Industrial IoT Defect Correction Cost Control in Smart Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In intelligent manufacturing, the correction of defective products incurs significant costs and resource consumption, affecting overall production efficiency and increasing the burden on correction devices, as current methods do not effectively assess the necessity of correcting defective products based on cost considerations.
Innovation Solution
An industrial IoT system with an obtaining module, total correction cost determination module, and defective product processing module is implemented to assess the correction cost of defective products and determine whether they should be repaired, thereby optimizing resource allocation and reducing unnecessary corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If defective products are corrected through classification repair and secondary processing, then product quality is improved, but correction cost and resource consumption increase significantly
Solution Approach 1:
The patent changes the decision parameter from binary (correct/discard) to multi-dimensional (defect type, correction cost, resource consumption, product value). By introducing cost parameters and resource consumption metrics, the system evaluates whether correction is economically viable, transforming the quality improvement process into a cost-optimized decision-making process.
Solution Approach 2:
The patent performs preliminary cost assessment and defect classification before actual correction occurs. The system pre-evaluates correction feasibility by analyzing defect types, estimating correction costs, and comparing against product value thresholds, thereby avoiding unnecessary correction operations that would waste resources.
2Manufacturing precision
If defective products are transferred to correction assembly lines for classification repair, then product quality is improved, but production efficiency of normal products decreases due to increased workload on correction devices
Solution Approach 1:
The patent applies partial correction action by selectively correcting only those defective products that meet the cost-benefit threshold. Not all defective products undergo correction - only those where correction cost is less than product value. This partial approach maintains quality for viable products while avoiding excessive correction operations that would burden correction devices and reduce overall production efficiency.
3Manufacturing precision
If comprehensive correction resources including manpower, materials, and equipment are allocated for defective product correction, then correction quality is improved, but total cost and resource consumption increase
Solution Approach 1:
The patent implements feedback mechanisms that continuously monitor correction costs, resource consumption, and product value. The system uses this feedback to dynamically adjust correction decisions, allocating comprehensive resources only when the feedback indicates high product value and low correction cost. This feedback-driven approach ensures optimal resource allocation rather than blanket resource deployment.
4Loss of substance
If all defective products undergo classification repair and secondary processing, then waste product loss is reduced, but the cost of correction exceeds the manufacturing cost of single-piece products in many cases
Solution Approach 1:
The patent applies the discarding principle by intentionally abandoning defective products when correction cost exceeds product value. Rather than attempting to recover all defective products through correction, the system economically discards those where correction is not viable, thereby avoiding greater resource waste. This selective discarding strategy reduces overall loss by preventing costly unsuccessful correction attempts.
Data Source
AI summary
The present disclosure provides an industrial IoT for correction and regulation of a defective product, a control method, and a storage medium. The industrial IoT includes a user platform, a service platform, a management platform, and a sensing network platform that interact in sequence. The service platform, the management platform, and the sensing network platform are all arranged in a front-sub-platform layout. The control method is applied in the industrial IoT. The industrial IoT may calculate whether a defective product is correctable according to a correction cost of the defective product, and may reduce the correction cost and a time consumption of a corresponding correction device, thereby reducing correction cost of the defective product and a loss in a manufacturing process, further ensuring a normal product manufacturing efficiency of the correction device, and thus reducing a correction loss of a waste product and the defective product.