Method for containing defective parts, computing device and computer program product

Abstract

A method performed by a computing device is disclosed, comprising: receiving a trigger signal, the trigger signal indicating that a particular type of part is defective; based on the trigger signal, creating a part containment project; configuring, for the part containment project, a work instruction for inspecting a plurality of parts of the particular type in inventory for defects; and receiving containment data, the containment data being obtained by performing the work instruction to inspect the plurality of parts of the particular type in inventory for defects, the containment data indicating information related to one or more parts of the plurality of parts that are defective.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of industrial production, and more specifically, to a method of containing defective parts, a computing device and a computer program product. BACKGROUND

[0002] Production of modern industrial products (e.g., automobiles) can require a large number of parts. These parts are provided by suppliers to a production factory and become inventory of the production factory. The inventoried parts are gradually consumed in the production process. However, there can be defective parts among the inventoried parts. When it is found that one or more parts of a particular type are defective, it is necessary to inspect parts of the same type in the inventory, so as to contain the defective parts, to reduce the risk to production. SUMMARY

[0003] The present disclosure provides a method performed by a computing device, the method comprising: receiving a trigger signal, the trigger signal indicating that a part of a particular type is defective; based on the trigger signal, creating a part containment project; for the part containment project, configuring a work instruction for inspecting a plurality of parts of the particular type in an inventory for defects; and receiving containment data, the containment data being obtained by performing the work instruction to inspect the plurality of parts of the particular type in the inventory for defects, the containment data indicating information related to one or more parts of the plurality of parts that are defective.

[0004] The present disclosure also provides a computing device comprising one or more hardware processors and a memory storing a computer program that, when executed by the one or more hardware processors, causes the one or more hardware processors to perform any of the methods as described herein.

[0005] The present disclosure also provides a computer program product comprising a computer program that, when executed by the one or more hardware processors, causes the one or more hardware processors to perform any of the methods as described herein.

[0006] The methods and systems of the present disclosure can efficiently and flexibly contain defective parts among inventoried parts, so that the risk of defective parts to industrial production can be reduced. The systems and methods of the present disclosure can reduce manual coordination for performing a containment process. The systems and methods of the present disclosure can provide standardized operations for performing a containment process, so that efficiency can be improved. The systems and methods of the present disclosure can aggregate data in a containment process. Through processing and analysis of the data, the containment process can be further improved. BRIEF DESCRIPTION OF DRAWINGS

[0007] The accompanying drawings, which constitute a part of this specification, illustrate embodiments of the present disclosure and serve to explain the principles of the present disclosure.

[0008] The disclosure can be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, in which:

[0009] Figure 1 An example environment in which embodiments of the disclosure can be implemented is shown.

[0010] Figure 2 A flow diagram of an example method according to embodiments of the disclosure is shown.

[0011] Figure 3 A screenshot of a graphical user interface for creating a part containment project is shown.

[0012] FIGS. 4A-4C show screenshots of a graphical user interface for configuring a work instruction.

[0013] Figure 5 A flow diagram of an approval process according to embodiments of the disclosure is shown.

[0014] Figure 6 A schematic diagram of a computing device according to embodiments is shown. DETAILED DESCRIPTION

[0015] The following description is provided to enable any person skilled in the art to implement and use the embodiments and is provided in the context of particular systems and in the context of specific configurations of those systems. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments and systems without departing from the spirit and scope of the embodiments. Thus, the present embodiments are not intended to be limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.

[0016] Figure 1 An example environment 1000 in which embodiments of the disclosure can be implemented is shown.

[0017] According to embodiments of the disclosure, the example environment 1000 can include a production area, shown by the dashed box. The production area can refer to a space used for producing industrial products. Examples of production areas include a final assembly plant of a manufacturing plant or other types of production plants.

[0018] According to embodiments of the disclosure, the production area can include a production line 1100. The production line 1100 can refer to a collection of mechanical equipment used for producing industrial products. The production line 1100 can receive one or more types of parts, process the parts, and output finished or semi-finished industrial products. Examples of production lines 1100 include a final assembly production line of an automobile plant or other types of production lines.

[0019] According to embodiments of the present disclosure, the example environment 1000 can include inventory devices 1200. The inventory devices 1200 can refer to one or more spaces, equipment, or facilities for storing various parts for industrial production. Examples of the inventory devices 1200 can include various racks, warehouses, warehousing facilities, and the like. The inventory devices 1200 can store various types of parts.

