Inspection Record Diagrams for Balancing False Rejects and Escapes
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Solution Overview
Problem
Existing techniques for setting inspection criteria in intermediate processes of a production line are complex and impractical, requiring reference to information from multiple intermediate inspections, which can lead to false rejection and false acceptance, affecting inspection efficiency and accuracy.
Innovation Solution
An inspection management system that displays inspection data and results, including an inspection record diagram, to facilitate the setting of criteria by showing the presence or absence of defective products across intermediate inspections, allowing users to intuitively evaluate and adjust criteria to minimize false rejections and acceptances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stricter inspection criteria are set to reduce false acceptance, then false acceptance decreases, but false rejection increases
Solution Approach 1:
The system dynamically adjusts inspection criteria based on process stability and defect patterns rather than using fixed thresholds. The inspection criterion changing unit modifies criteria in real-time according to process conditions, allowing the system to maintain high reliability while reducing false rejections through adaptive rather than static decision boundaries
Solution Approach 2:
The system changes inspection parameters (criteria thresholds) based on process stability indicators and defect analysis. By monitoring process variations and adjusting criteria parameters accordingly, the system optimizes the balance between detecting true defects and avoiding false rejections of acceptable products
2Productivity
If more lenient inspection criteria are set to reduce false rejection, then false rejection decreases, but false acceptance increases
Solution Approach 1:
The system uses feedback from process stability monitoring and defect pattern analysis to continuously optimize inspection criteria. By incorporating feedback loops that analyze inspection results and process variations, the system adjusts criteria to maintain appropriate stringency without excessive false rejections or false acceptances
Solution Approach 2:
The system performs preliminary analysis of process stability and defect patterns before setting inspection criteria. By pre-assessing process conditions and potential defect modes, the system establishes appropriate criteria thresholds in advance that prevent both false rejections and false acceptances
3Measurement precision
If inspection criteria are set based on multiple intermediate inspections, then inspection accuracy improves, but system complexity increases
Solution Approach 1:
The system merges information from multiple intermediate inspections and process data into a unified inspection criterion decision. By combining data from various inspection points and process parameters into a single integrated evaluation, the system achieves high accuracy without requiring complex manual coordination of multiple separate criteria sets
Solution Approach 2:
The inspection criterion changing unit acts as an intermediary that processes and synthesizes data from multiple intermediate inspections. This mediator component simplifies the complexity by automatically integrating multiple data sources and translating them into unified, easy-to-manage inspection criteria
Data Source
AI summary
An inspection management system manages, in a production line for a product including a plurality of processes, a final inspection for a product finished through the plurality of processes and a plurality of intermediate inspections before the final inspection. The production line includes a plurality of manufacturing apparatuses and a plurality of inspection apparatuses corresponding to the plurality of processes. The inspection management system includes an inspection data obtainer, an inspection result obtainer, and an inspection setting supporter that generates an inspection record diagram showing, as information about an inspection item in one of the plurality of intermediate inspections, a presence or an absence of a product determined defective in the final inspection and information identifying whether the product determined defective in the final inspection is determined defective under an inspection item in another of the plurality of intermediate inspections, and displays the inspection record diagram.