Tag Archives: deep learning

What is Quality 4.0?


My first post of 2018 addresses an idea that’s just starting to gain traction – one you’ll hear a lot more about from me soon: Quality 4.0.  It’s not a fad or trend, but a reminder that the business environment is changing, and that performance excellence in the future will depend on how well you adapt, change, and transform in response.

Although we started building community around this concept at the ASQ Quality 4.0 Summits on Disruption, Innovation, and Change in 2017 and 2018, the truly revolutionary work is yet to come.

What is Quality 4.0?

Quality 4.0 = Connectedness + Intelligence + Automation (C-I-A)

for Performance Innovation

The term “Quality 4.0” comes from “Industry 4.0” – the “fourth industrial revolution” originally addressed at the Hannover (Germany) Fair in 2011. That meeting emphasized the increasing intelligence and interconnectedness in “smart” manufacturing systems, and reflected on the newest technological innovations in historical context.

The Industrial Revolutions

  • In the first industrial revolution (late 1700’s), steam and water power made it possible for production facilities to scale up and expanded the potential locations for production.
  • By the late 1800’s, the discovery of electricity and development of associated infrastructure enabled the development of machines for mass production. In the US, the expansion of railways made it easier to obtain supplies and deliver finished goods. The availability of power also sparked a renaissance in computing, and digital computing emerged from its analog ancestor.
  • The third industrial revolution came at the end of the 1960’s, with the invention of the Programmable Logic Controller (PLC). This made it possible to automate processes like filling and reloading tanks, turning engines on and off, and controlling sequences of events based on changing conditions.

The Fourth Industrial Revolution

Although the growth and expansion of the internet accelerated innovation in the late 1990’s and 2000’s, we are just now poised for another industrial revolution. What’s changing?

  • Production & Availability of Information: More information is available because people and devices are producing it at greater rates than ever before. Falling costs of enabling technologies like sensors and actuators are catalyzing innovation in these areas.
  • Connectivity: In many cases, and from many locations, that information is instantly accessible over the internet. Improved network infrastructure is expanding the extent of connectivity, making it more widely available and more robust. (And unlike the 80’s and 90’s, there are far fewer communications protocols that are commonly encountered so it’s a lot easier to get one device to talk to another device on your network.)
  • Intelligent Processing: Affordable computing capabilities (and computing power!) are available to process that information so it can be incorporated into decision making. High-performance software libraries for advanced processing and visualization of data are easy to find, and easy to use. (In the past, we had to write our own… now we can use open-source solutions that are battle tested.
  • New Modes of Interaction: The way in which we can acquire and interact with information are also changing, in particular through new interfaces like Augmented Reality (AR) and Virtual Reality (VR), which expand possibilities for training and navigating a hybrid physical-digital environment with greater ease.
  • New Modes of Production: 3D printing, nanotechnology, and gene editing (CRISPR) are poised to change the nature and means of production in several industries. Technologies for enhancing human performance (e.g. exoskeletons, brain-computer interfaces, and even autonomous vehicles) will also open up new mechanisms for innovation in production. (Roco & Bainbridge (2002) describe many of these, and their prescience is remarkable.) New technologies like blockchain have the potential to change the nature of production as well, by challenging ingrained perceptions of trust, control, consensus, and value.

The fourth industrial revolution is one of intelligence: smart, hyperconnected cyber-physical systems that help humans and machines cooperate to achieved shared goals, and use data to generate value.

