Recent advancements in sensing technologies offer new opportunities for quality improvement and assurance in manufacturing and service systems. The sensor advances provide a vast amount of data, accommodating quality improvement decisions such as fault diagnosis (root cause analysis), and real-time process monitoring. These quality improvement decisions are typically made based on the predictive analysis of the sensor data, so called sensor-based predictive analytics. Sensor-based predictive analytics encompasses a variety of statistical, machine learning, and data mining techniques to identify patterns between the sensor data and historical facts. Given these patterns, predictions are made about the quality state of the process, and corrective actions are taken accordingly.

Although the recent advances in sensing technologies have facilitated the quality improvement decisions, they typically result in high dimensional sensor data, making the use of sensor-based predictive analytics challenging due to their inherently intensive computation. This research begins in Chapter 1 by raising an interesting question, whether all these sensor data are required for making effective quality improvement decisions, and if not, is there any way to systematically reduce the number of sensors without affecting the performance of the predictive analytics? Chapter 2 attempts to address this question by reviewing the related research in the area of signal processing, namely, compressive sensing (CS), which is a novel sampling paradigm as opposed to the traditional sampling strategy following the Shannon Nyquist rate. By CS theory, a signal can be reconstructed from a reduced number of samples, hence, this motivates developing CS based approaches to facilitate predictive analytics using a reduced number of sensors. The proposed research methodology in this dissertation encompasses CS approaches developed to deliver the following two major contributions, (1) CS sensing to reduce the number of sensors while capturing the most relevant information, and (2) CS predictive analytics to conduct predictive analysis on the reduced number of sensor data.

The proposed methodology has a generic framework which can be utilized for numerous real-world applications. However, for the sake of brevity, the validity of the proposed methodology has been verified with real sensor data associated with multi-station assembly processes (Chapters 3 and 4), additive manufacturing (Chapter 5), and wearable sensing systems (Chapter 6). Chapter 7 summarizes the contribution of the research and expresses the potential future research directions with applications to big data analytics.