[0020] The inventory devices 1200 can include multiple types, such as a first type of inventory device 1210 and a second type of inventory device 1220. The first type of inventory device 1210 and the second type of inventory device 1220 can have different characteristics and purposes.

[0021] The first type of inventory device 1210 can be located near the production lines 1100 (e.g., in or near the production areas), so that it can directly provide parts for current production activities on the production lines 1100. The inventory in the first type of inventory device 1210 can be referred to as “just-in-time inventory.” Just-in-time inventory is typically small in quantity and is continuously consumed as production proceeds.

[0022] In contrast to the first type of inventory device 1210, the second type of inventory device 1220 can be located away from the production lines 1100. The second type of inventory device 1220 typically does not directly provide parts for the production lines 1100, but replenishes the first type of inventory device 1210. In addition, the second type of inventory device 1220 can receive newly supplied parts from one or more part suppliers 1300. The inventory in the second type of inventory device 1220 can be referred to as “non-just-in-time inventory.” In contrast to just-in-time inventory, non-just-in-time inventory is typically large in quantity. In addition, the consumption of non-just-in-time inventory is discrete (e.g., when the first type of inventory device 1210 is replenished periodically) rather than continuous.

[0023] Although Figure 1 Although only one first type of inventory device 1210 and one second type of inventory device 1220 are shown, in other embodiments, more than one first type of inventory device 1210 and / or more than one second type of inventory device 1220 can be provided. For example, each production area can include a respective first type of inventory device 1210 to meet the needs of one or more production lines in that production area. Each first type of inventory device 1210 can be replenished with parts from multiple second type of inventory devices 1220. Each second type of inventory device 1220 can replenish multiple first type of inventory devices 1210.

[0024] According to embodiments of the present disclosure, the example environment 1000 can include a computer platform 1400. The computer platform 1400 can be configured for inspecting and containing defective parts in the inventory device 1200, and preventing these defective parts from being used in the production line 1100. Herein, this process of inspecting and intercepting defective parts can be referred to as “containment”. One example of the computer platform 1400 can be the Quality Containment Information Platform (QCIP) of the BMW Brilliance joint venture automobile factory.

[0025] According to embodiments of the present disclosure, in order to achieve such containment, the computer platform 1400 can be configured to be able to communicate with the inventory device 1200 and / or the supplier 1300. In one aspect, the computer platform 1400 can be configured to be able to communicate with a device managing the inventory device 1200 and / or the supplier 1300, such as a SAP system managing the inventory device 1200. In another aspect, the computer platform 1400 can be configured to be able to communicate with personnel (not shown) managing or operating the inventory device 1200 and / or the supplier 1300, such as a terminal device (not shown) of these personnel.

[0026] According to embodiments of the present disclosure, the computer platform 1400 can be implemented in various suitable forms without limitation. For example, the computer platform 1400 can be implemented as a single computing device (e.g., a server). Alternatively, the computer platform 1400 can be implemented as a cluster of computing devices. In yet further embodiments, the computer platform 1400 can be implemented as a set of microservices running on one or more cloud computers. Figure 6 A block diagram of an example computing device that can be used to implement the computer platform 1400 is shown.

[0027] Figure 2 A flowchart of an example method 2000 according to embodiments of the present disclosure is shown. The example method 2000 can be used to implement containment of defective parts. According to embodiments of the present disclosure, the example method 2000 can be performed, for example, by the computer platform 1400 of Figure 1 the Brilliance BMW joint venture automobile factory.

[0028] According to embodiments of the present disclosure, the example method 2000 can start from step 2100. In step 2100, the computer platform 1400 can be configured to receive a trigger signal. The received trigger signal can indicate that a defective part of a particular type exists. The trigger signal can contain information indicating the part type and information indicating the defect type. For example, the trigger signal can indicate that a rearview mirror part of an automobile has a mirror crack.

[0029] According to embodiments of the present disclosure, the computer platform 1400 can receive various trigger signals from various sources without limitation. As further described below, the computer platform 1400 can take different actions depending on the different sources of the trigger signals.

[0030] In one example, a first trigger signal can be provided by a production line (e.g., the production line 1100) that consumes a particular type of part. For example, in response to finding defects in the particular type of part, a worker of the production line can report such defects to the computer platform 1400. Accordingly, the computer platform 1400 can consider that a corresponding first trigger signal is received. In particular, in response to the number or proportion of the particular type of part with defects exceeding a predetermined threshold, the computer platform 1400 can consider that the first trigger signal is received, thereby initiating a containment process for the particular type of part.

