800 lines
33 KiB
Python
800 lines
33 KiB
Python
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"""
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Production Yield Predictor
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Predicts actual vs planned yield and identifies waste reduction opportunities
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"""
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import pandas as pd
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import numpy as np
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from typing import Dict, List, Any, Optional, Tuple
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from datetime import datetime, timedelta
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import structlog
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from scipy import stats
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from sklearn.ensemble import RandomForestRegressor, GradientBoostingRegressor
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from sklearn.linear_model import LinearRegression
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from sklearn.preprocessing import StandardScaler
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import warnings
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warnings.filterwarnings('ignore')
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logger = structlog.get_logger()
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class YieldPredictor:
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"""
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Predicts production yield based on historical data and production factors.
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Key Features:
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- Multi-factor yield prediction (recipe, worker, time-of-day, equipment, batch size)
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- Identifies low-yield patterns and root causes
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- Waste categorization (spoilage, measurement error, process inefficiency)
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- Actionable recommendations for yield improvement
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- Statistical validation of learned patterns
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Methodology:
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1. Feature Engineering: Extract worker skill, time factors, batch size effects
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2. Statistical Analysis: Identify significant yield loss factors
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3. ML Prediction: Ensemble of Random Forest + Gradient Boosting
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4. Pattern Detection: Find recurring low-yield situations
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5. Insight Generation: Actionable recommendations with confidence scores
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"""
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def __init__(self):
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self.model_cache = {} # Cache trained models per recipe
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self.baseline_yields = {} # Cache baseline yields per recipe
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async def predict_yield(
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self,
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tenant_id: str,
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recipe_id: str,
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production_history: pd.DataFrame,
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production_context: Dict[str, Any],
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min_history_runs: int = 30
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) -> Dict[str, Any]:
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"""
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Predict yield for upcoming production run and generate insights.
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Args:
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tenant_id: Tenant identifier
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recipe_id: Recipe identifier
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production_history: Historical production runs with columns:
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- production_run_id
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- recipe_id
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- planned_quantity
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- actual_quantity
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- yield_percentage
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- worker_id
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- started_at
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- completed_at
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- batch_size
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- equipment_id (optional)
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- notes (optional)
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production_context: Upcoming production context:
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- worker_id
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- planned_start_time
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- batch_size
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- equipment_id (optional)
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min_history_runs: Minimum production runs required for learning
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Returns:
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Prediction results with yield forecast, confidence, and insights
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"""
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logger.info(
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"Predicting production yield",
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tenant_id=tenant_id,
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recipe_id=recipe_id,
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history_runs=len(production_history)
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)
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# Validate production history
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if len(production_history) < min_history_runs:
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return self._insufficient_data_response(
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recipe_id, production_context, len(production_history), min_history_runs
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)
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# Step 1: Calculate baseline statistics
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baseline_stats = self._calculate_baseline_statistics(production_history)
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# Step 2: Feature engineering
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feature_df = self._engineer_features(production_history)
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# Step 3: Analyze yield factors
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factor_analysis = self._analyze_yield_factors(feature_df)
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# Step 4: Train predictive model
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model_results = self._train_yield_model(feature_df)
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# Step 5: Make prediction for upcoming run
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prediction = self._predict_upcoming_run(
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production_context, model_results, baseline_stats, feature_df
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)
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# Step 6: Identify low-yield patterns
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patterns = self._identify_yield_patterns(feature_df, factor_analysis)
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# Step 7: Generate insights
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insights = self._generate_yield_insights(
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tenant_id, recipe_id, baseline_stats, factor_analysis,
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patterns, prediction, production_context
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)
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# Step 8: Calculate confidence
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confidence = self._calculate_prediction_confidence(
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production_history, model_results, factor_analysis
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)
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return {
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'recipe_id': recipe_id,
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'predicted_at': datetime.utcnow().isoformat(),
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'history_runs': len(production_history),
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'baseline_yield': baseline_stats['mean_yield'],
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'baseline_std': baseline_stats['std_yield'],
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'predicted_yield': prediction['predicted_yield'],
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'prediction_range': prediction['prediction_range'],
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'expected_waste': prediction['expected_waste'],
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'confidence': confidence,
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'factor_analysis': factor_analysis,
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'patterns': patterns,
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'model_performance': model_results['performance'],
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'insights': insights
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}
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def _insufficient_data_response(
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self, recipe_id: str, production_context: Dict[str, Any],
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current_runs: int, required_runs: int
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) -> Dict[str, Any]:
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"""Return response when insufficient historical data."""
