Statistical process monitoring: basics and beyond

Abstract This paper provides an overview and analysis of statistical process monitoring methods for fault detection, identification and reconstruction. Several fault detection indices in the literature are analyzed and unified. Fault reconstruction for both sensor and process faults is presented which extends the traditional missing value replacement method. Fault diagnosis methods that have appeared recently are reviewed. The reconstruction‐based approach and the contribution‐based approach are analyzed and compared with simulation and industrial examples. The complementary nature of the reconstruction‐ and contribution‐based approaches is highlighted. An industrial example of polyester film process…