Manufacturing Process Sensitivity Analysis for Defect Response
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Solution Overview
Problem
Existing manufacturing process optimization systems fail to effectively manage intermediate production processes and quickly respond to changes in material properties or product specifications, leading to labor-intensive and costly investigations when defects occur.
Innovation Solution
A manufacturing process optimization system that calculates functional sensitivity to determine the influence of control factors on target physical properties, allowing for the selection and adjustment of process conditions to optimize the manufacturing process, including input devices, central control devices, and output devices to manage and output optimized control factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a database is used to store manufacturing process conditions and material properties, then information can be retained for future reference, but finding causes of defects or reviewing processes requires a lot of labor and costs
Solution Approach 1:
The patent replaces manual database searching and analysis with an automated computer-based system that calculates functional sensitivity. The system automatically identifies which process conditions affect material properties by computing sensitivity values, eliminating the need for labor-intensive manual investigation of defect causes while preserving all manufacturing process information in a structured format that enables rapid querying and analysis.
2Measurement precision
If manual review of manufacturing processes is performed to investigate defects or change specifications, then thorough analysis can be conducted, but the process is labor-intensive and costly
Solution Approach 1:
The patent transforms the manual review process into an automated computational process by changing the parameters from qualitative manual assessment to quantitative functional sensitivity calculations. The system computes sensitivity values that precisely quantify the relationship between process conditions and material properties, maintaining analytical accuracy while dramatically improving productivity through automated calculation and rapid result generation.
3Reliability
If intermediate product properties are monitored to ensure quality, then quality control can be improved, but the complexity of managing multiple process parameters increases
Solution Approach 1:
The patent extracts the essential relationships between process conditions and material properties by calculating functional sensitivity for each parameter pair. This extraction method identifies only the most influential relationships, separating critical quality factors from less important ones. The system manages complexity by focusing on key sensitivity relationships rather than requiring comprehensive monitoring of all possible parameters, thereby improving quality control without proportionally increasing system complexity.
Data Source
AI summary
A problem is to specify a more proper manufacturing process for a product as a material. A configuration of the present invention for solving the above problem is a manufacturing process optimization system 1 which includes an input device 12 which receives a final product and information on its manufacturing process, a central control device 11 which in accordance with a product management unit 21 stored in a main storage device 14, separates each process block constituting the manufacturing process into functions that the process thereof is responsible for, and selects the sensitivity of each separated function along the manufacturing process to thereby calculate process conditions in all manufacturing process, and an output device 13 which outputs the process conditions.