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return {
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'recipe_id': recipe_id,
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'predicted_at': datetime.utcnow().isoformat(),
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'history_runs': current_runs,
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'status': 'insufficient_data',
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'required_runs': required_runs,
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'baseline_yield': None,
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'predicted_yield': None,
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'confidence': 0,
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'insights': [{
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'type': 'warning',
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'priority': 'low',
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'category': 'production',
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'title': f'Insufficient Production History for Yield Prediction',
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'description': f'Only {current_runs} production runs available. Need at least {required_runs} runs to build reliable yield predictions. Continue tracking production data to enable yield optimization.',
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'impact_type': 'data_quality',
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'confidence': 100,
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'actionable': True,
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'recommendation_actions': [{
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'label': 'Track Production Data',
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'action': 'continue_production_tracking',
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'params': {'recipe_id': recipe_id}
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}]
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}]
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}
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def _calculate_baseline_statistics(
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self, production_history: pd.DataFrame
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) -> Dict[str, Any]:
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"""Calculate baseline yield statistics."""
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yields = production_history['yield_percentage'].values
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return {
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'mean_yield': float(np.mean(yields)),
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'median_yield': float(np.median(yields)),
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'std_yield': float(np.std(yields)),
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'min_yield': float(np.min(yields)),
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'max_yield': float(np.max(yields)),
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'cv_yield': float(np.std(yields) / np.mean(yields)), # Coefficient of variation
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'percentile_25': float(np.percentile(yields, 25)),
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'percentile_75': float(np.percentile(yields, 75)),
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'runs_below_90': int(np.sum(yields < 90)),
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'runs_above_95': int(np.sum(yields > 95))
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}
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def _engineer_features(self, production_history: pd.DataFrame) -> pd.DataFrame:
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"""Engineer features from production history."""
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df = production_history.copy()
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# Time-based features
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df['started_at'] = pd.to_datetime(df['started_at'])
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df['hour_of_day'] = df['started_at'].dt.hour
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df['day_of_week'] = df['started_at'].dt.dayofweek
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df['is_weekend'] = df['day_of_week'].isin([5, 6]).astype(int)
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df['is_early_morning'] = (df['hour_of_day'] < 6).astype(int)
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df['is_late_night'] = (df['hour_of_day'] >= 22).astype(int)
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# Duration features
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if 'completed_at' in df.columns:
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df['completed_at'] = pd.to_datetime(df['completed_at'])
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df['duration_hours'] = (df['completed_at'] - df['started_at']).dt.total_seconds() / 3600
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df['is_rushed'] = (df['duration_hours'] < df['duration_hours'].quantile(0.25)).astype(int)
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# Batch size features
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df['batch_size_normalized'] = df['batch_size'] / df['batch_size'].mean()
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df['is_large_batch'] = (df['batch_size'] > df['batch_size'].quantile(0.75)).astype(int)
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df['is_small_batch'] = (df['batch_size'] < df['batch_size'].quantile(0.25)).astype(int)
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# Worker experience features (proxy: number of previous runs)
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df = df.sort_values('started_at')
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df['worker_run_count'] = df.groupby('worker_id').cumcount() + 1
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df['worker_experience_level'] = pd.cut(
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df['worker_run_count'],
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bins=[0, 5, 15, 100],
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labels=['novice', 'intermediate', 'expert']
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)
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# Recent yield trend for worker
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df['worker_recent_avg_yield'] = df.groupby('worker_id')['yield_percentage'].transform(
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lambda x: x.rolling(window=5, min_periods=1).mean()
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)
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return df
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def _analyze_yield_factors(self, feature_df: pd.DataFrame) -> Dict[str, Any]:
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"""Analyze factors affecting yield using statistical tests."""
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factors = {}
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# Worker impact
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worker_yields = feature_df.groupby('worker_id')['yield_percentage'].agg(['mean', 'std', 'count'])
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worker_yields = worker_yields[worker_yields['count'] >= 3] # Min 3 runs per worker
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if len(worker_yields) > 1:
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# ANOVA test: Does worker significantly affect yield?
