Manufacturing Route Data Integration for Real-Time Yield Analysis
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Solution Overview
Problem
Modern manufacturing systems face challenges due to compartmentalization of information across geographically distributed steps, leading to product failures and waste, which reduce yield and require effective solutions for data collection and analysis to extend product lifetime and improve efficiency.
Innovation Solution
Implementing a cloud-based multidimensional manufacturing data collection system that configures manufacturing routes into a single database schema, allowing real-time data collection and analysis across various manufacturing processes, enabling insight into product yield, quality, and customer satisfaction, and facilitating corrective actions to prevent waste and extend product life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manufacturing systems are geographically distributed across multiple locations, then manufacturing capacity and flexibility are improved, but information compartmentalization occurs leading to reduced product reliability and increased waste
Solution Approach 1:
The patent combines data from multiple geographically distributed manufacturing locations into a single centralized database schema. This merging of information systems allows real-time tracking of products across all manufacturing steps and locations, eliminating information silos while maintaining the benefits of distributed manufacturing capacity.
Solution Approach 2:
The system implements real-time feedback loops where manufacturing data from all locations is continuously collected, analyzed, and used to make immediate corrections. This feedback mechanism enables proactive identification and resolution of issues before they result in product failures or waste, thereby maintaining high product reliability across distributed operations.
2Productivity
If data is collected and analyzed in real-time across manufacturing routes, then product waste is reduced and yield is improved, but system complexity and data infrastructure requirements increase
Solution Approach 1:
The patent segments the manufacturing system into discrete manufacturing routes, each with its own data collection points and parameters. This segmentation allows for modular data collection and analysis, where each route can be independently monitored and optimized, reducing overall system complexity while maintaining comprehensive oversight.
Solution Approach 2:
The system employs a universal database schema that can accommodate data from multiple manufacturing routes and locations through a standardized structure. This multi-functional database design eliminates the need for separate complex systems at each location, reducing overall system complexity while enabling centralized real-time analysis across all operations.
3Reliability
If comprehensive manufacturing data is collected and stored centrally, then product quality and customer satisfaction are improved, but data transmission and storage requirements increase
Solution Approach 1:
The patent extracts only the essential and relevant data parameters needed for quality control and manufacturing optimization from each manufacturing step. By selectively collecting only critical data points rather than all possible data, the system maintains high product quality monitoring capabilities while significantly reducing the volume of data that needs to be transmitted and stored centrally.
Data Source
AI summary
Systems and methods are described to improve efficiency in the manufacturing of a product for a manufacturer. The system includes a manufacturing route. The manufacturing route specifies at least two dimensions, where a first dimension of the at least two dimensions is a client machine and a second dimension of the at least two dimensions is a process associated with the client machine. A data stream is responsive to the plurality of dimensions. A database is configured to receive the data stream. A processor is configured to provide data from the data stream that indicates a symptom of a problem which can occur within the manufacturing route.