We are working on an NDT method to find flaws around fasteners in an aircraft. By experience the vast majority of fasteners are unflawed. The measurement returns approximately 5 descriptors depending on how we set things up. At the moment we are using a minimum covariance estimator to produce a covariance matrix on the fly. We then use that to calculate a Mahalanobis distance for each point from the unflawed centroid and make decisions about which is a flaw and which isn't based on a cut-off distance. It works pretty well, but has some challenges. The problem is basically one of finding a few outliers in a large (medium?) sample from a multidimensional normal (by assumption) distribution. Does anyone have any suggestion for an approach that might work better?

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