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worker_groups = [
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feature_df[feature_df['worker_id'] == worker]['yield_percentage'].values
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for worker in worker_yields.index
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]
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f_stat, p_value = stats.f_oneway(*worker_groups)
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factors['worker'] = {
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'significant': p_value < 0.05,
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'p_value': float(p_value),
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'f_statistic': float(f_stat),
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'best_worker': worker_yields['mean'].idxmax(),
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'best_worker_yield': float(worker_yields['mean'].max()),
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'worst_worker': worker_yields['mean'].idxmin(),
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'worst_worker_yield': float(worker_yields['mean'].min()),
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'yield_range': float(worker_yields['mean'].max() - worker_yields['mean'].min())
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}
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else:
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factors['worker'] = {'significant': False, 'reason': 'insufficient_workers'}
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# Time of day impact
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time_groups = {
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'early_morning': feature_df[feature_df['hour_of_day'] < 6]['yield_percentage'].values,
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'morning': feature_df[(feature_df['hour_of_day'] >= 6) & (feature_df['hour_of_day'] < 12)]['yield_percentage'].values,
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'afternoon': feature_df[(feature_df['hour_of_day'] >= 12) & (feature_df['hour_of_day'] < 18)]['yield_percentage'].values,
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'evening': feature_df[feature_df['hour_of_day'] >= 18]['yield_percentage'].values
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}
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time_groups = {k: v for k, v in time_groups.items() if len(v) >= 3}
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if len(time_groups) > 1:
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f_stat, p_value = stats.f_oneway(*time_groups.values())
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time_means = {k: np.mean(v) for k, v in time_groups.items()}
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factors['time_of_day'] = {
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'significant': p_value < 0.05,
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'p_value': float(p_value),
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'best_time': max(time_means, key=time_means.get),
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'best_time_yield': float(max(time_means.values())),
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'worst_time': min(time_means, key=time_means.get),
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'worst_time_yield': float(min(time_means.values())),
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'yield_range': float(max(time_means.values()) - min(time_means.values()))
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}
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else:
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factors['time_of_day'] = {'significant': False, 'reason': 'insufficient_data'}
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# Batch size impact (correlation)
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if len(feature_df) >= 10:
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correlation, p_value = stats.pearsonr(
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feature_df['batch_size'],
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feature_df['yield_percentage']
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)
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factors['batch_size'] = {
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'significant': abs(correlation) > 0.3 and p_value < 0.05,
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'correlation': float(correlation),
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'p_value': float(p_value),
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'direction': 'positive' if correlation > 0 else 'negative',
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'interpretation': self._interpret_batch_size_effect(correlation)
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}
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else:
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factors['batch_size'] = {'significant': False, 'reason': 'insufficient_data'}
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# Weekend vs weekday
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weekend_yields = feature_df[feature_df['is_weekend'] == 1]['yield_percentage'].values
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weekday_yields = feature_df[feature_df['is_weekend'] == 0]['yield_percentage'].values
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if len(weekend_yields) >= 3 and len(weekday_yields) >= 3:
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t_stat, p_value = stats.ttest_ind(weekend_yields, weekday_yields)
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factors['weekend_effect'] = {
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'significant': p_value < 0.05,
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'p_value': float(p_value),
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't_statistic': float(t_stat),
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'weekend_yield': float(np.mean(weekend_yields)),
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'weekday_yield': float(np.mean(weekday_yields)),
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'difference': float(np.mean(weekend_yields) - np.mean(weekday_yields))
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}
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else:
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factors['weekend_effect'] = {'significant': False, 'reason': 'insufficient_weekend_data'}
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return factors
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def _interpret_batch_size_effect(self, correlation: float) -> str:
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"""Interpret batch size correlation."""
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if abs(correlation) < 0.3:
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return "Batch size has minimal impact on yield"
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elif correlation > 0:
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return "Larger batches tend to have higher yield (economies of scale)"
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else:
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return "Larger batches tend to have lower yield (difficulty handling large volumes)"
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def _train_yield_model(self, feature_df: pd.DataFrame) -> Dict[str, Any]:
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"""Train ML model to predict yield."""
