Quality assurance in manufacturing is demanding and expensive, yes, but also absolutely crucial. After all, selling flawed goods results in returns and disappointed customers. Harnessing the power of image recognition and deep learning may significantly reduce the cost of visual quality control while also boosting overall process efficiency.

According to “Forbes”, automating quality testing with machine learning can increase defect detection rates by up to 90%. Machines never tire, nor lose focus or need a break. And every product on a production line is inspected with the same focus and meticulousness.
Yield losses, the products that need to be reworked due to defects, may be one of the biggest cost-drivers in the production process. In semiconductor production, testing cost and yield losses can constitute up to 30% of total production costs.

Time and money for quality

Traditional quality control is time-consuming. It is manually performed by specialists testing the products for flaws. Yet the process is crucial for business, as product quality is the pillar a brand will stand on. It is also expensive. Electronics industry giant Flex claims that for every 1 dollar it spends creating a product, it lays out 100 more on resolving quality issues.
Since the inception of image recognition software, manufacturers have been able to incorporate IP cameras into the quality control process. Most of the implementations are based on complex systems of triggers. But with the conditions predefined by programmers, the cameras were able to spot only a limited number of flaws. While the technology may not yet have been worthy of the title game changer, the image recognition revolution was one step further.

Deep learning about perfection

Artificial intelligence may enhance the company’s ability to spot flawed products. Instead of embedding complex and lengthy lists of possible flaws into an algorithm, the algorithm learns the product’s features. With the vision of the perfect product, the software can easily spot imperfect ones.

Visual quality control in Fujitsu

A great example of how AI combined with vision systems can improve product quality is on display at Fujitsu’s Oyama factory. The Image Recognition System the company uses not only helps it ensure the production of parts of an optimal quality, but also supervises the assembly process. This dual role has markedly boosted the company’s efficiency.
As the company stated, the solution lacked the flexibility today’s fast-moving world demands. But powering up an AI-driven solution allowed it to quickly adapt its software to new products without the need for time-consuming recalibration. With the AI solutions, Fujitsu reduced its development time by 80% while keeping part recognition rates at 97%+.
As their solution proved successful, Fujitsu deployed it at all of its production sites.
Visual quality control is also factoring in the agricultural product packing arena. One company has recently introduced a high-performance fruit sorting machine that uses computer vision and machine learning to classify skin defects. The operator can teach the sorting platform to distinguish between different types of blemishes and sort the fruit into sophisticated pack grades. The solution combines hardware, software and operational optimization to reduce the complexity of the sorting process.

Summary

As automation becomes more widespread and manufacturing more complex, factories will need to employ AI. Self-learning machines ultimately allow the companies forward-thinking enough to use them to reduce operational costs while maintaining the highest quality possible.
However, an out-of-box solution is not always the best option. Limited flexibility and lower accuracy are the most significant obstacles most companies face. Sometimes building an in-house team of machine learning experts is the best way to provide both the competence and ability to tailor the right solutions for one’s business. As building the internal team to design visual quality control is more than challenging, finding the reliable partner to gain knowledge may be the best option.

In this post, we provide an example of how to run a TensorFlow experiment on a Slurm cluster. Since TensorFlow doesn’t yet officially support this task, we developed a simple Python module for automating the configuration. It parses the environment variables set by Slurm and creates a TensorFlow cluster configuration based on them. We’re sharing this code along with a simple image recognition example on CIFAR-10. You can find it in our github repo.

But first, why do we even need distributed machine learning?

Distributed TensorFlow

When machine learning models are developed, training time is an important factor. Some experiments can take weeks or even months on a single machine. Shortening this time enables us to try out more approaches, test many similar models and use the best one. That’s why it’s useful to use multiple machines for faster training.
One of of TensorFlow’s strongest points is that it’s designed to support distributed computation. To use multiple nodes, you just have to create and start a tf.train.Server and use a tf.train.MonitoredTrainingSession.

Between Graph Replication

In our example we’re going be using a concept called ‘Between Graph Replication’. If you’ve ever run MPI jobs or used the ‘fork’ system call, you’ll be familiar with it.
In Distributed TensorFlow, Between Graph Replication means that when several processes are being run on different machines, each process (worker) runs the same code and constructs the same TensorFlow computational graph. However, each worker uses a discriminator (the worker’s I.D., for example) to execute instructions differently from the rest (e.g. process different batches of the training data).
This information is also used to make processes on some machines work as ‘Parameter Servers’. These jobs don’t actually run any computations – they’re only responsible for storing the weights of the model and sending them over the network to other processes.

Connections between tasks in a distributed TensorFlow job with 3 workers and 2 parameter servers.

Apart from the worker I.D. and the job type (normal worker or parameter server), TensorFlow also needs to know the network addresses of other workers performing the computations. All this information should be passed as configuration for the tf.train.Server. However, keeping track of it all in addition to starting multiple processes on multiple machines with different parameters can be really tedious. That’s why we have cluster managers, such as Slurm.

