Jaime Camelio

• PhD
• Professor at Virginia Tech

With recent technological advancements, production systems have become more susceptible to cyber‐physical attacks. Such attacks can be intelligently designed to both alter product dimensions and avoid detection by current Quality Control (QC) tools. The objective of this work is to assess the performance of random sampling strategies for control ch...

As sensor and measurement technologies advance, there is a continual need to adapt and develop new Statistical Process Control (SPC) techniques to effectively and efficiently take advantage of these new datasets. Currently high-density noncontact measurement technologies, such as 3D laser scanners, are being implemented in industry to rapidly colle...

In-process machining data (e.g., cutting forces and vibrations) have been typically collected and structured as time-referenced measurements (i.e., time-series data) and utilized in this structure to develop statistical data models used in process monitoring and control methods. This paper argues that a time-only-referenced representation overlooks...

With the latest advances in computer and networking technologies, the threat of cyber-physical attacks against manufacturing systems is growing. Unlike traditional cyber-attacks, cyber-physical attacks are not limited to intellectual property theft and affect the physical world, which could be devastating to manufacturing, if they are undetected. R...

With advances in computer and networking technologies, along with the increasing dependency on interconnected cyber-physical components, the threat of cyber-physical attacks against manufacturing is on the rise. As opposed to traditional cyber-attacks, cyber-physical attacks go beyond intellectual property theft and can affect the physical world. I...

Smart manufacturing promises to provide significant increases in productivity and effectiveness of manufacturing systems by better connecting the data from people, processes, and things. However, there is no uniform, generalized method for deploying linked-data concepts to the manufacturing domain. The literature describes and commercial vendors of...

With recent advancements in computer and network technologies, cyber-physical systems have become more susceptible to cyber-attacks, with production systems being no exception. Unlike traditional information technology systems, cyber-physical systems are not limited to attacks aimed solely at intellectual property theft, but include attacks that ma...

With the latest developments in networking and internet technology, cyber-physical attacks are becoming more frequent across a wide range of industries, including manufacturing. Cyber-physical attacks, as the name implies, affect the physical components of the system and go beyond just intellectual property theft. Attacks of this nature in manufact...

The rise of the interconnected manufacturing enterprise has extended its vulnerability space to malicious cyber-physical attacks. To improve the resilience of a manufacturing enterprise to cyber-to-physical attacks, a robust set of quality tools for part and process authentication and verification are needed. However, current Non-Destructive Evalua...

Trust in product data quality (PDQ) is critical to successful implementation of the model-based enterprise (MBE). Such trust does not extend to the exchange and the reuse of three-dimensional (3D) product models across the product life cycle because verifiable traceability in the product data is lacking. This assurance is especially crucial when “s...

This chapter contains sections titled: Introduction to Assembly Systems & Operations Fundamentals of Assembly Operations Characterizing Assembly System Energy Consumption Direct Energy Considerations of Assembly Joining Processes Assembly System Energy Metrics Case Study: Heavy Duty Truck Assembly Future of Energy Efficient Assembly Operations

With the latest advancements in three-dimensional (3D) measurement technologies, obtaining 3D point cloud data for inspection purposes in manufacturing is becoming more common. While 3D point cloud data allows for better inspection capabilities, their analysis is typically challenging. Especially with unstructured 3D point cloud data, containing co...

Manufacturing companies depend on several support systems to manage production operations, enabling them to produce a wide array of products and services. Quality Control (QC) support systems are used to ensure the production of high quality parts and to maintain stable manufacturing processes. As with any other system, QC tools can be unintentiona...

Making high-quality manufacturing decisions in real-time is difficult. Smart manufacturing requires sufficient knowledge be available to the decision maker to ensure the manufacturing system runs efficiently and effectively. This paper will present a literature review of managing and controlling decision making and technological innovation. We pres...

Making high-quality manufacturing decisions in real-time is difficult. Smart manufacturing requires sufficient knowledge be available to the decision maker to ensure the manufacturing system runs efficiently and effectively. This paper will present background information for managing and controlling decision-making and technological innovation. We...

With recent technological advancements, production systems have become more susceptible to cyber-attacks. Such attacks can be designed to both alter product dimensions and avoid detection by current Statistical Process Control tools. This work discusses a novel approach to better detect attacks against manufacturing, which is based upon introducing...

The rampant increase in frequency and complexity of cyber-attacks against manufacturing firms has motivated the development of identification and assessment techniques for cyber-physical vulnerabilities in manufacturing. While the field of cybersecurity assessment approaches is expansive, there is a gap in assessments for cyber-physical vulnerabili...