Enabling Technologies are Physical, Digital, and Biological

These enabling technologies include:

  • Information (Generate & Share)
    • Affordable Sensors and Actuators
    • Big Data infrastructure (e.g. MapReduce, Hadoop, NoSQL databases)
  • Connectivity
    • 5G Networks
    • IPv6 Addresses (which expand the number of devices that can be put online)
    • Internet of Things (IoT)
    • Cloud Computing
  • Processing
    • Predictive Analytics
    • Artificial Intelligence
    • Machine Learning (incl. Deep Learning)
    • Data Science
  • Interaction
    • Augmented Reality (AR)
    • Mixed Reality (MR)
    • Virtual Reality (VR)
    • Diminished Reality (DR)
  • Construction
    • 3D Printing
    • Additive Manufacturing
    • Smart Materials
    • Nanotechnology
    • Gene Editing
    • Automated (Software) Code Generation
    • Robotic Process Automation (RPA)
    • Blockchain

Today’s quality profession was born during the middle of the second industrial revolution, when methods were needed to ensure that assembly lines ran smoothly – that they produced artifacts to specifications, that the workers knew how to engage in the process, and that costs were controlled. As industrial production matured, those methods grew to encompass the design of processes which were built to produce to specifications. In the 1980’s and 1990’s, organizations in the US started to recognize the importance of human capabilities and active engagement in quality as essential, and TQM, Lean, and Six Sigma gained in popularity. 

How will these methods evolve in an adaptive, intelligent environment? The question is largely still open, and that’s the essence of Quality 4.0.

Roco, M. C., & Bainbridge, W. S. (2002). Converging technologies for improving human performance: Integrating from the nanoscale. Journal of nanoparticle research4(4), 281-295. (http://citeseerx.ist.psu.edu/viewdoc/download?doi=

A Newbie’s Install of Keras & Tensorflow on Windows 10 with R

This weekend, I decided it was time: I was going to update my Python environment and get Keras and Tensorflow installed so I could start doing tutorials (particularly for deep learning) using R. Although I used to be a systems administrator (about 20 years ago), I don’t do much installing or configuring so I guess that’s why I’ve put this task off for so long. And it wasn’t unwarranted: it took me the whole weekend to get the install working. Here are the steps I used to get things running on Windows 10, leveraging clues in about 15 different online resources — and yes (I found out the hard way), the order of operations is very important. I do not claim to have nailed the order of operations here, but definitely one that works.

Step 0: I had already installed the tensorflow and keras packages within R, and had been wondering why they wouldn’t work. “Of course!” I finally realized, a few weeks later. “I don’t have Python on this machine, and both of these packages depend on a Python install.” Turns out they also depend on the reticulate package, so install.packages(“reticulate”) if you have not already.

Step 1: Installed Anaconda3 to C:/Users/User/Anaconda3 (from https://www.anaconda.com/download/)

Step 2: Opened “Anaconda Prompt” from Windows Start Menu. First, to create an “environment” specifically for use with tensorflow and keras in R called “tf-keras” with a 64-bit version of Python 3.5 I typed:

conda create -n tf-keras python=3.5 anaconda

… and then after it was done, I did this:

activate tf-keras

Step 3: Install TensorFlow from Anaconda prompt. Using the instructions at https://storage.googleapis.com/tensorflow/windows/cpu/tensorflow-1.1.0-cp35-cp35m-win_amd64.whl I typed this:

pip install --ignore-installed --upgrade

I didn’t know whether this worked or not — it gave me an error saying that it “can not import html5lib”, so I did this next:

conda install -c conda-forge html5lib

I tried to run the pip command again, but there was an error so I consulted https://www.tensorflow.org/install/install_windows. It told me to do this:

pip install --ignore-installed --upgrade tensorflow

This failed, and told me that the pip command had an error. I searched the web for an alternative to that command, and found this, which worked!!

conda install -c conda-forge tensorflow


Step 4: From inside the Anaconda prompt, I opened python by typing “python”. Next, I did this, line by line:

import tensorflow as tf
 hello = tf.constant('Hello, TensorFlow!')
 sess = tf.Session()

It said “b’Hello, TensorFlow!'” which I believe means it works. (Ctrl-Z then Enter will then get you out of Python and back to the Anaconda prompt.) This means that my Python installation of TensorFlow was functional.

