Multivariate statistical process control (MSPC) that is based on principal component analysis
(PCA) has been applied to many industrial processes. Such an approach assumes that the process
signals are normally distributed and exhibit stationary behavior. These assumptions significantly
limit the range of applicability of the methodology. In this paper, a monitoring scheme based on
a maximum-likelihood PCA (MLPCA) mixture is proposed. The main idea behind the approach
is that complex data patterns obtained from a process can be described by several local models.
A learning algorithm that helps determine model structure, i.e., the number of local PCA models
to be constructed and the number of principal components to be included in each local model, is
proposed, resulting in the efficient determination of a MLPCA mixture model. Two monitoring
statistics used in the MLPCA-based monitoring scheme are then derived and a two-step fault
detection method is proposed. Several mathematical models that describe different process
features, including multiple steady states, nonlinearity, and process dynamics, are used to
demonstrate the potential of the proposed method. The approach is compared with previous
approaches, including nonlinear PCA and dynamic PCA, and it is confirmed that the developed
methodology is a good alternative. Finally, the method is applied for fault detection on a
continuously stirred tank reactor process, and its performance for detecting six types of faults,
in terms of false alarm rate, missed alarm rate, and detection delay, is shown to outperform
current approaches.