[0031] In another example, a second trigger signal can be provided by a supplier (e.g., the supplier 1300) that supplies the particular type of part. For example, the supplier can find defects in the particular type of part when conducting quality inspection on the parts it supplies. Accordingly, the supplier can report such defects to the computer platform 1400 of a customer that purchased the same type and / or batch of parts. Accordingly, the computer platform 1400 can consider that the second trigger signal is received, thereby initiating a containment process for the particular type of part.

[0032] In other examples, the computer platform 1400 can receive other trigger signals from other sources. For example, the parts in the inventory devices 1210 and / or 1220 can be periodically subjected to spot checks. In response to finding defects in the particular type of part in the spot checks, a trigger signal can be sent by the inventory device 1200 (or its associated personnel) to the computer platform 1400.

[0033] According to embodiments of the present disclosure, the example method 2000 can then proceed to step 2200. In step 2200, the computer platform 1400 can create a part containment project based on the received trigger signal. The part containment project can refer to a project for containing defective parts, which can include a collection of associated data and metadata. The collection of data and metadata is structured into specific data structures and executable files, so that it can be created, edited, stored, opened, transmitted, and presented on various computing devices.

[0034] According to embodiments of the present disclosure, creating the part containment project can include receiving one or more information associated with the part containment project. Figure 3 A screenshot 3000 of a graphical user interface (GUI) for creating a part containment project is shown. As shown, the GUI can include a project name field 3002, a project description field 3004, a project type field 3006, a project status field 3008, a project priority field 3010, a project owner field 3012, a project start date field 3014, a project end date field 3016, a project location field 3018, a project contact field 3020, a project notes field 3022, and a project documents field 3024. Figure 3As shown, to create a part containment project, computer platform 1400 can receive one or more of a first set of information 3100, a second set of information 3200, and a third set of information 3300. In screenshot 3000, the different sets of information are separated by straight lines. The information can be input by a user and / or loaded by computer platform 1400 from a file.

[0035] The first set of information 3100 can be required information to create a part containment project. Each field in the required information is marked with an “*” symbol. By way of example and not limitation, Figure 3 The first set of information 3100 can include one or more of a Plant, a Technology, a Project Category, a Project Name, a Sensor, a Containment Reason, a Send Approve Type. In other embodiments, the first set of information 3100 can contain different, more, or less information than what is listed here without limitation. Computer platform 1400 must receive all of the required information before it can create a part containment project.

[0036] The second set of information 3200 can be optional information to create a part containment project. Each field in the second set of information 3200 is marked with a “#” symbol, and can be considered information that can be required based on the type of project. For some types of part containment projects (e.g., Official projects), the second set of information 3200 can be required. For another type of part containment project (e.g., Temp projects), the second set of information 3200 can not be required. By way of example and not limitation, Figure 3 The second set of information 3200 can include one or more of a Commodity, a SRI Set up, a SRI Nr, an Expect Stop, Expect Stop Comments. In other embodiments, the second set of information 3200 can contain different, more, or less information than what is listed here without limitation. It is advantageous to require different required information for different types of projects, which can improve the flexibility and efficiency of containment projects.

[0037] The third set of information 3300 can be additional optional information to create a part containment project. The additional optional information is not required, but can facilitate the configuration of the project. By way of example and not limitation, Figure 3The third set of information 3300 in the containment initial evaluation (Containment Initial Evaluation), the project close time (Project Close), the project start time (Project start), the actual days (Actual Days), the project duration (Project Duration), the project type (Temp / Official) can include one or more of. In other embodiments, the third set of information 3300 can contain different, more or less information than that listed here without limitation.

[0038] According to embodiments of the present disclosure, when creating a part containment project, the computer platform 1400 can first receive the first set of information 3100. Further, the computer platform 1400 can classify the part containment project as a first project type or a second project type based on the received first set of information 3100. For example, if the “send approval type” in the received first set of information 3100 indicates that a complex approval is required, the part containment project can be classified as a first project type, which indicates an official project. If the “send approval type” in the received first set of information 3100 indicates that a simple approval is required, the part containment project can be classified as a second project type, which indicates a temporary project.

[0039] According to embodiments of the present disclosure, an official project allows a longer processing period and requires perfect project information. The official project is particularly suitable for containment of parts in a large quantity (e.g., tens of thousands of parts) or non-urgent containment. Due to the involvement of a large quantity of parts, perfect project information can be advantageous, which can provide the most information for analysis and traceability. Therefore, in response to classifying the part containment project as an official project, the computer platform 1400 can require receiving the second set of information 3200 to complete the creation of the project. In addition, an official project will consume more resources (manpower, time, resources). Therefore, in order to prevent the establishment of false or incorrect projects from wasting resources, the computer platform 1400 can also verify one or more of the received first set of information 3100 and the second set of information 3200. For example, the computer platform 1400 can send the received information (e.g., part number, etc.) to the SAP system for comparison to verify, and only after successful verification, the project is created.