The Internet of Things (IoT) has transformed many aspects of modern manufacturing, from design to production to quality control. In particular, IoT and digital manufacturing technologies have substantially accelerated product development- cycles and manufacturers can now create products of a complexity and precision not heretofore possible. New thr...

With recent technological advancements, manufacturing systems have become more susceptible to cyber-attacks that can maliciously affect the physical world. Moreover, such cyber-physical attacks can be designed to avoid detection by traditional Quality Control (QC) tools. Hence, this work proposes a framework that allows for understanding the relati...

The rampant increase in frequency and complexity of cyber-attacks against manufacturing firms, has motivated the development of identification and mitigation techniques for cyber-physical vulnerabilities in manufacturing. While the field of cybersecurity assessment approaches is expansive, there is no literature aimed at assessing cyber-physical vu...

In many manufacturing processes, process data are observed in the form of time-based profiles, which may contain rich information for process monitoring and fault diagnosis. Most approaches currently available in profile monitoring focus on single-stage processes or multistage processes with repeating cyclic profiles. However, a number of manufactu...

Research of the microtube hydroforming (MTHF) process is being investigated for potential medical and fuel cell applications. This is largely due to the fact that at the macroscale the tube hydroforming (THF) process, like most metal forming processes, has realized many advantages, especially when comparing products made using traditional machining...

Objective: To assess whether a patient's in-hospital length of stay (LOS) and mortality can be explained by early objective and/or physicians' subjective-risk assessments. Data sources/study setting: Analysis of a detailed dataset of 1,021 patients admitted to a large U.S. hospital between January and September 2014. Study design: We empirical...

Correlations between variables. Table A1 in this appendix shows the matrix for correlation coefficients between control variables. (DOCX)

Patients? Data. Data file includes all patients? data that are used for analysis in this paper. (XLSX)

With rapid advancements in sensing technologies and computation capabilities, high-resolution machine vision data have become available for various manufacturing processes. For machining, the use of machine vision data has shown great promise in machining tool condition monitoring, a critical factor for final product quality. Extensive research has...

As the maliciousness and frequency of cyber-attacks continues to grow, the safety and security of cyber-physical critical infrastructures, such as manufacturing, is quickly becoming a significant concern across the globe. Outside of traditional intellectual property theft, attacks against manufacturing systems pose a threat to maintaining a product...

State-of-the-art measurement technologies, such as 3D laser scanners, provide new opportunities for knowledge discovery and development of quality control (QC) strategies for complex manufacturing systems. These technologies can rapidly provide millions of data points to represent a manufactured part's surface. The resulting highdensity (HD) datase...

Manufacturing relies heavily upon the use of Quality Control tools to detect quality losses and to ensure high quality parts production. However, current tools are not designed to detect the effects of cyber-attacks, as they are based on assumptions (sustained shifts, rational subgrouping, etc.) that may no longer be valid under the presence of an...

According to some researchers, laboratories can be considered as " missed opportunities " in the sense that there is potential for them to be more useful to students in many different aspects than they are now. Their role can be extended far beyond just being a mean for students to practice implementing what they learn in lectures, since they can a...

Monitoring tool wear is essential to ensure consistently high quality of machined products. In the past, tool wear has been well characterized in common machining processes such as turning or milling. However, for cutting complex profiles, such as linear broaching, the only method reported for quantifying tool wear has been manual characterization...

Recent cyberattacks have highlighted the risk of physical equipment operating outside designed tolerances to produce catastrophic failures. A related threat is cyberattacks that change the design and manufacturing of a machine's part, such as an automobile brake component, so it no longer functions properly. These risks stem from the lack of cyber-...

Uncertainty management is a priority in remanufacturing operations due to uncertain end-of-life (EoL) product quality, quantity and return timing. Ignoring EoL product uncertainty can result in inefficient remanufacturing operations. In this work, an approach is developed that addresses the impact of EoL product quality uncertainty on partial disas...

Newly designed layer multiplying blocks are introduced in the process line of a melt blown spinning machine. The layer multiplying blocks have the capability to produce filament composites up to 1025 layers. Multilayer filament composites of polypropylene (PP) with poly(caprolactone) (PCL), a water soluble polyester or poly(l-lactic acid) are succe...

The Weibull distribution can be used to effectively model many different failure mechanisms due to its inherent flexibility through the appropriate selection of a shape and a scale parameter. In this paper, we evaluate and compare the performance of three cumulative sum (CUSUM) control charts to monitor Weibull-distributed time-between-event observ...

