Manufacturing Quality Management System Using 4M Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing quality management systems, such as those disclosed in Japanese Patent Application Laid-Open (JP-A) No. 2015-153914, are limited to surface mounting lines and do not effectively utilize the advancements in information and communication technology to provide comprehensive quality management for various manufacturing lines.
Innovation Solution
A management system that acquires state information from manufacturing equipment, determines events, and displays the likelihood of factors contributing to these events from the perspectives of Machine, Man, Material, and Method, along with images representing the manufacturing lines, allowing for analysis and output of results to identify the causes of events like suspension or abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a quality management device is designed for a specific manufacturing line (e.g., surface mounting line), then quality management for that specific line is improved, but the device cannot be used for other manufacturing lines
Solution Approach 1:
The quality management device is designed to collect and analyze state information from multiple types of manufacturing equipment across different manufacturing lines. The system uses a standardized data collection framework that can adapt to various equipment types (sensors, machines, handlers) while maintaining consistent quality management functions, enabling the same device to serve multiple manufacturing lines with different processes and equipment
2Reliability
If state information from all sensors is collected comprehensively, then quality management capability is improved, but system complexity increases
Solution Approach 1:
The system segments state information collection and analysis by manufacturing line, equipment type, and factor category (4M: Machine, Man, Material, Method). Each segment has dedicated data collection and analysis functions, allowing comprehensive monitoring while maintaining manageable system complexity through modular organization of data handling and analysis processes
Solution Approach 2:
The system introduces an intermediary analysis layer that processes raw state information from multiple sensors and transforms it into structured quality management data. This intermediary layer includes components that aggregate sensor data, identify events, determine causes using 4M framework, and present results in a standardized format, simplifying the complexity of handling comprehensive sensor information
Data Source
AI summary
Provided is a management system for performing quality management on manufacturing equipment. A management system that includes: an acquisition component that acquires state information for manufacturing equipment that is subject to management; a determination component that, on the basis of the acquired state information, determines whether an event has occurred; a display component that displays both an image that schematically or realistically represents a manufacturing line included in the manufacturing equipment and, separated into the four perspectives Machine, Man, Material, and Method, indexes that indicate the likelihood that there is a factor that caused an event; and an output component that, when a specific event has occurred, outputs, in response to a user selection, analysis results for each of one or more factors belonging to each of the four perspectives, the analysis results indicating a likelihood of having caused the specific event that occurred.