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# Prepare features
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feature_columns = [
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'hour_of_day', 'day_of_week', 'is_weekend',
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'batch_size_normalized', 'is_large_batch', 'is_small_batch',
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'worker_run_count'
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]
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if 'duration_hours' in feature_df.columns:
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feature_columns.append('duration_hours')
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# Encode worker_id
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worker_encoding = {worker: idx for idx, worker in enumerate(feature_df['worker_id'].unique())}
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feature_df['worker_encoded'] = feature_df['worker_id'].map(worker_encoding)
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feature_columns.append('worker_encoded')
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|
|
X = feature_df[feature_columns].fillna(0).values
|
||
|
|
y = feature_df['yield_percentage'].values
|
||
|
|
|
||
|
|
# Split into train/test (temporal split)
|
||
|
|
split_idx = int(len(X) * 0.8)
|
||
|
|
X_train, X_test = X[:split_idx], X[split_idx:]
|
||
|
|
y_train, y_test = y[:split_idx], y[split_idx:]
|
||
|
|
|
||
|
|
# Scale features
|
||
|
|
scaler = StandardScaler()
|
||
|
|
X_train_scaled = scaler.fit_transform(X_train)
|
||
|
|
X_test_scaled = scaler.transform(X_test)
|
||
|
|
|
||
|
|
# Train ensemble of models
|
||
|
|
models = {
|
||
|
|
'random_forest': RandomForestRegressor(n_estimators=100, max_depth=5, random_state=42),
|
||
|
|
'gradient_boosting': GradientBoostingRegressor(n_estimators=50, max_depth=3, random_state=42),
|
||
|
|
'linear': LinearRegression()
|
||
|
|
}
|
||
|
|
|
||
|
|
performances = {}
|
||
|
|
predictions = {}
|
||
|
|
|
||
|
|
for name, model in models.items():
|
||
|
|
model.fit(X_train_scaled, y_train)
|
||
|
|
y_pred = model.predict(X_test_scaled)
|
||
|
|
|
||
|
|
mae = np.mean(np.abs(y_test - y_pred))
|
||
|
|
rmse = np.sqrt(np.mean((y_test - y_pred) ** 2))
|
||
|
|
r2 = 1 - (np.sum((y_test - y_pred) ** 2) / np.sum((y_test - np.mean(y_test)) ** 2))
|
||
|
|
|
||
|
|
performances[name] = {
|
||
|
|
'mae': float(mae),
|
||
|
|
'rmse': float(rmse),
|
||
|
|
'r2': float(r2)
|
||
|
|
}
|
||
|
|
predictions[name] = y_pred
|
||
|
|
|
||
|
|
# Select best model based on MAE
|
||
|
|
best_model_name = min(performances, key=lambda k: performances[k]['mae'])
|
||
|
|
best_model = models[best_model_name]
|
||
|
|
|
||
|
|
# Feature importance (if available)
|
||
|
|
feature_importance = {}
|
||
|
|
if hasattr(best_model, 'feature_importances_'):
|
||
|
|
importances = best_model.feature_importances_
|
||
|
|
feature_importance = {
|
||
|
|
feature_columns[i]: float(importances[i])
|
||
|
|
for i in range(len(feature_columns))
|
||
|
|
}
|
||
|
|
feature_importance = dict(sorted(
|
||
|
|
feature_importance.items(),
|
||
|
|
key=lambda x: x[1],
|
||
|
|
reverse=True
|
||
|
|
))
|
||
|
|
|
||
|
|
return {
|
||
|
|
'best_model': best_model,
|
||
|
|
'best_model_name': best_model_name,
|
||
|
|
'scaler': scaler,
|
||
|
|
'feature_columns': feature_columns,
|
||
|
|
'worker_encoding': worker_encoding,
|
||
|
|
'performance': performances[best_model_name],
|
||
|
|
'all_performances': performances,
|
||
|
|
'feature_importance': feature_importance
|
||
|
|
}
|
||
|
|
|
||
|
|
def _predict_upcoming_run(
|
||
|
|
self,
|
||
|
|
production_context: Dict[str, Any],
|
||
|
|
model_results: Dict[str, Any],
|
||
|
|
baseline_stats: Dict[str, Any],
|
||
|
|
feature_df: pd.DataFrame
|
||
|
|
) -> Dict[str, Any]:
|
||
|
|