As technology progresses, cyber-physical systems are becoming susceptible to a wider range of attacks. In manufacturing, these attacks pose a significant threat to ensuring products conform to their original design intent and to maintaining the safety of equipment, employees, and consumers. This letter discusses the importance of research and devel...

Statistical process control (SPC) methods have been extensively applied to monitor the quality performance of manufacturing processes to quickly detect and correct out-of-control conditions. As sensor and measurement technologies advance, there is a continual need to adapt and refine SPC methods to effectively and efficiently use these new data-set...

Sustainable manufacturing requires simultaneous consideration of economic, environmental, and social implications associated with the production and delivery of goods. Fundamentally, sustainable manufacturing relies on descriptive metrics, advanced decision-making, and public policy for implementation, evaluation, and feedback. In this paper, recen...

Statistical process monitoring and control has been popularized in manufacturing as well as various other industries interested in improving product quality and reducing costs. Advances in this field have focused primarily on more efficient ways for diagnosing faults, reducing variation, developing robust design techniques, and increasing sensor ca...

The aggregation of event counts is a common, and often necessary, practice in many applications. When working with large numbers of events, it may be more practical to consider the number of events occurring during time intervals of a given length rather than the individual interarrival times between successive events. However, when data collection...

The tube hydroforming (THF) process is a metal forming process that uses a pressurized fluid as the forming mechanism. Recently, this process has increased in popularity in the automotive industry as a method to reduce the number of required components and consolidate parts which can substantially reduce the overall automobile weight. This reductio...

Ever advancing sensor and measurement technologies continually provide new opportunities for knowledge discovery and quality control (QC) strategies for complex manufacturing systems. One such state-of-the-art measurement technology currently being implemented in industry is the 3D laser scanner, which can rapidly provide millions of data points to...

Current engineering students receive an extensive education in the technical principles associated with the design and manufacturing of products and services. However, collaboration, communication and innovative thinking are not often stressed in traditional engineering curriculums. This study proposes a new interdisciplinary, group-based education...

This paper quantitatively motivates the need for active monitoring of occupational safety incident data through the use of cumulative sum (CUSUM) control charts. The frequency of incidents within a subset of historical accident data is analysed. The performance of Poisson CUSUM and exponential CUSUM (time-between-events) charts is compared in an il...

A sustainable manufacturing system integrates production systems, consumer usage behavior, and End-of-Life (EoL) product value recovery activities. Facilitating multi-objective disassembly planning can be a step toward analyzing the tradeoffs between the environmental impact and profitability of value recovery. In this paper, a Genetic Algorithm (G...

In order to reduce the rates of occupational fatalities and nonfatal injuries in industry, it is important to measure, monitor, and report safety performance over time, and act accordingly upon any findings. Real-time statistical monitoring for occupational safety has focused mostly on monitoring and improving upon accident frequency considerations...

The implementation of statistical process control (SPC) strategies over the past several decades has been fundamental in improving product quality in manufacturing. This is especially true for machining processes, where maintaining tight tolerances is critical to overall product quality and end-user performance. However, more often than not SPC str...

Cerium oxide nanoparticles (ceria NPs) attract a great research and commercial interests due to its observable capability to capture radicals and dissolved oxygen molecules. Keeping ceria NPs in active form; containing Ce +3 ions with O-vacancies, is a big challenge to be fitted into wide variety of applications such as free radical scavengers in b...

Machine vision systems are increasingly being used in industrial applications because of their ability to quickly provide information on product geometry, surface defects, surface finish, and other product and process characteristics. Previous research for monitoring these visual characteristics using image data has focused on either detecting chan...

This paper provides a framework that allows industrial practitioners to visualize the most significant variation patterns within their process using three-dimensional animation software. In essence, this framework complements Phase I statistical monitoring methods by enabling users to: (1) acquire detailed understanding of common-cause variability...

Assembly fixtures are commonly used to locate rigid and compliant components for joining operations. Piezoelectric (PZT) impedance sensors can be used to individually monitor assembly fixtures and have been proven effective for structural health monitoring applications. The sensors rapidly record significant quantities of data, but must be bonded t...

Hydroforming at the macro scale offers the opportunity to create products that have superior mechanical properties and intricate complex geometries. Micro tube hydroforming is a process that is gaining popularity for similar reasons. At the same time, due to the physical size of the operations, there are many challenges including working with extre...

