Board Production Tracking for Real-Time Quality Feedback
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Solution Overview
Problem
The production of boards often results in a significant amount of fall-out due to unpredictable combinations of parameters affecting quality, making it difficult to identify and address the specific causes of inferior quality, and reducing fall-out is challenging without slowing down production.
Innovation Solution
A method where each board is linked to an ID tag containing detailed production parameters, allowing for real-time monitoring and optimization using artificial intelligence, enabling direct quality feedback and adaptive production adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If production speed is maintained at high levels, then productivity is improved, but fall-out increases due to inability to identify and correct quality issues in real-time
Solution Approach 1:
The patent implements a feedback system where ID tags attached to boards carry production parameters through all production stages. Measuring devices read these tags and feed quality data back to the control system in real-time, enabling immediate detection and correction of quality deviations without slowing down production.
Solution Approach 2:
The patent replaces traditional mechanical quality inspection methods with an automated system combining ID tags, optical/electronic measuring devices, and computer-controlled parameter adjustment. This substitution enables real-time quality monitoring and correction that maintains high production speeds while improving quality consistency.
2Manufacturing precision
If production parameters are monitored and adjusted in real-time, then manufacturing precision is improved, but device complexity increases due to additional ID tags and measuring devices
Solution Approach 1:
The ID tags serve multiple functions: they identify individual boards, store production parameters, and enable tracking through all production stages. The measuring devices also perform multiple roles by reading ID tags, detecting quality parameters, and communicating with the control system, thereby reducing the need for separate dedicated components for each function.
Solution Approach 2:
The patent utilizes changes in measurable parameters (dimensions, density, moisture content) of the boards during production as indicators of quality. By monitoring these natural parameter variations and comparing them against target values, the system achieves precise quality control without requiring complex specialized sensing equipment for each quality attribute.
3Reliability
If fall-out is reduced through traditional methods by lowering production speed, then quality control improves, but productivity decreases
Solution Approach 1:
The system performs preliminary quality assessment by continuously monitoring production parameters and comparing them against predetermined quality criteria during the production process itself. This allows potential quality issues to be detected and corrected before they result in defective boards, eliminating the need for post-production sorting and reducing fall-out without lowering production speed.
Solution Approach 2:
The real-time feedback loop enables immediate corrective action when quality deviations are detected. The control system automatically adjusts production parameters based on feedback from measuring devices, preventing the development of quality defects that would otherwise require production slowdowns or stoppages for manual intervention.
Data Source
Figure 1
AI summary
A method for producing boards, wherein raw material (6) is provided and production steps are performed to obtain said boards, with half products formed during said production steps, wherein the productions steps comprise at least the following production steps: -a basic step wherein at least said raw material (6) is transported to a shaping unit (1); -a shaping step, wherein said raw material (6) is formed into plate shaped material to form a plate shaped half product (7); -a sawing step wherein said plate shaped half product (7) is sawn to board shaped half products (8); wherein these board shaped half products (8) are formed into respective boards, wherein, a number of boards is linked to a respective ID tag or comprises a respective ID tag, wherein said ID tags comprise individual data about parameters relating to production steps of said respective boards.