,0 +1,205 @@
|
|
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|
|
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|
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|
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|
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|
|
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|
|
|
|
|
|
|
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|
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|
|
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|
|
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|
|
|
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|
|
|
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| 1 |
+
"""
|
| 2 |
+
Data Preprocessing Module for AI4I 2020 Predictive Maintenance Dataset
|
| 3 |
+
Handles missing values, encoding, scaling, and train-test splitting
|
| 4 |
+
"""
|
| 5 |
+
|
| 6 |
+
import pandas as pd
|
| 7 |
+
import numpy as np
|
| 8 |
+
from sklearn.model_selection import train_test_split
|
| 9 |
+
from sklearn.preprocessing import StandardScaler, LabelEncoder
|
| 10 |
+
from sklearn.impute import SimpleImputer
|
| 11 |
+
|
| 12 |
+
class DataPreprocessor:
|
| 13 |
+
def __init__(self, data_path='ai4i2020.csv'):
|
| 14 |
+
"""Initialize the preprocessor"""
|
| 15 |
+
self.df = pd.read_csv(data_path)
|
| 16 |
+
self.scaler = StandardScaler()
|
| 17 |
+
self.label_encoder = LabelEncoder()
|
| 18 |
+
self.feature_columns = None
|
| 19 |
+
self.is_fitted = False
|
| 20 |
+
|
| 21 |
+
def create_features(self):
|
| 22 |
+
"""Create additional features"""
|
| 23 |
+
# Temperature difference
|
| 24 |
+
self.df['Temperature difference [K]'] = (
|
| 25 |
+
self.df['Process temperature [K]'] -
|
| 26 |
+
self.df['Air temperature [K]']
|
| 27 |
+
)
|
| 28 |
+
|
| 29 |
+
# Power calculation
|
| 30 |
+
self.df['Power [W]'] = (
|
| 31 |
+
self.df['Rotational speed [rpm]'] *
|
| 32 |
+
self.df['Torque [Nm]'] / 9.5488
|
| 33 |
+
)
|
| 34 |
+
|
| 35 |
+
# Tool wear rate (if we had time data, but we'll use a proxy)
|
| 36 |
+
# We can create bins for tool wear
|
| 37 |
+
self.df['Tool wear category'] = pd.cut(
|
| 38 |
+
self.df['Tool wear [min]'],
|
| 39 |
+
bins=[0, 50, 100, 150, 200, 300],
|
| 40 |
+
labels=['Very Low', 'Low', 'Medium', 'High', 'Very High']
|
| 41 |
+
)
|
| 42 |
+
|
| 43 |
+
def handle_missing_values(self):
|
| 44 |
+
"""Handle missing values"""
|
| 45 |
+
# Check for missing values
|
| 46 |
+
missing = self.df.isnull().sum()
|
| 47 |
+
|
| 48 |
+
if missing.sum() > 0:
|
| 49 |
+
# For numerical columns, use mean imputation
|
| 50 |
+
numerical_cols = self.df.select_dtypes(include=[np.number]).columns
|
| 51 |
+
imputer = SimpleImputer(strategy='mean')
|
| 52 |
+
self.df[numerical_cols] = imputer.fit_transform(self.df[numerical_cols])
|
| 53 |
+
|
| 54 |
+
# For categorical columns, use mode imputation
|
| 55 |
+
categorical_cols = self.df.select_dtypes(include=['object']).columns
|
| 56 |
+
for col in categorical_cols:
|
| 57 |
+
if self.df[col].isnull().sum() > 0:
|
| 58 |
+
mode_value = self.df[col].mode()[0]
|
| 59 |
+
self.df[col].fillna(mode_value, inplace=True)
|
| 60 |
+
else:
|
| 61 |
+
print("No missing values found in the dataset.")