New image processing techniques as well digital image capture equipment provide an opportunity for fast detection and diagnosis of quality problems in manufacturing environments compared with traditional dimensional measurement techniques. This paper proposes a new use of image processing to detect in real-time quality faults using images tradition...

Dimensional variation in assembly processes is one of the most important issues that affect quality. Although robust design and statistical process quality control help to reduce this problem, they cannot be used for instant variation reduction during assembly operations, especially during process ramp-up. This paper introduces a complete methodolo...

Fixture faults have been identified as a principal root cause of defective products in assembly lines; however, there exists a lack of fast and accurate monitoring tools to detect fixture fault damage. Locating fixture damage causes a decrease in product quality and production throughput due to the extensive work required to detect and diagnosis a...

Machine-vision systems are increasingly being used in industrial applications due to their ability to provide not only dimensional information but also information on product geometry, surface defects, surface finish, and other product and process characteristics. There are a number of applications of control charts for these high-dimensional image...

Sustainable manufacturing has been defined by the U.S. Department of Commerce as the creation of manufactured products using processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and consumers, and are economically sound. Thus, it requires simultaneous consideration of ec...

Research of the micro tube hydroforming (MTHF) process is being investigated for potential medical and fuel cell applications. This is largely due to the fact that at the macro scale the tube hydroforming (THF) process, like most metal forming processes has realized many advantages. Unfortunately, large forces and high pressures are required to for...

Statistical process monitoring and control has been popularized throughout the manufacturing industry as well as various other industries interested in improving product quality and reducing costs. Advances in this field have focused primarily on more efficient ways for diagnosing faults, reducing variation, developing robust design techniques, and...

New emission regulations in the US have increased parasitic weight in commercial vehicles. As a result, payload capacity in weight-restricted commercial vehicles has decreased. Manufacturing commercial vehicle side rails from high strength, lightweight aluminum alloys can reduce frame weight, thus, preserving payload capacity and profit margins of...

Compliance with tighter emission regulations has increased the proportion of parasitic weight in commercial vehicles. In turn, the amount of payload must be reduced to comply with transportation weight requirements. A re-design of commercial vehicle components is necessary to decrease the vehicle weight and improve payload capacity. Side rails have...

The emphasis placed on statistical process control over the past few decades has significantly aided manufacturers in measuring and monitoring dimensional parameters of production parts, and inferring process behavior from control charting. However, current manufacturing quality control methods fail to incorporate technologically innovative measure...

The development of micro-electromechanical systems (MEMS) and micro-system technologies (MST) has increased the need for a better understanding of new micro scale manufacturing processes. Recent research has focused on creating new processes that manufacture better quality and low cost products. The use of micro metal forming processes presents exc...

Dimensional integrity of assembled products is a critical factor in defining product functionality and process productivity. It has been reported that fixture faults are one of the root causes of defective sheet metal assemblies. Therefore, integrating new sensor technologies into manufacturing process fixtures will have a direct impact on improvin...

End-of-life product recovery operations require performance improvement to be viable in an industrial environment. A genetic algorithm (GA) is proposed to optimize end-of-life partial disassembly decisions based on disassembly costs, revenues, and environmental impacts. Facilitating disassembly optimization with costs, revenues, and environmental i...

An experimental evaluation of the robustness of an oval stamp forming die with a flexible binder designed using finite element modeling was performed using aluminum sheet metal as blanks. A systematic approach was used to determine the operational envelop of the die. The study indicates that a die with a flexible binder is significantly more robust...

New vision technologies provide an opportunity for fast detection and diagnosis of quality problems compared with traditional dimensional measurement techniques. This paper proposes a new use of image processing to detect quality faults using images traditionally obtained to guide manufacturing processes. The proposed method utilizes face recogniti...

Dimensional variation propagation and accumulation in multistage manufacturing processes are among the most important issues that affect quality. Although robust design and statistical process quality control help to reduce the effects of these problems, neither of these two methods can be used for instant variation reduction during assembly operat...

Using piezoelectric impedance sensors embedded in machining fixtures and clamps, the structural integrity of parts can be monitored. When considering the high cost of machining and finishing metal matrix composite (MMC) parts, this technology can prevent continuing to machine parts after defects appear during their processing. An autoregressive pie...

Dimensional variation is inherent to any manufacturing process. In order to minimize its impact on assembly products is important to understand how it propagates through the assembly process. Unfortunately, manufacturing processes are complex and in many cases highly non-linear. Traditional assembly models have represented assembly as a linear proc...

The value of a product at the end of its useful life determines whether it is disposed, recycled, remanufactured or is handled some other way within the recovery infrastructure. This value changes over time, and depends on factors such as the quality of the product and its perception by business entities within the recovery infrastructure. Under th...