"""Predict yield for upcoming production run."""
|
||
|
|
# Extract context
|
||
|
|
worker_id = production_context.get('worker_id')
|
||
|
|
planned_start = pd.to_datetime(production_context.get('planned_start_time'))
|
||
|
|
batch_size = production_context.get('batch_size')
|
||
|
|
|
||
|
|
# Get worker experience
|
||
|
|
worker_runs = feature_df[feature_df['worker_id'] == worker_id]
|
||
|
|
worker_run_count = len(worker_runs) if len(worker_runs) > 0 else 1
|
||
|
|
|
||
|
|
# Build feature vector
|
||
|
|
mean_batch_size = feature_df['batch_size'].mean()
|
||
|
|
batch_size_normalized = batch_size / mean_batch_size
|
||
|
|
is_large_batch = 1 if batch_size > feature_df['batch_size'].quantile(0.75) else 0
|
||
|
|
is_small_batch = 1 if batch_size < feature_df['batch_size'].quantile(0.25) else 0
|
||
|
|
|
||
|
|
features = {
|
||
|
|
'hour_of_day': planned_start.hour,
|
||
|
|
'day_of_week': planned_start.dayofweek,
|
||
|
|
'is_weekend': 1 if planned_start.dayofweek in [5, 6] else 0,
|
||
|
|
'batch_size_normalized': batch_size_normalized,
|
||
|
|
'is_large_batch': is_large_batch,
|
||
|
|
'is_small_batch': is_small_batch,
|
||
|
|
'worker_run_count': worker_run_count,
|
||
|
|
'duration_hours': 0, # Not known yet
|
||
|
|
'worker_encoded': model_results['worker_encoding'].get(worker_id, 0)
|
||
|
|
}
|
||
|
|
|
||
|
|
# Create feature vector in correct order
|
||
|
|
X = np.array([[features.get(col, 0) for col in model_results['feature_columns']]])
|
||
|
|
X_scaled = model_results['scaler'].transform(X)
|
||
|
|
|
||
|
|
# Predict
|
||
|
|
predicted_yield = float(model_results['best_model'].predict(X_scaled)[0])
|
||
|
|
|
||
|
|
# Prediction range (based on model RMSE)
|
||
|
|
rmse = model_results['performance']['rmse']
|
||
|
|
prediction_range = {
|
||
|
|
'lower': max(0, predicted_yield - 1.96 * rmse),
|
||
|
|
'upper': min(100, predicted_yield + 1.96 * rmse)
|
||
|
|
}
|
||
|
|
|
||
|
|
# Expected waste
|
||
|
|
planned_quantity = production_context.get('planned_quantity', 100)
|
||
|
|
expected_waste_pct = max(0, 100 - predicted_yield)
|
||
|
|
expected_waste_units = planned_quantity * (expected_waste_pct / 100)
|
||
|
|
|
||
|
|
return {
|
||
|
|
'predicted_yield': round(predicted_yield, 2),
|
||
|
|
'prediction_range': prediction_range,
|
||
|
|
'expected_waste_pct': round(expected_waste_pct, 2),
|
||
|
|
'expected_waste_units': round(expected_waste_units, 2),
|
||
|
|
'baseline_comparison': round(predicted_yield - baseline_stats['mean_yield'], 2),
|
||
|
|
'features_used': features
|
||
|
|
}
|
||
|
|
|
||
|
|
def _identify_yield_patterns(
|
||
|
|
self, feature_df: pd.DataFrame, factor_analysis: Dict[str, Any]
|
||
|
|
) -> List[Dict[str, Any]]:
|
||
|
|
"""Identify recurring low-yield patterns."""
|
||
|
|
patterns = []
|
||
|
|
|
||
|
|
# Pattern 1: Specific worker consistently low
|
||
|
|
if factor_analysis.get('worker', {}).get('significant'):
|
||
|
|
worst_worker = factor_analysis['worker']['worst_worker']
|
||
|
|
worst_yield = factor_analysis['worker']['worst_worker_yield']
|
||
|
|
best_yield = factor_analysis['worker']['best_worker_yield']
|
||
|
|
|
||
|
|
if worst_yield < 90 and (best_yield - worst_yield) > 5:
|
||
|
|
patterns.append({
|
||
|
|
'pattern': 'low_yield_worker',
|
||
|
|
'description': f'Worker {worst_worker} consistently produces {worst_yield:.1f}% yield vs best worker {best_yield:.1f}%',
|
||
|
|
'severity': 'high' if worst_yield < 85 else 'medium',
|
||
|
|
'affected_runs': int(len(feature_df[feature_df['worker_id'] == worst_worker])),
|
||
|
|
'yield_impact': round(best_yield - worst_yield, 2),
|
||
|
|
'recommendation': 'Provide additional training or reassign to different recipes'
|
||
|
|
})
|
||
|
|
|
||
|
|
# Pattern 2: Time-of-day effect
|
||
|
|
if factor_analysis.get('time_of_day', {}).get('significant'):
|
||
|
|
worst_time = factor_analysis['time_of_day']['worst_time']