[0040] According to embodiments of the present disclosure, the temporary project can be an emergency containment, or involve only a small number of parts. Temporary projects can require light and fast handling, and thus can not require perfect project information. In response to classifying the part containment project as a temporary project, the computer platform 1400 can complete creation of the project without requiring receipt of the second set of information 3200. This can save time for the user to collect the second set of information 3200, and thus can move the project along more quickly.

[0041] Additionally or alternatively, the computer platform 1400 can classify the part containment project in conjunction with one or more factors in addition to the first set of information 3100.

[0042] In one example, the computer platform 1400 can classify the part containment project based on a particular type of defective part. The computer platform 1400 can determine whether the defective part is a critical part of industrial production based on the type of defective part indicated by the trigger signal. If the particular type indicates a non-critical part, the computer platform 1400 can classify the part containment project as a formal project. If the particular type indicates a critical part, the computer platform 1400 can classify the part containment project as a temporary project, enabling fast containment of critical parts.

[0043] In one example, the computer platform 1400 can classify the part containment project based on a current inventory quantity of the particular type of part. The computer platform 1400 can retrieve the current inventory quantity of the particular type of part from the SAP system, including the current inventory quantity of each of the first type of inventory device and the second type of inventory device. If the current inventory quantity is below a predetermined threshold, the potential defective part can soon enter the production line. In this case, the part containment project can be classified as a temporary project, enabling fast containment of high-risk parts. If the current inventory quantity is not below the predetermined threshold, the part containment project is classified as a formal project. Preferably, the part containment project can also be classified as a formal project or a temporary project based on both the current inventory quantity of the particular type of part and a nominal inventory consumption rate. Specifically, if the current inventory quantity is low and the nominal inventory consumption rate is high, the part containment project will be classified as a temporary project.

[0044] In one example, the computer platform 1400 can classify the part containment project based on a type of trigger signal. If the trigger signal is a first trigger signal from the production line, it indicates that the defective part has already entered the production line. In this case, the part containment project can be classified as a temporary project, enabling fast containment of high-risk parts. If the trigger signal is a second trigger signal from a supplier, it indicates that the defective part can still have some time before entering the production line. In this case, the part containment project can be classified as a formal project.

[0045] According to embodiments of the present disclosure, the example method 2000 can then proceed to step 2300. In step 2300, the computer platform 1400 can configure a working instruction (WI) for inspecting a plurality of parts of a particular type in the inventory for defects for the created part containment project. The “working instruction” herein can include one or more procedural steps and / or parameters that describe how to inspect the defects of the parts of the particular type. FIGS. 4A-4C show screenshots 4000a-4000c of a graphical user interface (GUI) for configuring the working instruction.

[0046] As shown in FIG. 4A, to configure the working instruction, the computer platform 1400 can receive one or more of a first set of information 4100, a second set of information 4200, and a third set of information 4300. These information can be inputted by a user or read by the computer platform 1400 from a file. The first set of information 4100 represents information necessary to configure the working instruction, marked with “*”. The second set of information 4200 represents optional information to configure the working instruction, marked with “#”. The second set of information 4200 is required to be further configured for a formal project. The second set of information 4200 can not be configured for an interim project. The third set of information 4300 represents additional optional information to configure the working instruction, which can be optional for both a formal project and an interim project. Figure 3 Similarly, the first set of information 4100 represents information necessary to configure the working instruction, marked with “*”. The second set of information 4200 represents optional information to configure the working instruction, marked with “#”. The second set of information 4200 is required to be further configured for a formal project. The second set of information 4200 can not be configured for an interim project. The third set of information 4300 represents additional optional information to configure the working instruction, which can be optional for both a formal project and an interim project.

[0047] As shown in FIG. 4B, to configure the working instruction, the computer platform 1400 can receive a part picture that describes the part of the particular type. The part picture can be one or more pictures or videos of the part of the particular type. The part picture can be included in the working instruction. This facilitates quick identification of the part of the particular type from a large number of parts in the inventory device when performing the inspection.

