A knowledge-based system to improve the quality and efficiency of titanium melting

This paper outlines the application of a knowledge-based expert system to assist the furnace production staff in diagnosing and correcting Electron Beam (EB) guns, which are used to melt titanium. The characteristics of a titanium melting facility, its business objectives, and the responsibilities of its furnace operators are reviewed. Alternative solutions to the problem of accurately troubleshooting EB gun failures are discussed. The chosen solution (i.e. the knowledge-based system) was in alignment with the company’s on-going continuous improvement efforts designed to improve operational efficiencies and thus was met with support. Next, we discuss the costs and benefits associated with the system. A description of the system architecture is provided along with a review of the knowledge acquisition process. Development, testing and implementation of the system is reviewed. Finally, the impacts of the system on the company are discussed. q 2002 Elsevier Science Ltd. All rights reserved.