Non-conformance Mapping and Visualization for Manufacturing
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Solution Overview
Problem
Current methods for tracking non-conformances in manufactured products, such as aircraft, are inefficient as they rely on manual recording using non-standard text formatting and spreadsheets, which do not integrate with other data sources and fail to accurately locate defects in 3D space, leading to unintentional rework and increased costs.
Innovation Solution
A system for mapping and visualizing non-conformances using a 3D visualization program that processes spatial coordinates to generate electronic records and display boundaries of areas containing multiple non-conformances, integrated with dashboard software and data systems to provide a comprehensive dashboard view for production environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual recording using non-standard text formatting and spreadsheets is used, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical recording methods (spreadsheets and text formatting) with an automated computer vision system that captures images and automatically identifies non-conformances, eliminating the need for manual data entry while achieving precise location tracking through coordinate extraction from images
Solution Approach 2:
The system creates a digital copy of the physical object through image capture, allowing non-conformances to be identified and located in the digital domain. This copying approach enables precise coordinate measurement without interfering with the physical object while maintaining accurate spatial information
2Device complexity
If manual recording methods are used, then device complexity is reduced, but loss of information increases
Solution Approach 1:
The system integrates multiple functions into a single platform: image capture, non-conformance detection, coordinate extraction, data storage, and integration with existing manufacturing data sources. This multi-functional approach eliminates information silos while maintaining system accessibility
Solution Approach 2:
The patent introduces an intermediary computer vision system that bridges the gap between manual recording simplicity and comprehensive data integration. This intermediary layer processes images and extracts information that can then be seamlessly integrated with various data sources without requiring direct complex connections between them
3Ease of operation
If exact 3D coordinate location is not recorded, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The system replaces manual coordinate recording with automated image-based coordinate extraction. The computer vision system automatically determines precise 3D coordinates from captured images, eliminating human error in location recording while maintaining ease of operation through automated processes
Solution Approach 2:
The system provides visual feedback by displaying captured images with identified non-conformances and their coordinates. This feedback mechanism allows operators to verify the accuracy of detected non-conformances and their locations, ensuring reliability while maintaining operational simplicity through visual confirmation
Data Source
AI summary
Areas of non-conformances in a manufactured object are electronically mapped within a coordinate system of the object. Boundary lines of the areas containing the non-conformances are displayed on a 3-D image of the product. Visualization of the boundary lines of areas containing multiple non-conformances allows tracking of non-conformances, identification of trends in non-conformances and correction of production processes in order to reduce non-conformances.