|
||
|
|
worst_yield = factor_analysis['time_of_day']['worst_time_yield']
|
||
|
|
|
||
|
|
if worst_yield < 90:
|
||
|
|
patterns.append({
|
||
|
|
'pattern': 'low_yield_time',
|
||
|
|
'description': f'{worst_time} shifts produce {worst_yield:.1f}% yield',
|
||
|
|
'severity': 'medium',
|
||
|
|
'affected_runs': 'varies',
|
||
|
|
'yield_impact': round(factor_analysis['time_of_day']['yield_range'], 2),
|
||
|
|
'recommendation': f'Avoid scheduling this recipe during {worst_time}'
|
||
|
|
})
|
||
|
|
|
||
|
|
# Pattern 3: Large batch issues
|
||
|
|
if factor_analysis.get('batch_size', {}).get('significant'):
|
||
|
|
if factor_analysis['batch_size']['direction'] == 'negative':
|
||
|
|
patterns.append({
|
||
|
|
'pattern': 'large_batch_yield_loss',
|
||
|
|
'description': 'Larger batches have lower yield - equipment or process capacity issues',
|
||
|
|
'severity': 'medium',
|
||
|
|
'correlation': round(factor_analysis['batch_size']['correlation'], 3),
|
||
|
|
'recommendation': 'Split large batches or upgrade equipment'
|
||
|
|
})
|
||
|
|
|
||
|
|
# Pattern 4: Weekend effect
|
||
|
|
if factor_analysis.get('weekend_effect', {}).get('significant'):
|
||
|
|
weekend_yield = factor_analysis['weekend_effect']['weekend_yield']
|
||
|
|
weekday_yield = factor_analysis['weekend_effect']['weekday_yield']
|
||
|
|
|
||
|
|
if abs(weekend_yield - weekday_yield) > 3:
|
||
|
|
if weekend_yield < weekday_yield:
|
||
|
|
patterns.append({
|
||
|
|
'pattern': 'weekend_yield_drop',
|
||
|
|
'description': f'Weekend production {weekend_yield:.1f}% vs weekday {weekday_yield:.1f}%',
|
||
|
|
'severity': 'low',
|
||
|
|
'yield_impact': round(weekday_yield - weekend_yield, 2),
|
||
|
|
'recommendation': 'Review weekend staffing or processes'
|
||
|
|
})
|
||
|
|
|
||
|
|
return patterns
|
||
|
|
|
||
|
|
def _generate_yield_insights(
|
||
|
|
self,
|
||
|
|
tenant_id: str,
|
||
|
|
recipe_id: str,
|
||
|
|
baseline_stats: Dict[str, Any],
|
||
|
|
factor_analysis: Dict[str, Any],
|
||
|
|
patterns: List[Dict[str, Any]],
|
||
|
|
prediction: Dict[str, Any],
|
||
|
|
production_context: Dict[str, Any]
|
||
|
|
) -> List[Dict[str, Any]]:
|
||
|
|
"""Generate actionable insights for yield improvement."""
|
||
|
|
insights = []
|
||
|
|
|
||
|
|
# Insight 1: Low predicted yield warning
|
||
|
|
if prediction['predicted_yield'] < 90:
|
||
|
|
waste_value = prediction['expected_waste_units'] * production_context.get('unit_cost', 5)
|
||
|
|
|
||
|
|
insights.append({
|
||
|
|
'type': 'warning',
|
||
|
|
'priority': 'high' if prediction['predicted_yield'] < 85 else 'medium',
|
||
|
|
'category': 'production',
|
||
|
|
'title': f'Low Yield Predicted: {prediction["predicted_yield"]:.1f}%',
|
||
|
|
'description': f'Upcoming production run predicted to yield {prediction["predicted_yield"]:.1f}%, below baseline {baseline_stats["mean_yield"]:.1f}%. Expected waste: {prediction["expected_waste_units"]:.1f} units (€{waste_value:.2f}).',
|
||
|
|
'impact_type': 'waste',
|
||
|
|
'impact_value': prediction['expected_waste_units'],
|
||
|
|
'impact_unit': 'units',
|
||
|
|
'confidence': 75,
|
||
|
|
'metrics_json': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'predicted_yield': prediction['predicted_yield'],
|
||
|
|
'expected_waste': prediction['expected_waste_units'],
|
||
|
|
'waste_value': round(waste_value, 2)
|
||
|
|
},
|
||
|
|
'actionable': True,
|
||
|
|
'recommendation_actions': [{
|
||
|
|
'label': 'Review Production Setup',
|
||
|
|
'action': 'review_production_factors',
|
||
|
|
'params': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'worker_id': production_context.get('worker_id')
|
||
|
|
}
|
||
|
|
}]
|
||
|
|
})
|
||
|
|
|
||
|
|
# Insight 2: High-severity patterns
|
||
|
|
for pattern in patterns:
|
||
|
|
if pattern.get('severity') == 'high':
|
||
|
|
if pattern['pattern'] == 'low_yield_worker':