Dimensional variation in assembled products directly affects product performance. To reduce dimensional variation it is necessary that an assembly be robust. A robust assembly is less sensitive to input variation from the product and process components such as incoming parts, subassemblies, fixtures and welding guns. In order to effectively underst...

With the use of new materials and nanoprocessing techniques such as layered deposition and surface micromachining, a three dimensional nanodrill has been successfully manufactured [O’ Neal et al., 2002]. The nanodrill is intended for drilling holes on the order of a few hundred nanometers. Several applications can be envisioned for such a device, f...

Recent advances in process monitoring technology have introduced an influx of exceptionally large data sets containing information on manufacturing process health. Recorded data sets are comprised of numerous parameters for which multivariate statistical process control (MSPC) methodologies are required. Current multivariate control charts are idea...

Traditional manufacturing process fault monitoring and detection methodologies have been based on Statistical Process Control (SPC) charts and rules. In most cases, SPC is used to detect a fault or an out-of-control condition while fault diagnosis relies on operator expertise to identify the potential root causes. Current sensor developments allow...

The assembly of compliant, non-rigid parts is widely used in automotive, aerospace, electronics, and appliance manufacturing. Dimensional variation is one important measure of quality in such assembly. This paper presents models for analyzing the propagation of dimensional variation in multi-stage compliant assembly systems and the use of such mode...

Failure diagnosis is critical to reduce variability in sheet metal assembly processes. Various diagnosis methodologies have been reported. Unfortunately, no investigation has been done to compare them in terms of their advantages and limitations for sheet metal assemblies. This paper presents a comparison of different methodologies for multiple fau...

This paper presents a new sensor placement methodology for effective fault diagnosis in an N-2-1 locating scheme used in compliant sheet metal assembly processes. The proposed approach is based on the effective independence (EfI) sensor placement method. The EfI method is a computational algorithm that starts with all feasible sensor locations and...

This paper presents a new fixture design methodology for sheet metal assembly processes. It focuses on the impact of fixture position on the dimensional quality of sheet metal parts after assembly by considering the effect of part variation, tooling variation and assembly springback. An optimization algorithm combines finite element analysis and no...

Fixture imperfections influence dimensional variation on machining processes. Therefore, a systematic method to isolate fixture faults will allow improvement in product quality. This paper presents a diagnosis methodology to identify root causes of fixture-induced workpiece variation in machining. The methodology is based on designated component an...

Dimensional variation is one of the most critical issues in the design of assembled products. This is especially important for the assembly of compliant, non-rigid parts since clamping and joining during assembly may introduce additional variation due to part deformation and springback. This paper presents a new methodology to predict sheet metal a...

This paper presents a new approach to multiple fault diagnosis for sheet metal fixtures using designated component analysis (DCA). DCA first defines a set of patterns based on product/process information, then finds the significance of these patterns from the measurement data and maps them to a particular set of faults. Existing diagnostics methods...

Compliant sheet metal assembly is a hierarchical manufac-turing process that plays a significant role in automotive product development. Parts are joined in different stations to form the fi-nal product (e.g., the vehicle body structure). Dimensional varia-tion is a product attribute of major importance that characterizes quality, and is mainly aff...

Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process with. compliant parts is dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dimensional variati...

Sheet metal assembly is a common manufacturing process for several products such as automobiles and airplanes. Since all manufacturing processes are affected by variation, the key characteristics or critical dimensions may not be nominal. This paper presents a new fixture design methodology for early evaluation of sheet metal assemblies. Fixture de...

Manufacturability of micro and nano systems has gained importance with the advent of microelectromechanical systems (MEMS). Whereas the manufacturability of macro systems has been a widely researched subject, the behavior of MEMS devices in large scale manufacturing operations is virtually an unexplored field. Therefore, in order to predict resulti...

Dissertation (Ph.D.)--University of Michigan.

Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process of such compliant parts is the assembly dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dime...

Assembly processes for compliant non-rigid parts are widely used in manufacturing automobiles, furniture, and electronic appliances. One of the major issues in the sheet metal assembly process is to control the dimensional variation of assemblies throughout the assembly line. This paper provides an overview of the recent development in variation an...

Assembly processes for compliant non-rigid parts are widely used in manufacturing automobiles, furniture, and electronic appliances. One of the major issues in the sheet metal assembly process is to control the dimensional variation of assemblies throughout the assembly line. This paper provides an overview of the recent development in variation an...