[0048] As also shown in FIG. 4B, to configure the working instruction, the computer platform 1400 can also receive a gauge picture and / or a tool picture that describe taking measurements of the part of the particular type. The gauge picture and the tool picture can also be included in the working instruction to facilitate selection of appropriate tools for taking correct measurements when performing the inspection.

[0049] As shown in FIG. 4C, to configure the work instruction, the computer platform 1400 can also receive a description of one or more steps of the containment process. The description of each step can include one or more of a number (No), a photo (Photo), a description (Description), a risk (Risk), a remark (Remark). In this way, a coherent and detailed standardized procedure can be formed. The standardized procedure can be included in the work instruction, thereby providing specific operation specifications for the inspection of the part.

[0050] In addition to the specific embodiments shown in FIGS. 4A-4C for configuring the work instruction, other configurations of the work instruction are available. For example, the computer platform 1400 can configure a defect list for a specific type of part and include the defect list in the generated work instruction. In this way, the defect list can be presented on the terminal device of the inspector, so that the inspector can input defects of the part by selection when performing the inspection, without having to input characters. This can significantly improve the efficiency of the inspection when performing the inspection on a large number of parts.

[0051] According to embodiments of the present disclosure, the computer platform 1400 can generate the configured work instruction described above as a work instruction data structure. The work instruction data structure can contain various data associated with the configured work instruction. The work instruction data structure can be stored, modified, read, transmitted by the computer platform 1400. The computer platform 1400 can transmit the work instruction data structure to one or more terminal devices associated with each of the trainer or the inspector. The work instruction data structure configured by the computer platform 1400 ensures that each inspector performs the same containment process, improving the degree of standardization of the containment process.

[0052] According to embodiments of the present disclosure, the example method 2000 can then proceed to step 2400. In step 2400, the computer platform 1400 can receive containment data. The computer platform 1400 can receive the containment data from the inspector (e.g., the associated terminal device) performing the containment process. The containment data is obtained by performing the work instruction configured in step 2300 to inspect defects of a plurality of parts of a specific type in the inventory. The containment data can indicate information related to one or more parts of the plurality of parts having defects. The computer platform 1400 can analyze the containment data and take one or more further actions.

[0053] According to optional embodiments of the present disclosure, the example method 2000 can also include one or more optional steps.

[0054] In an optional embodiment, after obtaining the work instruction in step 2300, the computer platform 1400 can further perform an approval process. Specifically, the computer platform 1400 can send one or more approval requests to one or more roles associated with the created part containment project and / or the work instruction. The computer platform 1400 can receive confirmation of each of the one or more approval requests. In response to receiving the confirmation of each of the one or more approval requests, the computer platform 1400 can initiate the execution of the work instruction. If any of the one or more approval requests is not approved by the corresponding role, the computer platform 1400 can return to step 2200 or step 2300 to reconfigure the information of the part containment project and / or the work instruction. The approval process can enable the corresponding roles in the system to be aware of the occurrence of the containment process. Moreover, the best work instruction can be obtained through the approval process, as described below.

[0055] Figure 5 A flowchart of an approval process 5000 according to an embodiment of the present disclosure is shown. The approval process 5000 can be performed by the computer platform 1400. In Figure 5 the example, the approval process 5000 can involve multiple roles, including an outsourcing party engineer, an outsourcing party project manager, an outsourcing party manager, a factory QMT (quality management test) specialist, and a factory QMT manager. Among them, the outsourcing party engineer, the outsourcing party project manager, and the outsourcing party manager belong to outsourcing personnel performing the containment process, while the factory QMT specialist and the factory QMT manager belong to personnel of the production factory. The outsourcing party engineer is responsible for interacting with the computer platform 1400 to configure the containment project or the work instruction. It should be understood that more or fewer roles can be involved in other embodiments.

[0056] In step 5100, the computer platform 1400 can configure the part containment project or the work instruction. This step can correspond to step 2200 or step 2300 of Figure 2 .

[0057] Then, in step 5200, the computer platform 1400 can determine whether the configured part containment project or the work instruction belongs to a specific type. Based on the specific type, the computer platform 1400 can take corresponding subsequent steps.

[0058] In an embodiment, the computer platform 1400 can determine whether the part containment project belongs to a formal project. If the part containment project belongs to a formal project, a complex approval process can be adopted. Otherwise, a simple approval process can be adopted.

[0059] In another embodiment, the computer platform 1400 can determine whether the part involved in the project can cause the entire product (e.g., a car) to be returned for repair. For example, if the part involved in the project is a spray paint coating, a defect in the spray paint coating can cause the entire vehicle to be returned for repair. In this case, a complex approval process can be employed. If the part involved in the project is an external bolt, a defect in the external bolt can not cause the entire product to be returned for repair. In this case, a simple approval process can be employed.

