Automated process monitoring in injection molding via representation learning and setpoint regression

Online process monitoring is essential to detect failures and respond promptly in automated industrial processes such as injection molding. Traditional systems rely on experienced operators manually defining operational boundaries around a reference signal. We propose a data-driven representation that auto-tunes the sensitivity to a pre-set specificity threshold and automatically detects anomalies alongside interpretable indices that help identify root causes. Our automated system achieved an average AUC of 0.998 and detected 100 percent of the anomalies with the proposed dynamic calibration of the data-driven embedding method. The dynamic calibration, which accounted for drift, boosts the average specificity from 0.362 to 0.869. The outputs also indicate the direction and relative magnitude of characteristic deviations caused by machine parameters, including holding pressure, mold temperature, and injection speed. The AI-derived process boundaries are superior to manual annotation in tested real-world production environments.