Defect Data Issue Items for Root Cause Analysis
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Solution Overview
Problem
Conventional methods for managing manufacturing process defects are inefficient, leading to improper identification and handling of defects, and often fail to identify the root causes due to the lack of effective systems for analyzing large volumes of defect data.
Innovation Solution
A computer-based system that stores and analyzes defect data objects, generates issue items based on user input, determines similarity between data objects, and includes candidate defect data objects to identify potential responsible parameters, facilitating the determination of root causes through a graphical user interface and user interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If conventional defect management methods are used, then defect data can be stored in databases, but root causes cannot be identified due to lack of analysis systems
Solution Approach 1:
The patent introduces an issue item as an intermediary data structure that connects multiple defect data objects. This issue item serves as a mediator that groups related defects together, enabling systematic analysis of defect patterns and relationships without requiring complex analysis systems. The issue item acts as a bridge between raw defect data and root cause identification.
Solution Approach 2:
The patent segments the defect management process into distinct components: defect data objects (individual defect records), issue items (grouped defects with potential root causes), and parameter associations (links between defects and manufacturing parameters). This segmentation allows for manageable analysis of large volumes of defect data by breaking down the complex problem into smaller, analyzable units.
2Quantity of substance
If large volumes of defect data are recorded, then comprehensive defect information is available, but efficiency decreases due to inability to properly identify and handle defects
Solution Approach 1:
The patent merges multiple individual defect data objects into a single issue item when they share common characteristics or potential root causes. This combining process reduces the complexity of analyzing large volumes of defects by grouping them into manageable clusters, thereby improving defect management efficiency while retaining comprehensive defect information.
Solution Approach 2:
The patent creates issue items as simplified representations or copies of groups of defect data objects. Instead of analyzing each individual defect record separately, the system creates condensed issue item representations that capture the essential characteristics and relationships, enabling efficient analysis of large defect volumes without losing critical information.
3Measurement precision
If defect data objects are grouped into issue items, then root cause analysis becomes possible, but user interaction complexity increases
Solution Approach 1:
The patent implements self-service functionality where the system automatically performs similarity comparisons between defect data objects and generates candidate issue items without requiring extensive manual user intervention. The system autonomously identifies potential groupings and presents them to users for confirmation, reducing the operational burden while maintaining high root cause identification accuracy.
Solution Approach 2:
The patent incorporates feedback mechanisms where users can review generated issue items and candidate groupings, provide corrections or confirmations, and the system learns from this feedback to improve future automatic grouping accuracy. This feedback loop maintains ease of operation by allowing users to work with pre-generated suggestions rather than manually creating issue items from scratch.
Data Source
AI summary
Systems are provided for managing defect data objects. A system stores a plurality of defect data objects that have been input to the system, and generates an issue item including one or more defect data objects that are selected from the stored defect data objects based on user input. The system determines similarity between the one or more defect data objects in the issue item and one or more of the stored defect data objects that are out of the issue item, based on comparison of one or more parameter values. The system determines one or more candidate defect data objects to be included in the issue item from the one or more of the stored defect data objects that are out of the issue item based on the similarity, and includes one or more of the determined candidate defect data objects in the issue item based on user input.