Slurm

Slurm is a workload manager for Linux used by many of the world’s fastest supercomputers. It provides the means for running computational jobs on multiple nodes, queuing the jobs until sufficient resources are available and monitoring jobs that have been submitted. For more information about Slurm, you can read the official documentation here.
When running a Slurm job you can discover other nodes taking part by examining environment variables:

• SLURMD_NODENAME – name of the current node
• SLURM_JOB_NODELIST – number of nodes the job is using
• SLURM_JOB_NUM_NODES – list of all nodes allocated to the job

Our python module parses these variables to make using distributed TensorFlow easier. With the tf_config_from_slurm function you can automate this process. Let’s see how it can be used to train a simple CIFAR-10 model on a CPU Slurm cluster.

Distributed TensorFlow on Slurm

In this section we’re going to show you how to run TensorFlow experiments on Slurm. A complete example of training a convolutional neural network on the CIFAR-10 dataset can be found in our github repo, so you might want to take a look at it. Here we’ll just examine the most interesting parts.
Most of the code responsible for training the model comes from this TensorFlow tutorial. The modifications allow the code to be run in a distributed setting on the CIFAR-10 dataset. Let’s examine the changes one by one.

Starting the Server

import tensorflow as tf
from tensorflow_on_slurm import tf_config_from_slurm
cluster, my_job_name, my_task_index = tf_config_from_slurm(ps_number=1)
cluster_spec = tf.train.ClusterSpec(cluster)
server = tf.train.Server(server_or_cluster_def=cluster_spec,
                         job_name=my_job_name, task_index=my_task_index)
if my_job_name == 'ps':
    server.join()
    sys.exit(0)

Here we import our Slurm helper module and use it to create and start the tf.train.Server. The tf_config_from_slurm function returns the cluster spec necessary to create the server along with the task name and task index of the current job. The ‘ps_number’ parameter specifies how many parameter servers to set up (we use 1). All other nodes will be working as normal workers and everything gets passed to the tf.train.Server constructor.
Afterwards we immediately check whether the current job is a parameter server. Since all the work in a parameter server (ps) job is handled by the tf.train.Server (which is running in a separate thread), we can just call server.join() and not execute the rest of the script.

Placing the Variables on a parameter server

def weight_variable(shape):
    with tf.device("/job:ps/task:0"):
        initial = tf.truncated_normal(shape, stddev=0.1)
        return tf.Variable(initial)
def bias_variable(shape):
    with tf.device("/job:ps/task:0"):
        initial = tf.constant(0.1, shape=shape)
        return tf.Variable(initial)

These two functions are used when defining the model parameters. Note the “with tf.device(“/job:ps/task:0”)” statements telling TensorFlow that the variables should be placed on the parameter server, thus enabling them to be shared between the workers. The “0” index denotes the I.D. of the parameter server used to store the variable. Here we’re only using one server, so all the variables are placed on task “0”.

Optimizer

loss = tf.reduce_mean(cross_entropy)
opt = tf.train.AdamOptimizer(1e-3)
opt = tf.train.SyncReplicasOptimizer(opt, replicas_to_aggregate=len(cluster['worker']),
                                     total_num_replicas=len(cluster['worker']))
is_chief = my_task_index == 0
sync_replicas_hook = opt.make_session_run_hook(is_chief)
train_step = opt.minimize(loss, global_step)

Instead of using the usual AdamOptimizer, we’re wrapping it with the SyncReplicasOptimizer. This enables us to prevent the application of stale gradients. In distributed training, the network communication may introduce communication delays which make it harder to train the model.

Creating the session

sync_replicas_hook = opt.make_session_run_hook(is_chief)
sess = tf.train.MonitoredTrainingSession(master=server.target,
                                         is_chief=is_chief,
                                         hooks=[sync_replicas_hook])
batch_size = 64
max_epoch = 10000

In distributed settings we’re using the tf.train.MonitoredTrainingSession instead of the usual tf.Session. This ensures the variables are properly initialized. It also allows you to restore a previously saved model and control how the summaries and checkpoints are written to disk.

Training

During the training, we split the batches between workers so everyone has their own unique batch subset to train on:

for i in range(max_epoch):
    batch = mnist.train.next_batch(batch_size)
    if i % len(cluster['worker']) != my_task_index:
        continue
    _, train_accuracy, xentropy = sess.run([train_step, accuracy, cross_entropy],
                                           feed_dict={x: batch[0], y_: batch[1],
                                           keep_prob: 0.5})

Summary

We hope this example was helpful in your experiments with TensorFlow on Slurm clusters. If you’d like to reproduce it or use our Slurm helper module in your experiments, don’t hesitate to clone our github repo.