Production Control Apparatus for Workpiece Traceability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In mass production lines, identifying the traceability data of defective products is challenging due to the limitations of IC memory capacity in ID tags, high costs associated with large-scale production, and the need for continuous attachment and disassembly of ID tags during manufacturing processes.
Innovation Solution
A production control apparatus that generates unique identifiers for each workpiece as it moves through manufacturing machines, recording these identifiers and corresponding traceability data in a storage unit, allowing for easy retrieval of production information without the need for IC tags, and using a tree structure to associate identifiers of assembled workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If IC tags with IC memory are attached to each workpiece to store traceability data, then traceability data can be recorded and retrieved, but the IC memory capacity is limited and cannot record more traceability data
Solution Approach 1:
The patent extracts the traceability data storage function from the workpiece itself (by removing IC tags after data collection) and stores the data externally in a database system. The IC tags are used only temporarily during manufacturing to collect data, then removed and discarded, while the traceability data is permanently stored in the host computer's database, overcoming the IC memory capacity limitation.
Solution Approach 2:
The patent introduces the host computer and database as an intermediary between the manufacturing machines and the final product traceability. The database serves as a mediator that collects, stores, and manages traceability data from multiple machines, allowing unlimited storage capacity beyond what IC tags can provide.
2Quantity of substance
If a large number of ID tags are prepared for mass production, then each workpiece can have its own identifier, but the cost increases significantly
Solution Approach 1:
The patent implements a system where IC tags are temporarily attached to workpieces during manufacturing to collect traceability data, then the tags are removed and discarded after the data is transferred to the database. This allows reuse of the tag attachment/removal process while eliminating the need to permanently retain expensive IC tags on each finished product, reducing overall costs.
Solution Approach 2:
The patent creates a digital copy of the traceability data from the IC tag to the database, then removes the physical IC tag. This copying process allows the information to be preserved permanently in the database while the physical carrier (IC tag) is discarded, reducing the need for continuous IC tag inventory.
3Loss of information
If ID tags are attached to workpieces during the entire manufacturing process, then traceability data can be collected, but the workpieces must be machinable and assemblable with ID tags attached
Solution Approach 1:
The patent attaches IC tags to workpieces at the beginning of the manufacturing process before any machining or assembly operations. The tags remain attached throughout all manufacturing steps to continuously collect traceability data, and are only removed after manufacturing is complete and data collection is finished, ensuring maximum processing flexibility.
Solution Approach 2:
The patent separates the data collection function (performed by IC tags during manufacturing) from the final product state (where tags are removed). The IC tags are extracted from the workpiece after serving their purpose of collecting traceability data, allowing the workpiece to be processed without permanent tag attachment constraints.
4Loss of information
If traceability data of all products produced on the same date is analyzed to identify defective product causes, then complete data is available, but it becomes very difficult to discover the reason for defects
Solution Approach 1:
The patent segments traceability data by individual workpiece identifiers instead of grouping all products by manufacturing date. Each workpiece has its own unique traceability record linked to specific manufacturing parameters, machines, and operators. This segmentation allows direct retrieval of the specific workpiece's complete manufacturing history without analyzing data from all other products made on the same date, dramatically reducing analysis complexity.
Solution Approach 2:
The patent implements a database system that provides immediate feedback when a defective product is identified. By storing traceability data with unique workpiece identifiers and linking it to manufacturing parameters, the system can quickly retrieve and present the specific traceability information for the defective workpiece, enabling rapid root cause analysis without manual sorting through大量 date-grouped data.
Data Source
AI summary
A production control apparatus includes a workpiece position detection unit, an ID generation unit, an ID notification unit, a data receiving unit, and a storage unit. The data receiving unit receives the unique IDs generated by the ID generation unit and the traceability data (actual production information) when the workpieces for which the unique IDs have been generated are processed, from the manufacturing machines to which the unique IDs have been notified by the ID notification unit. The storage unit records the unique IDs and the traceability data received by the data receiving unit in association with each other.