|
||
|
|
insights.append({
|
||
|
|
'type': 'opportunity',
|
||
|
|
'priority': 'high',
|
||
|
|
'category': 'production',
|
||
|
|
'title': f'Worker Training Opportunity: {pattern["yield_impact"]:.1f}% Yield Gap',
|
||
|
|
'description': pattern['description'] + f'. Improving this worker to average performance would save significant waste.',
|
||
|
|
'impact_type': 'yield_improvement',
|
||
|
|
'impact_value': pattern['yield_impact'],
|
||
|
|
'impact_unit': 'percentage_points',
|
||
|
|
'confidence': 85,
|
||
|
|
'metrics_json': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'pattern': pattern['pattern'],
|
||
|
|
'yield_impact': pattern['yield_impact']
|
||
|
|
},
|
||
|
|
'actionable': True,
|
||
|
|
'recommendation_actions': [{
|
||
|
|
'label': 'Schedule Training',
|
||
|
|
'action': 'schedule_worker_training',
|
||
|
|
'params': {'recipe_id': recipe_id}
|
||
|
|
}]
|
||
|
|
})
|
||
|
|
|
||
|
|
# Insight 3: Excellent yield
|
||
|
|
if prediction['predicted_yield'] > 98:
|
||
|
|
insights.append({
|
||
|
|
'type': 'positive',
|
||
|
|
'priority': 'low',
|
||
|
|
'category': 'production',
|
||
|
|
'title': f'Excellent Yield Expected: {prediction["predicted_yield"]:.1f}%',
|
||
|
|
'description': f'Optimal production conditions detected. Expected yield {prediction["predicted_yield"]:.1f}% exceeds baseline {baseline_stats["mean_yield"]:.1f}%.',
|
||
|
|
'impact_type': 'yield_improvement',
|
||
|
|
'impact_value': prediction['baseline_comparison'],
|
||
|
|
'impact_unit': 'percentage_points',
|
||
|
|
'confidence': 70,
|
||
|
|
'metrics_json': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'predicted_yield': prediction['predicted_yield']
|
||
|
|
},
|
||
|
|
'actionable': False
|
||
|
|
})
|
||
|
|
|
||
|
|
# Insight 4: Yield variability issue
|
||
|
|
if baseline_stats['cv_yield'] > 0.05: # Coefficient of variation > 5%
|
||
|
|
insights.append({
|
||
|
|
'type': 'opportunity',
|
||
|
|
'priority': 'medium',
|
||
|
|
'category': 'production',
|
||
|
|
'title': f'High Yield Variability: {baseline_stats["cv_yield"]*100:.1f}% CV',
|
||
|
|
'description': f'Yield varies significantly across production runs (CV={baseline_stats["cv_yield"]*100:.1f}%, range {baseline_stats["min_yield"]:.1f}%-{baseline_stats["max_yield"]:.1f}%). Standardizing processes could reduce waste.',
|
||
|
|
'impact_type': 'process_improvement',
|
||
|
|
'confidence': 80,
|
||
|
|
'metrics_json': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'cv_yield': round(baseline_stats['cv_yield'], 3),
|
||
|
|
'yield_range': round(baseline_stats['max_yield'] - baseline_stats['min_yield'], 2)
|
||
|
|
},
|
||
|
|
'actionable': True,
|
||
|
|
'recommendation_actions': [{
|
||
|
|
'label': 'Standardize Process',
|
||
|
|
'action': 'review_production_sop',
|
||
|
|
'params': {'recipe_id': recipe_id}
|
||
|
|
}]
|
||
|
|
})
|
||
|
|
|
||
|
|
return insights
|
||
|
|
|
||
|
|
def _calculate_prediction_confidence(
|
||
|
|
self,
|
||
|
|
production_history: pd.DataFrame,
|
||
|
|
model_results: Dict[str, Any],
|
||
|
|
factor_analysis: Dict[str, Any]
|
||
|
|
) -> int:
|
||
|
|
"""Calculate overall confidence score for predictions."""
|
||
|
|
confidence_factors = []
|
||
|
|
|
||
|
|
# Factor 1: Sample size (0-30 points)
|
||
|
|
n_runs = len(production_history)
|
||
|
|
if n_runs >= 100:
|
||
|
|
sample_score = 30
|
||
|
|
elif n_runs >= 50:
|
||
|
|
sample_score = 25
|
||
|
|
elif n_runs >= 30:
|
||
|
|
sample_score = 20
|
||
|
|
else:
|
||
|
|
sample_score = 10
|
||
|
|
confidence_factors.append(('sample_size', sample_score))
|
||
|
|
|
||
|
|
# Factor 2: Model performance (0-30 points)
|
||
|
|
r2 = model_results['performance']['r2']
|
||
|
|
mae = model_results['performance']['mae']
|
||
|
|
|
||
|
|
if r2 > 0.7 and mae < 3:
|
||
|
|
model_score = 30
|
||
|
|
elif r2 > 0.5 and mae < 5:
|
||
|
|
model_score = 25
|
||
|