|
| 62 |
+
|
| 63 |
+
def encode_categorical_variables(self):
|
| 64 |
+
"""Encode categorical variables"""
|
| 65 |
+
# Encode Type column
|
| 66 |
+
self.df['Type_encoded'] = self.label_encoder.fit_transform(self.df['Type'])
|
| 67 |
+
|
| 68 |
+
# One-hot encode Type (alternative approach)
|
| 69 |
+
type_dummies = pd.get_dummies(self.df['Type'], prefix='Type')
|
| 70 |
+
self.df = pd.concat([self.df, type_dummies], axis=1)
|
| 71 |
+
|
| 72 |
+
# Encode Tool wear category if it exists
|
| 73 |
+
if 'Tool wear category' in self.df.columns:
|
| 74 |
+
self.df['Tool_wear_category_encoded'] = LabelEncoder().fit_transform(
|
| 75 |
+
self.df['Tool wear category'].astype(str)
|
| 76 |
+
)
|
| 77 |
+
|
| 78 |
+
def select_features(self):
|
| 79 |
+
"""Select features for modeling"""
|
| 80 |
+
# Drop non-feature columns
|
| 81 |
+
columns_to_drop = [
|
| 82 |
+
'UDI', 'Product ID', 'Type', 'Tool wear category'
|
| 83 |
+
]
|
| 84 |
+
|
| 85 |
+
# Keep only relevant columns
|
| 86 |
+
feature_columns = [
|
| 87 |
+
'Air temperature [K]',
|
| 88 |
+
'Process temperature [K]',
|
| 89 |
+
'Rotational speed [rpm]',
|
| 90 |
+
'Torque [Nm]',
|
| 91 |
+
'Tool wear [min]',
|
| 92 |
+
'Temperature difference [K]',
|
| 93 |
+
'Power [W]',
|
| 94 |
+
'Type_encoded',
|
| 95 |
+
'Type_H',
|
| 96 |
+
'Type_L',
|
| 97 |
+
'Type_M'
|
| 98 |
+
]
|
| 99 |
+
|
| 100 |
+
# Remove columns that don't exist
|
| 101 |
+
feature_columns = [col for col in feature_columns if col in self.df.columns]
|
| 102 |
+
|
| 103 |
+
self.feature_columns = feature_columns
|
| 104 |
+
return feature_columns
|
| 105 |
+
|
| 106 |
+
def scale_features(self, X_train, X_test):
|
| 107 |
+
"""Scale numerical features"""
|
| 108 |
+
# Scale training data
|
| 109 |
+
X_train_scaled = self.scaler.fit_transform(X_train)
|
| 110 |
+
X_test_scaled = self.scaler.transform(X_test)
|
| 111 |
+
|
| 112 |
+
# Convert back to DataFrame
|
| 113 |
+
X_train_scaled = pd.DataFrame(
|
| 114 |
+
X_train_scaled,
|
| 115 |
+
columns=X_train.columns,
|
| 116 |
+
index=X_train.index
|
| 117 |
+
)
|
| 118 |
+
X_test_scaled = pd.DataFrame(
|
| 119 |
+
X_test_scaled,
|
| 120 |
+
columns=X_test.columns,
|
| 121 |
+
index=X_test.index
|
| 122 |
+
)
|
| 123 |
+
|
| 124 |
+
return X_train_scaled, X_test_scaled
|
| 125 |
+
|
| 126 |
+
def prepare_data(self, target='Machine failure', test_size=0.2, random_state=42):
|
| 127 |
+
"""Complete preprocessing pipeline"""
|
| 128 |
+
print("Starting data preprocessing...")
|
| 129 |
+
|
| 130 |
+
# Step 1: Create features
|
| 131 |
+
print("1. Creating additional features...")
|
| 132 |
+
self.create_features()
|
| 133 |
+
|
| 134 |
+
# Step 2: Handle missing values
|
| 135 |
+
print("2. Handling missing values...")
|
| 136 |
+
self.handle_missing_values()
|
| 137 |
+
|
| 138 |
+
# Step 3: Encode categorical variables
|
| 139 |
+
print("3. Encoding categorical variables...")
|
| 140 |
+
self.encode_categorical_variables()
|
| 141 |
+
|
| 142 |
+
# Step 4: Select features
|
| 143 |
+
print("4. Selecting features...")
|
| 144 |
+
feature_columns = self.select_features()
|
| 145 |
+
|
| 146 |
+
# Step 5: Prepare X and y
|
| 147 |
+
X = self.df[feature_columns]
|
| 148 |
+
y = self.df[target]
|
| 149 |
+
|
| 150 |
+
# Step 6: Split data
|
| 151 |
+
print("5. Splitting data into train and test sets...")
|
| 152 |
+
X_train, X_test, y_train, y_test = train_test_split(
|
| 153 |
+
X, y, test_size=test_size, random_state=random_state, stratify=y
|
| 154 |
+
)
|
| 155 |
+
|
| 156 |
+
# Step 7: Scale features
|
| 157 |
+
print("6. Scaling features...")
|
| 158 |
+
X_train_scaled, X_test_scaled = self.scale_features(X_train, X_test)
|
| 159 |
+
|
| 160 |
+
self.is_fitted = True
|
| 161 |
+
|
| 162 |
+
print("Preprocessing complete!")