[0060] Therefore, the step 5200 can achieve a balance between the security and flexibility of the containment process.

[0061] In the complex approval process, the approval of each of the outsourcer project manager, the outsourcer manager, the factory QMT specialist, and the factory QMT manager is required. In the simple approval process, the approval of only the outsourcer project manager and the factory QMT specialist can be required. The computer platform 1400 can send an approval request to each according to the described process, and send an approval request to the next one after receiving the approval. If all the required personnel in any approval process give the approval, the approval process 5000 can end. If there is any personnel who does not give the approval among all the required personnel in any approval process, the approval process 5000 can return to the step 5100. In this step 5100, the project or work instruction can be reconfigured and the approval process can be re-performed. For example, the outsourcer engineer can modify the project or work instruction based on the suggestion or comment of the role that does not give the approval, and re-enter the step 5200. Figure 5

[0062] According to an optional embodiment of the present disclosure, after obtaining the approval (in some embodiments, it can also not be necessary to obtain the approval), the computer platform 1400 can start the execution of the work instruction. Starting the execution of the work instruction can include assigning a training personnel for the execution of the work instruction, and instructing the training personnel to train an inspection personnel based on the work instruction. The inspection personnel is usually an outsourcer personnel. The computer platform 1400 can distribute the configured work instruction to the training personnel and the inspection personnel. Additionally, starting the execution of the work instruction can also include receiving a confirmation that the inspection personnel has received the training, and instructing the inspection personnel to perform the inspection based on the work instruction. In this way, the computer platform 1400 can confirm that all the inspection personnel have received the training of the work instruction, thereby guaranteeing the standardized operation of the containment process.

[0063] ​In response to receiving the indication from the computer platform 1400, the trained inspectors can perform the inspection on the inventory parts in the inventory device. The inspectors can identify the corresponding parts in the inventory device, perform the inspection on the parts, and collect the inspection results according to the procedure described in the work instruction. Specifically, for each of the plurality of parts being inspected, the inspectors can inspect the part based on the work instruction to determine whether the part has a defect. In response to determining that the part has a defect, the inspectors can remove the part from the inventory tote, increase the count of defective parts in the inventory tote, and record the number of the inventory tote and / or the number of the part. Since each inspector performs the inspection according to the same work instruction, the standardized operation of the containment process can be guaranteed.

[0064] According to embodiments of the present disclosure, to avoid the defective parts flowing into the production line as much as possible, the computer platform 1400 can instruct to first inspect the ready-to-use inventory in the inventory device (e.g., the inventory device 1210) located near the production line, and then inspect the non-ready-to-use inventory in the inventory device (e.g., the inventory device 1220) located far away from the production line. In this way, the defective parts in the ready-to-use inventory can be excluded as soon as possible, thereby minimizing the number of defective parts flowing into the production line.

[0065] According to embodiments of the present disclosure, the inspection on the ready-to-use inventory can include recording a break point. The break point can be associated with: the number of the last product produced using the particular type of parts before the inspection starts; and / or the number of the particular type of parts used by the last product. For example, in the final assembly shop of an automobile factory, the frame number can be recorded as the number of the product. The products produced after the break point are all produced using the inspected parts, which do not have to go through further inspection. Whereas the products produced before the break point are produced using the un-inspected parts, which can need to go through further inspection. Therefore, the computer platform 1400 can trace back to a subset of the plurality of industrial products produced by the production line based on the recorded break point, without having to perform further inspection on each of the industrial products.

[0066] According to embodiments of the present disclosure, the work instructions configured for the containment process can be adjusted based on the evaluation of the containment process. For example, an escape rate of the inspection can be determined based on the spot check of the inspected parts. The escape rate refers to the proportion of the escaped parts. The escaped parts refer to the parts that have defects but are not removed from the inventory by the inspectors. The computer platform 1400 can receive the escape rate of the inspection and determine to update the work instructions based on a comparison of the escape rate with a predetermined threshold. For example, if the escape rate exceeds the predetermined threshold, the work instructions can be updated in a direction to reduce the escape rate. Optionally, the updated work instructions can be subjected to the approval process again. Then, the subsequent inspection or a new inspection can be performed based on the updated work instructions. Since the updated work instructions typically do not change too much, retraining of the inspectors is generally not needed, and the updated work instructions can be directly distributed to the inspectors by the computer platform 1400. Accordingly, the computer platform 1400 can receive the containment data generated based on the performance of the updated work instructions from the inspectors. In this way, the evaluation, feedback, and update of the containment process can be flexibly implemented.