|
elif r2 > 0.3 and mae < 7:
|
||
|
|
model_score = 20
|
||
|
|
else:
|
||
|
|
model_score = 10
|
||
|
|
confidence_factors.append(('model_performance', model_score))
|
||
|
|
|
||
|
|
# Factor 3: Statistical significance of factors (0-25 points)
|
||
|
|
significant_factors = sum(
|
||
|
|
1 for factor in factor_analysis.values()
|
||
|
|
if isinstance(factor, dict) and factor.get('significant')
|
||
|
|
)
|
||
|
|
|
||
|
|
if significant_factors >= 3:
|
||
|
|
stats_score = 25
|
||
|
|
elif significant_factors >= 2:
|
||
|
|
stats_score = 20
|
||
|
|
elif significant_factors >= 1:
|
||
|
|
stats_score = 15
|
||
|
|
else:
|
||
|
|
stats_score = 10
|
||
|
|
confidence_factors.append(('significant_factors', stats_score))
|
||
|
|
|
||
|
|
# Factor 4: Data recency (0-15 points)
|
||
|
|
most_recent = production_history['started_at'].max()
|
||
|
|
days_old = (datetime.utcnow() - pd.to_datetime(most_recent)).days
|
||
|
|
|
||
|
|
if days_old <= 7:
|
||
|
|
recency_score = 15
|
||
|
|
elif days_old <= 30:
|
||
|
|
recency_score = 12
|
||
|
|
elif days_old <= 90:
|
||
|
|
recency_score = 8
|
||
|
|
else:
|
||
|
|
recency_score = 5
|
||
|
|
confidence_factors.append(('data_recency', recency_score))
|
||
|
|
|
||
|
|
total_confidence = sum(score for _, score in confidence_factors)
|
||
|
|
|
||
|
|
return min(100, max(0, total_confidence))
|
||
|
|
|
||
|
|
async def analyze_recipe_yield_history(
|
||
|
|
self,
|
||
|
|
tenant_id: str,
|
||
|
|
recipe_id: str,
|
||
|
|
production_history: pd.DataFrame,
|
||
|
|
min_history_runs: int = 30
|
||
|
|
) -> Dict[str, Any]:
|
||
|
|
"""
|
||
|
|
Analyze historical yield performance for a recipe (no prediction).
|
||
|
|
|
||
|
|
Args:
|
||
|
|
tenant_id: Tenant identifier
|
||
|
|
recipe_id: Recipe identifier
|
||
|
|
production_history: Historical production runs
|
||
|
|
min_history_runs: Minimum production runs required
|
||
|
|
|
||
|
|
Returns:
|
||
|
|
Historical analysis with insights
|
||
|
|
"""
|
||
|
|
logger.info(
|
||
|
|
"Analyzing recipe yield history",
|
||
|
|
tenant_id=tenant_id,
|
||
|
|
recipe_id=recipe_id,
|
||
|
|
history_runs=len(production_history)
|
||
|
|
)
|
||
|
|
|
||
|
|
if len(production_history) < min_history_runs:
|
||
|
|
return self._insufficient_data_response(
|
||
|
|
recipe_id, {}, len(production_history), min_history_runs
|
||
|
|
)
|
||
|
|
|
||
|
|
# Calculate statistics
|
||
|
|
baseline_stats = self._calculate_baseline_statistics(production_history)
|
||
|
|
|
||
|
|
# Feature engineering
|
||
|
|
feature_df = self._engineer_features(production_history)
|
||
|
|
|
||
|
|
# Analyze factors
|
||
|
|
factor_analysis = self._analyze_yield_factors(feature_df)
|
||
|
|
|
||
|
|
# Identify patterns
|
||
|
|
patterns = self._identify_yield_patterns(feature_df, factor_analysis)
|
||
|
|
|
||
|
|
# Generate insights (without prediction)
|
||
|
|
insights = []
|
||
|
|
|
||
|
|
# Add insights for patterns
|
||
|
|
for pattern in patterns:
|
||
|
|
if pattern.get('severity') in ['high', 'medium']:
|
||
|
|
insights.append({
|
||
|
|
'type': 'opportunity',
|
||
|
|
'priority': pattern['severity'],
|
||
|
|
'category': 'production',
|
||
|
|
'title': f'Yield Pattern Detected: {pattern["pattern"]}',
|
||
|
|
'description': pattern['description'],
|
||
|
|
'impact_type': 'yield_improvement',
|
||
|
|
'confidence': 80,
|
||
|
|
'metrics_json': {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'pattern': pattern
|
||
|
|
},
|
||
|
|
'actionable': True,
|
||
|
|
'recommendation': pattern['recommendation']
|
||
|
|
})
|
||
|
|
|
||
|
|
return {
|
||
|
|
'recipe_id': recipe_id,
|
||
|
|
'analyzed_at': datetime.utcnow().isoformat(),
|
||
|
|
'history_runs': len(production_history),
|
||
|
|
'baseline_stats': baseline_stats,
|
||
|
|
'factor_analysis': factor_analysis,
|
||
|
|
'patterns': patterns,
|
||
|
|
'insights': insights
|
||
|
|
}
|