Step 5: Install Keras. I tried this:

pip install keras

…but I got the same error message that pip could not be installed or found or imported or something. So I tried this, which seemed to work:

conda install -c conda-forge keras


Step 6: Load them up from within R. First, I opened a 64-bit version of R v3.4.1 and did this:


It took a couple minutes but it seemed to work.



Step 7: Try a tutorial! I decided to go for https://www.analyticsvidhya.com/blog/2017/06/getting-started-with-deep-learning-using-keras-in-r/ which guides you through developing a classifier for the MNIST handwritten image database — a very popular data science resource. I loaded up my dataset and checked to make sure it loaded properly:

data <- data_mnist()
List of 2
 $ train:List of 2
 ..$ x: int [1:60000, 1:28, 1:28] 0 0 0 0 0 0 0 0 0 0 ...
 ..$ y: int [1:60000(1d)] 5 0 4 1 9 2 1 3 1 4 ...
 $ test :List of 2
 ..$ x: int [1:10000, 1:28, 1:28] 0 0 0 0 0 0 0 0 0 0 ...
 ..$ y: int [1:10000(1d)] 7 2 1 0 4 1 4 9 5 9 ...


Step 8: Here is the code I used to prepare the data and create the neural network model. This didn’t take long to run at all.


train_x <- array(train_x, dim = c(dim(train_x)[1], prod(dim(train_x)[-1]))) / 255

test_x <- array(test_x, dim = c(dim(test_x)[1], prod(dim(test_x)[-1]))) / 255


model %>% 
layer_dense(units = 784, input_shape = 784) %>% 
layer_activation(activation = 'relu') %>% 
layer_dense(units = 10) %>% 
layer_activation(activation = 'softmax')

model %>% compile(
loss = 'categorical_crossentropy',
optimizer = 'adam',
metrics = c('accuracy')


Step 9: Train the network. THIS TOOK ABOUT 12 MINUTES on a powerful machine with 64GB high-performance RAM. It looks like it worked, but I don’t know how to find or evaluate the results yet.

model %>% fit(train_x, train_y, epochs = 100, batch_size = 128)
 loss_and_metrics <- model %>% evaluate(test_x, test_y, batch_size = 128)

Layer (type) Output Shape Param #
dense_1 (Dense) (None, 784) 615440
dropout_1 (Dropout) (None, 784) 0
activation_1 (Activation) (None, 784) 0
dense_2 (Dense) (None, 10) 7850
activation_2 (Activation) (None, 10) 0
Total params: 623,290
Trainable params: 623,290
Non-trainable params: 0


Step 10: Next, I wanted to try the tutorial at https://cran.r-project.org/web/packages/kerasR/vignettes/introduction.html. Turns out this uses the kerasR package, not the keras package:

X_train <- mnist$X_train
Y_train <- mnist$Y_train
X_test <- mnist$X_test
Y_test <- mnist$Y_test

> dim(X_train)
[1] 60000 28 28

X_train <- array(X_train, dim = c(dim(X_train)[1], prod(dim(X_train)[-1]))) / 255
X_test <- array(X_test, dim = c(dim(X_test)[1], prod(dim(X_test)[-1]))) / 255

To check and see what’s in any individual image, type:


At this point, the to_categorical function stopped working. I was supposed to do this but got an error:

Y_train <- to_categorical(mnist$Y_train, 10)

So I did this instead:

mm <- model.matrix(~ Y_train)

Y_train <- to_categorical(mm[,2])


But then I tried this, and it was clear I was stuck again — it wouldn’t work:

mod$add(Dense(units = 512, input_shape = dim(X_train)[2]))

Stack Overflow recommended grabbing a version of kerasR from GitHub, so that’s what I did next:


I got an error in R which told me to go to the Anaconda prompt (which I did), and type this:

conda install m2w64-toolchain

Then I went back into R and this worked fantastically:

mod <- Sequential()

mod$Add would still not work though, and this is where my patience expired for the evening. I’m pretty happy though — Python is up, keras and tensorflow are up on Python, all three (keras, tensorflow, and kerasR) are up in R, and some tutorials seem to be working.