Batch Traceability Estimation Across Unsequenced Manufacturing Processes
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Solution Overview
Problem
Existing systems face challenges in estimating traceability for products that are not individually managed, particularly in manufacturing processes where the sequence between processes is not ensured, leading to difficulties in defect and quality analysis due to collective batch management and unclear batch correspondence.
Innovation Solution
An analysis system with a traceability estimation unit that generates batch combination output data by associating batches across processes using feature data, enabling the estimation of traceability even without individual product management and ensuring manufacturing sequence, through a system comprising a handy terminal, sensor, quality measuring device, and analysis server connected via a network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual management of each batch is not performed and collective management number is used, then ease of operation is improved, but measurement precision of traceability deteriorates
Solution Approach 1:
The patent segments the collective management number into multiple management numbers, each corresponding to specific batches. This segmentation allows the system to maintain ease of operation by using management numbers while improving traceability precision by enabling specific batch identification when needed, resolving the contradiction between operational simplicity and measurement precision.
2Productivity
If manufacturing sequence between processes is not ensured, then productivity is improved, but reliability of traceability estimation deteriorates
Solution Approach 1:
The patent changes the parameters used for traceability estimation from time-based sequences to feature-based comparisons. By using features such as production conditions, material properties, and process parameters instead of relying on manufacturing sequence, the system maintains high productivity while improving the reliability of traceability estimation even when batches are produced in parallel or out of sequence.
3Measurement precision
If feature comparison method is used for traceability estimation, then measurement precision of batch correspondence is improved, but device complexity increases
Solution Approach 1:
The patent implements a multi-functional analysis system where the same feature comparison mechanism serves multiple purposes: traceability estimation, quality analysis, and defect analysis. By making the system universal and capable of performing multiple functions with a single feature comparison mechanism, the patent improves measurement precision while minimizing the increase in device complexity.
Data Source
AI summary
A traceability estimation unit generates batch combination output data configured by a plurality of combinations of a batch in the first process and a batch in the second process, and the feature of the batch. The traceability estimation unit estimates the combination of the batch in the first process and the batch in the second process, which is used as traceability, from the plurality of the combinations of the batches in the batch combination output data by using the feature.