A Decision Analysis Framework for High-fidelity and Low-fidelity Systems with Applications in Manufacturing Processes

Abstract: Optimizing complex manufacturing processes often involves a trade-off between data accuracy and acquisition cost. High-fidelity data are accurate but limited, while low-fidelity data are abundant but often biased. Balancing these two sources is critical for efficient manufacturing optimization. To address this challenge, we develop a decision analysis framework based on multi-fidelity Gaussian process (GP) modeling based on the Kennedy-O'Hagan (KOH) framework. We propose a systematic Bayesian calibration approach using multi-fidelity GPs that explicitly quantifies the model discrepancy, and an algorithm that combines posterior sampling of calibration parameters with predictive sampling to characterize the distribution of optimal input settings and their associated uncertainty. These components are integrated into a five-stage practical workflow for the optimization of manufacturing processes. Through an illustrative example and two real-world applications in composite cure cycle optimization and injection molding process control, we demonstrate how the framework integrates information from both high-fidelity and low-fidelity data sources to support decision-making under parameter uncertainty.