Production Management System Feedback Loop for Quality Control
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Solution Overview
Problem
In manufacturing supply chains, existing systems lack effective methods to analyze and feedback quality issues from downstream processes to upstream processes, leading to inefficiencies and quality control challenges.
Innovation Solution
A production management system that acquires and analyzes operational and quality data across multiple production processes, estimating the influence of upstream products on downstream product quality and providing feedback to optimize production element control and reduce costs and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quality feedback from downstream processes is not implemented, then system complexity is reduced, but quality control capability deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where quality data from downstream production processes is collected and transmitted back to upstream processes. The feedback data includes quality evaluation results and is used to adjust production parameters in upstream processes, thereby improving quality control capability through closed-loop management.
Solution Approach 2:
The production management system performs multiple functions including data collection, quality evaluation, feedback generation, and production parameter adjustment. By integrating these functions into a single system, the patent improves quality control without proportionally increasing system complexity.
2Reliability
If operational data and quality data are collected and analyzed across multiple processes, then quality control capability is improved, but information processing complexity increases
Solution Approach 1:
The patent extracts only the necessary quality evaluation results and feedback data from the collected operational and quality data, rather than processing all available data. This selective extraction approach improves quality control capability while minimizing information processing complexity.
Solution Approach 2:
The production management system acts as an intermediary that collects data from multiple production processes, evaluates quality, generates feedback, and transmits it to relevant processes. This intermediary approach simplifies the overall information processing by centralizing data handling and analysis functions.
3Loss of information
If feedback data from downstream processes is implemented, then quality information completeness is improved, but data acquisition complexity increases
Solution Approach 1:
The patent merges the data acquisition functions for operational data and quality data into a single production management system. This consolidation improves quality information completeness by collecting both types of data systematically while reducing data acquisition complexity through unified management.
Data Source
AI summary
Provided is a production management system including: an operational data acquisition unit for acquiring operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material; a quality data acquisition unit for acquiring, as quality data indicating quality of a target product, feedback data for evaluating the production element in the target production process based on quality of a downstream product in the target production process, the feedback data being output from a production management system for managing a downstream production process of producing the downstream product by using, as a material, the target product; an analysis unit for analyzing the operational feedback data; and a control information decision unit for deciding control information for controlling the production element in the target production process based on an analysis result.