Production Line Capability Analysis Using Outlier-Filtered Metrics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing production management systems struggle to quickly identify and prioritize improvement areas in a production line, as they lack clear methods to distinguish between ideal and actual production capabilities, leading to inefficiencies in productivity and quality improvements.
Innovation Solution
A production management system that calculates a production performance value and a production capability value by excluding statistical outliers and data affected by predetermined condition changes, allowing for a clearer identification of improvement areas by comparing these values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a production management system aggregates and reports all production data including outliers and condition changes, then comprehensive data coverage is achieved, but the ability to quickly identify preferential improvement points deteriorates
Solution Approach 1:
The patent extracts and separates outlier data and data affected by predetermined condition changes from the overall production data. By removing these problematic data points, the system can clearly identify the production line's capability value without distortion, enabling faster identification of preferential improvement points while maintaining comprehensive analysis of valid data.
2Reliability
If ideal values from business plans are compared with performance values including troubles, then target achievement monitoring is enabled, but clarity on actual production capability deteriorates
Solution Approach 1:
The patent segments production data into three distinct categories: capability value (excluding outliers and condition change data), performance value (including all data), and ideal value (from business plans). This segmentation allows simultaneous monitoring of target achievement through performance value comparison while maintaining clear capability measurement through capability value analysis.
3Quantity of substance
If all production data including statistical outliers is used for capability assessment, then complete data utilization is achieved, but accuracy of capability value deteriorates
Solution Approach 1:
The patent converts the harmful effect of statistical outliers and condition change data into a beneficial filtering mechanism. By identifying and excluding these problematic data points, the system achieves more accurate capability value measurement. The excluded data is not lost but separately tracked to understand sources of variation and improve production stability.
Data Source
AI summary
The production management system (1) is characterized by comprising: a performance value calculation unit (110a) that calculates a production performance value, which is a performance value of an index relating to productivity or quality of a product on the production line (10); and an actual ability value calculation unit (110a) that calculates an actual production ability value, which is an actual ability value of the index relating to productivity or quality of the product on the production line. The actual production ability value is the index relating to productivity or quality of the product, which is calculated by eliminating, from index data relating to productivity or quality of the product on the production line (10), the index data corresponding to statistical outliers in distribution of the production performance values, and/or the index data affected by a predetermined condition change in the production line.