arXiv subjects

Joseph E. Hernandez

Publications and source records attributed to Joseph E. Hernandez.

5 recordsLinked to original sources

arXiv2026

A Kafka-Centric Communication Fabric for Near-Real-Time, Cloud-Replicated Closed-Loop Manufacturing Process Control

Smart manufacturing needs to move sensor data off the plant floor, react to it, and feed decisions back to actuators within bounded time. Programmable logic controllers (PLCs) handle fast, deterministic, safety-critical actuation, but they are not designed for the higher-level functions required by Industry 4.0, such as predictive maintenance, machine learning inference, and cross-facility analytics. These functions need a scalable, durable, and observable communication substrate. We present the communication architecture of a production system that provides this substrate and closes the loop back to the plant in near real time. The design is built from industry-standard components: Apache Kafka as the streaming backbone, OPC-UA for PLC connectivity, a relational time-series database for persistence, and JSON for serialization. The novelty is architectural. We show how these standards are integrated for closed-loop industrial control through four design choices: a single event stream per production line serves control, monitoring, machine learning, and durable recording, allowing one producer to serve many independent consumers; a protocol bridge converts polled OPC-UA traffic into publish/subscribe streams, aligns per-signal timestamps to a common time base to remove cross-signal jitter, and provides a symmetric actuation path; a transport technique carries sub-second process dynamics at a coarser publication cadence by packing timestamped samples into fixed-order arrays; and an edge-to-cloud replication scheme keeps the edge authoritative, so local control continues during wide-area network outages while cloud analytics operate on replicated data. We describe the loop latency budget, report measured broker transport latency, and discuss operational experience. The system provides soft, near-real-time behavior rather than hard real-time guarantees.

cs.NI↗

arXiv2026

Event-Driven ML Pipeline Orchestration for Manufacturing: An AWS Industry Experience

We present an industry experience report on three years of operating an event-driven cloud infrastructure for continuous machine learning training in automotive manufacturing. Our system orchestrates GPU-accelerated training of product-specialized model pairs, a physics prediction model and a reinforcement-learning control policy, across multiple plants, coordinating long-running GPU workloads triggered by manufacturing events. The architecture combines Amazon ECS with EC2 GPU capacity providers, SQS-based messaging with dead-letter queues, and an admission-controlled Lambda dispatcher that enforces cluster concurrency limits. A Conductor orchestrator on ECS Fargate initiates dependency-aware retraining chains on a weekly schedule. The entire infrastructure is codified in modular Terraform with multi-account separation. From 40000+ production training jobs we report a 72-78% cost reduction versus always-on GPU infrastructure. A discrete-event simulation confirms that admission control is necessary (naive dispatch loses 65% of jobs) and that queue-draining matches AWS Step Functions latency while eliminating per-job startup overhead. We provide lessons learned and release the simulator and Terraform module skeletons as open-source artifacts.

cs.LG↗

arXiv2026

Autonomous Model Lifecycle Management for Digital Twin-Based Manufacturing Control

Manufacturing AI systems must autonomously adapt to continuous distributional shift from raw-material variability, ambient changes, and equipment aging, under strict safeguard and operator-trust requirements where model failures risk physical damage. This paper presents a closed-loop Cyber-Physical System (CPS) for autonomous model lifecycle management in automotive manufacturing, deployed since 2023. The system manages product-specialized model pairs: a sequence-to-sequence physics model (LPP) serving as a digital twin, and a deep Reinforcement Learning (RL) control policy (LCP) trained against it. Per retraining cycle, multiple model variants spanning architecture families and RL algorithms compete; only the best-scoring candidate advances. A Conductor orchestrator autonomously manages plant-wide model inventories with dependency-aware retraining and Proportional-Integral-Derivative (PID) fallback. Reflecting the principle of Human-Centric Intelligence, the LCP composite score embeds an operator-trust gate penalizing policies deviating from established practice; without it, 23% of policies are rejected by operators despite passing accuracy thresholds. Across multiple facilities, LCP-controlled processes achieve process stability improvements of 28-45% over uncontrolled baselines with zero safety incidents.

cs.LG↗

arXiv2026

Augmenting PID Control with Deep Reinforcement Learning: A Hybrid Approach to the Industrial Benchmark

As industrial processes grow in complexity, traditional Proportional-Integral-Derivative (PID) controllers are often insufficient for handling their non-linear, multi-input dynamics. We propose using advanced Deep Reinforcement Learning (DRL) to prove its advantages in these complex environments. To do this, we rely on the Industrial Benchmark (IB). The IB is a realistic simulation that tests DRL algorithms against the key challenges of industrial applications: high-dimensional state spaces, delayed effects, and conflicting multi-criterial objectives. This testbed highlights DRL's core trade-off: while its final policies can often be unstable, its unique strength is the ability to autonomously discover optimal, non-obvious policies in multi-dimensional spaces where simple controllers fail. In this paper, we propose a novel hybrid PID-RL controller that leverages DRL's discovery capability while ensuring Reliability. After developing a multi-objective reward function to make DRL viable, we use a twin-delayed deep deterministic (TD3) agent as a discovery tool to find the optimal, non-obvious settings for the IB's 'Gain' and 'Shift' parameters. By feeding these discovered parameters to a simple, tuned PID controller, our hybrid model successfully combines all three characteristics: it achieves the optimal Performance and Efficiency of the best DRL agent with the Reliability of a classical controller. This work demonstrates a practical methodology for using DRL to augment, rather than replace, trusted industrial control systems.

cs.LG↗

arXiv2026

Benchmarking Hybrid Deep Learning Architectures for Predictive Maintenance in Industry 4.0

Predictive maintenance in Industry 4.0 refers to using data from sensors, machines, and production systems to estimate when equipment is likely to fail, so maintenance can be planned before a breakdown occurs [1]. However, a model that predicts maintenance may work perfectly in the lab but fail unexpectedly when applied to real factory data [2]. To solve this "reliability" gap, we evaluated six deep learning architectures across more than 700 experimental runs. We focused on the two dominant approaches in the field: Recurrent Neural Networks (RNNs), which process data step-by-step, like reading a sentence [3], and Transformers, a recent dominant approach, which look at the entire sequence at once to spot important connections [4]. We examined whether Transformers still outperform recurrent neural networks (RNNs) when the data includes noise [5]. We found that while Transformers excelled at tracking stable, slow-moving processes, they tend to overreact to chaotic data, mistakenly taking sensor noise for meaningful signals [6]. We also found that the hybrid method that combines a Long Short-Term Memory (LSTM) layer with a Transformer layer is more resilient to noisy data from factory shops [7]. Functioning as a noise filter, the LSTM smooths out data volatility, allowing the Transformer to focus on the bigger picture without being distracted [8]. The hybrid model did not just improve accuracy; it proved to be significantly more consistent than complex models, delivering reliable predictions regardless of how chaotic the underlying system became.

cs.LG↗