[0067] According to embodiments of the present disclosure, the computer platform 1400 can take one or more actions based on receiving the containment data. For example, the computer platform 1400 can calculate defect statistics. The defect statistics can include the proportion of the defective parts among the inspected parts, which can be referred to as a defect rate.

[0068] In one use case, the defect rate can be used to predict the number of defective parts (or alternatively, the number of non-defective parts) in the inventory that has not been inspected. The rate of replenishing the inventory device (e.g., the inventory device 1210) near the production line with parts can be adjusted based on the defect rate and / or the predicted number. This way is meaningful. Because the inventory quantity of certain types of parts can be very large, it can take a long time (e.g., days or even weeks) to complete the entire containment process. During this period, it is necessary to adjust the rate of replenishing the inventory device near the production line with parts based on the predicted defect rate to ensure that the production line always has enough non-defective parts. Specifically, in response to an increase in the defect rate, the computer platform 1400 can instruct to increase the rate of replenishing the inventory device 1210 with parts to ensure that there are enough non-defective parts in the inventory device 1210 to support the usual consumption rate of the production line.

[0069] In another use case, the defect rate can be used to terminate execution of a containment project for a part. In normal circumstances, a part is allowed to have a lower defect rate that does not pose a significant risk to production. Thus, in response to determining that the defect rate is below a predetermined threshold (e.g., the allowed lower defect rate), the computer platform 1400 can end the associated containment project for the part. Ending the associated containment project for the part includes closing the project file and / or instructing the inspector to stop inspecting the un-inspected inventory parts.

[0070] In yet another use case, the computer platform 1400 can also generate visualizations based on the containment data to provide a basis for personnel decision making, analysis, and reporting.

[0071] In yet another use case, the computer platform 1400 can also initiate a claim to a supplier based on the containment data.

[0072] Figure 6 A schematic diagram of a computing device 6000 is shown, in accordance with an embodiment. The computing device 6000 can be used to implement the computer platform 1400 of the present disclosure. The computing device 6000 can be implemented as a server, a computer, a tablet, a smartphone, a wearable device, etc. The computing device 6000 can include a communication module 6100, a storage module 6200, and a processing circuit 6300.

[0073] According to an embodiment, the communication module 6100 can perform communication of the computing device 6000 with other devices. According to an embodiment, the communication module 6100 can be adapted to different wired or wireless communication protocols, including but not limited to various Ethernet communications, fiber optic communications, cellular communications, Bluetooth, Wi-Fi, etc. According to an embodiment, the communication module 6100 can be implemented, for example, as an antenna device, radio frequency circuitry, and partial baseband processing circuitry, etc. communication interface components. The communication module 6100 is drawn with a dashed line because it can also be located within the processing circuit 6300 or outside of the computing device 6000.

[0074] According to an embodiment, the storage module 6200 can store information generated by the processing circuit 6300, information received by the communication module 6100 from other devices, programs, machine code, and data used for operation of the computing device 6000, etc. The storage module 6200 is drawn with a dashed line because it can also be located within the processing circuit 6300 or outside of the computing device 6000. The storage module 6200 can be a volatile memory and / or a non-volatile memory. For example, the storage module 6200 can include, but is not limited to, a random access memory (RAM), a dynamic random access memory (DRAM), a static random access memory (SRAM), a read only memory (ROM), and a flash memory.

[0075] According to embodiments, the processing circuit 6300 can be used to implement various functions of the computing device 6000. According to embodiments, the computing device 6000 can be implemented as the computer platform 1400. Accordingly, the processing circuit 6300 can perform the corresponding methods and functions described herein. The processing circuit 6300 can be implemented as one or more processors, integrated circuits, field-programmable gate arrays, etc. The processing circuit 6300 can execute computer program or instructions to perform one or more methods and functions described in the present disclosure.

[0076] The present disclosure can be implemented as a system, method, and / or computer program product. The computer program product can include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present disclosure.

[0077] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium can be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.

[0078] Computer readable program instructions described herein can be downloaded to respective computing / processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and / or a wireless network. The network can comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and / or edge servers. A network adapter card or network interface in each computing / processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing / processing device.