|
| 163 |
+
print(f"Training set shape: {X_train_scaled.shape}")
|
| 164 |
+
print(f"Test set shape: {X_test_scaled.shape}")
|
| 165 |
+
print(f"Features: {feature_columns}")
|
| 166 |
+
|
| 167 |
+
return X_train_scaled, X_test_scaled, y_train, y_test, feature_columns
|
| 168 |
+
|
| 169 |
+
def preprocess_new_data(self, new_data):
|
| 170 |
+
"""Preprocess new data for prediction (using fitted scaler and encoders)"""
|
| 171 |
+
if not self.is_fitted:
|
| 172 |
+
raise ValueError("Preprocessor must be fitted first using prepare_data()")
|
| 173 |
+
|
| 174 |
+
# Create a copy
|
| 175 |
+
df_new = new_data.copy()
|
| 176 |
+
|
| 177 |
+
# Create features
|
| 178 |
+
df_new['Temperature difference [K]'] = (
|
| 179 |
+
df_new['Process temperature [K]'] -
|
| 180 |
+
df_new['Air temperature [K]']
|
| 181 |
+
)
|
| 182 |
+
df_new['Power [W]'] = (
|
| 183 |
+
df_new['Rotational speed [rpm]'] *
|
| 184 |
+
df_new['Torque [Nm]'] / 9.5488
|
| 185 |
+
)
|
| 186 |
+
|
| 187 |
+
# Encode Type
|
| 188 |
+
df_new['Type_encoded'] = self.label_encoder.transform(df_new['Type'])
|
| 189 |
+
type_dummies = pd.get_dummies(df_new['Type'], prefix='Type')
|
| 190 |
+
|
| 191 |
+
# Ensure all Type columns exist
|
| 192 |
+
for col in ['Type_H', 'Type_L', 'Type_M']:
|
| 193 |
+
if col not in type_dummies.columns:
|
| 194 |
+
type_dummies[col] = 0
|
| 195 |
+
|
| 196 |
+
df_new = pd.concat([df_new, type_dummies[['Type_H', 'Type_L', 'Type_M']]], axis=1)
|
| 197 |
+
|
| 198 |
+
# Select features
|
| 199 |
+
X_new = df_new[self.feature_columns]
|
| 200 |
+
|
| 201 |
+
# Scale
|
| 202 |
+
X_new_scaled = self.scaler.transform(X_new)
|
| 203 |
+
X_new_scaled = pd.DataFrame(X_new_scaled, columns=self.feature_columns)
|
| 204 |
+
|
| 205 |
+
return X_new_scaled
|
requirements.txt
CHANGED
|
@@ -1,3 +1,5 @@
|
|
| 1 |
-
|
| 2 |
-
|
| 3 |
-
|
|
|
|
|
|
|
|
|
| 1 |
+
pandas==2.1.4
|
| 2 |
+
numpy==1.26.2
|
| 3 |
+
scikit-learn==1.4.0
|
| 4 |
+
streamlit==1.29.0
|
| 5 |
+
plotly==5.18.0
|
train_model.py
ADDED
|
@@ -0,0 +1,52 @@
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| 1 |
+
"""
|
| 2 |
+
Script to train and save the predictive maintenance model
|
| 3 |
+
Run this script before using the Streamlit app for the first time
|
| 4 |
+
"""
|
| 5 |
+
|
| 6 |
+
from preprocessing import DataPreprocessor
|
| 7 |
+
from model import PredictiveMaintenanceModel
|
| 8 |
+
import pickle
|
| 9 |
+
|
| 10 |
+
def main():
|
| 11 |
+
print("="*60)
|
| 12 |
+
print("Training Predictive Maintenance Model")
|
| 13 |
+
print("="*60)
|
| 14 |
+
|
| 15 |
+
# Initialize preprocessor
|
| 16 |
+
print("\n1. Loading and preprocessing data...")
|
| 17 |
+
preprocessor = DataPreprocessor('ai4i2020.csv')
|
| 18 |
+
|
| 19 |
+
# Prepare data
|
| 20 |
+
X_train, X_test, y_train, y_test, feature_columns = preprocessor.prepare_data()
|
| 21 |
+
|
| 22 |
+
# Train model
|
| 23 |
+
print("\n2. Training model...")
|
| 24 |
+
model = PredictiveMaintenanceModel()
|
| 25 |
+
model.train(X_train, y_train)
|
| 26 |
+
|
| 27 |
+
# Evaluate model
|
| 28 |
+
print("\n3. Evaluating model...")
|
| 29 |
+
results = model.evaluate(X_test, y_test)
|
| 30 |
+
|
| 31 |
+
# Save model and preprocessor
|
| 32 |
+
print("\n4. Saving model and preprocessor...")
|
| 33 |
+
model.save_model('predictive_maintenance_model.pkl')
|
| 34 |
+
|
| 35 |
+
with open('preprocessor.pkl', 'wb') as f:
|
| 36 |
+
pickle.dump(preprocessor, f)
|
| 37 |
+
|
| 38 |
+
print("\n5. Saving feature columns...")
|
| 39 |
+
with open('feature_columns.pkl', 'wb') as f:
|
| 40 |
+
pickle.dump(feature_columns, f)
|
| 41 |
+
|
| 42 |
+
print("\n" + "="*60)
|
| 43 |
+
print("Model training complete!")
|
| 44 |
+
print("="*60)
|
| 45 |
+
print("\nModel files saved:")
|
| 46 |
+
print(" - predictive_maintenance_model.pkl")
|
| 47 |
+
print(" - preprocessor.pkl")
|
| 48 |
+
print(" - feature_columns.pkl")
|
| 49 |
+
print("\nYou can now run the Streamlit app: streamlit run app.py")
|
| 50 |
+
|
| 51 |
+
if __name__ == "__main__":
|
| 52 |
+
main()
|