Packaging Quality Control via Machine Data Linking
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Solution Overview
Problem
Current quality control systems for carton-based packaging systems rely heavily on manual processes, leading to potential errors and inefficiencies in detecting anomalies, which can result in increased downtime due to unclear machine and production data.
Innovation Solution
A method and apparatus for dynamic quality control that involves marking packages with identification data, linking machine data to packages using time stamps, and using historical and cross-system data to identify and request quality parameters for analysis, enabling automated and efficient detection of quality issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual quality control processes are used, then operational simplicity is maintained, but measurement precision and reliability of quality data deteriorate
Solution Approach 1:
The patent replaces manual quality control processes with an automated data processing system that collects, stores, and analyzes machine data and quality data through electronic communication networks. This substitution eliminates human error in data collection while maintaining operational simplicity through user-friendly interfaces and automated workflows.
Solution Approach 2:
The patent introduces a data processing apparatus as an intermediary between the packaging machine and the quality control analyst. This intermediary automatically collects machine data, links it to quality data through package identification, and presents analyzed results, thereby improving measurement precision without requiring direct complex interactions between operators and multiple data sources.
2Loss of time
If manual quality control processes are used, then system complexity is reduced, but loss of time in detecting anomalies increases
Solution Approach 1:
The patent implements continuous automated data collection and analysis throughout the packaging process. Machine data is continuously monitored and automatically linked to quality data in real-time, enabling immediate anomaly detection without the delays inherent in manual sampling and analysis. This continuous automated process significantly reduces the time to detect quality issues while maintaining manageable system complexity through modular architecture.
3Reliability
If package identification data is linked to machine data, then reliability of quality control improves, but device complexity increases
Solution Approach 1:
The patent uses package identification data (such as codes or labels) as a copying mechanism to link machine data with quality data. Instead of creating complex direct connections between all system components, the identification data serves as a simple key or reference that automatically associates relevant information, thereby improving reliability without proportionally increasing system complexity.
Data Source
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AI summary
A method for quality control of a packaging system is provided. The method comprises receiving a record of packaging identification data, wherein the record of packaging identification data being related to a package. Next, identifying and receiving a record of machine data using said record of packaging identification data, wherein said record of machine data being related to a machine set up used when producing said package. Thereafter, identifying a packaging quality parameter to be checked based on said record of machine data, and requesting a record of packaging quality data related to said packaging quality parameter.