[0079] Computer readable program instructions for carrying out operations of the present disclosure can be assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state setting data, or any combination of one or more of the above, or in any combination of source code with object code, or in any combination of source code with object code generated from the source code, or in any combination of the above with source code and object code, written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The computer readable program instructions can execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer can be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection can be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) can execute the computer readable program instructions by utilizing state information of the computer readable program instructions to customize the electronic circuitry, in order to perform aspects of the present disclosure.

[0080] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems) and computer program products according to embodiments. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0081] These computer readable program instructions can be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions can also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0082] The computer readable program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0083] The computer readable program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0084] Those skilled in the art will further appreciate that the various operations illustrated in the figures can not be performed in the sequence illustrated. In some embodiments, the order of the operations can be different, and / or two or more operations can be performed at the same time. Those skilled in the art will also appreciate that the various embodiments described herein can be implemented using special purpose hardware, software, or a combination of special purpose hardware and software. In some embodiments, the operations illustrated in the figures can be performed by one or more computers, one or more servers, one or more cloud computing resources, or any combination thereof.

[0085] The description of various embodiments of the disclosure has been presented for purposes of illustration but is not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A method performed by a computing device, comprising: receiving a trigger signal, the trigger signal indicating that a particular type of part is defective; based on the trigger signal, creating a part containment project, including classifying the part containment project as a first project type or a second project type, the classifying including: in response to the trigger signal being provided by a supplier that supplies the particular type of part, classifying the part containment project as the first project type, the first project type requiring a lower level of processing urgency; and in response to the trigger signal being provided by a production line that consumes the particular type of part, classifying the part containment project as the second project type, the second project type requiring a higher level of processing urgency; for the part containment project, configuring a work instruction for inspecting a plurality of parts of the particular type in inventory for defects; and receiving containment data, the containment data being obtained by performing the work instruction to inspect the plurality of parts of the particular type in inventory for defects, the containment data indicating information related to one or more of the plurality of parts that are defective.

2. The method of claim 1, wherein, creating the part containment project includes receiving a first set of information associated with the part containment project; and the method further comprises: based on at least the first set of information, classifying the part containment project as the first project type or the second project type; for the first project type, requiring receipt and verification of an additional second set of project information; and for the second project type, not requiring receipt of an additional second set of project information.

3. The method of claim 2, wherein, classifying the part containment project as the first project type or the second project type is further based on one or more of: the particular type of part; or a current inventory quantity of the particular type of part.

4. The method of claim 1, wherein, prior to the work instruction being performed, the method further comprises: sending one or more approval requests; and receiving confirmation of each of the one or more approval requests; and in response to receiving confirmation of each of the one or more approval requests, initiating performance of the work instruction.

5. The method of claim 4, wherein, initiating performance of the work instruction includes: assigning a trainer for performance of the work instruction; instructing the trainer to train an inspector based on the work instruction; receiving confirmation that the inspector has been trained; and instructing the inspector to perform the inspection based on the work instruction.

6. The method of claim 1, wherein, performing the work instruction to inspect the plurality of parts of the particular type in inventory for defects includes: for each of the plurality of parts: based on the work instruction, inspecting the part to determine whether the part is defective; in response to determining that the part is defective: removing the part from an inventory tote; increasing a count of defective parts in the inventory tote; and recording a number of the inventory tote and / or a number of the part.

7. The method of claim 1, further comprising: receiving an escape rate of the inspection; based on a comparison of the escape rate to a predetermined threshold, determining to update the work instruction; and ​ Receiving containment data generated based on execution of the updated work instruction.

8. The method of claim 1, wherein, The inventory includes: a just-in-time inventory located near a production line that consumes the particular type of part; and / or a non-just-in-time inventory located away from the production line.

9. The method of claim 8, wherein, Executing the work instruction to inspect the particular type of the plurality of parts in inventory for defects includes: inspecting the just-in-time inventory first, and then inspecting the non-just-in-time inventory.

10. The method of claim 9, wherein, Inspecting the just-in-time inventory includes recording a breakpoint associated with: a number of a last product produced using the particular type of part before the inspection started; and / or a number of the particular type of part used for the last product; and The method further includes: based on the breakpoint, tracing a subset of a plurality of products produced by the production line.

11. The method of claim 1, wherein, The method further includes: calculating a defect rate for the particular type of part based on the containment data; ending the part containment project in response to the defect rate being below a predetermined threshold.

12. A computing device comprising one or more hardware processors and memory storing a computer program that, when executed by the one or more hardware processors, causes the one or more hardware processors to perform the method of any of claims 1-11.

13. A computer program product comprising a computer program that, when executed by one or more hardware processors, causes the one or more hardware processors to perform the method of any of claims 1-11.

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