Production Quality Monitoring with Adjustable Allowable Ranges
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Solution Overview
Problem
Conventional production methods struggle to maintain product quality due to increased deviations in the four elements of production (raw material, facility, process, and person) across global supply chains, leading to difficulties in balancing productivity, quality, cost, delivery, and safety indices, and often result in inadequate real-time evaluation and countermeasure implementation.
Innovation Solution
A production support system that acquires element values, determines if they are within allowable ranges, and resets these ranges to ensure product quality by outputting information on the necessary adjustments, allowing for real-time adaptation and improved countermeasure selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preset production conditions are maintained for each element, then product quality can be secured under stable conditions, but the system cannot adapt to increased deviations in global supply chains
Solution Approach 1:
The patent implements dynamic adjustment of allowable ranges for production elements. When a deviation in one element is detected, the system automatically resets the allowable ranges of other elements to compensate and maintain product quality. This transforms the static preset conditions into dynamic adaptive conditions that respond to real-time deviations.
Solution Approach 2:
The system continuously monitors element values and provides feedback when deviations occur. Based on this feedback, the system automatically resets allowable ranges of other elements to compensate for the deviation, creating a closed-loop control system that adapts to changing conditions while maintaining quality.
2Reliability
If real-time monitoring of all element deviations is implemented, then product quality can be maintained, but system complexity and computational requirements increase
Solution Approach 1:
The patent divides the production system into separate monitorable units (elements) with predefined allowable ranges. Each element can be monitored and adjusted independently, allowing the complex system to be managed through modular, segmented control rather than requiring comprehensive analysis of all interactions simultaneously.
Solution Approach 2:
The system monitors parameter changes (element values) against predefined allowable ranges. When parameters deviate, the system responds by resetting allowable ranges of other elements rather than requiring complex real-time recalculation of all production conditions, simplifying the computational burden.
3Ease of operation
If allowable ranges are fixed for all production elements, then control is simplified, but quality cannot be maintained when one element deviates significantly
Solution Approach 1:
The patent transforms fixed allowable ranges into dynamic ranges that automatically adjust when deviations occur. The simplicity of fixed ranges is maintained during normal operation, while the system automatically adapts ranges when needed, combining ease of operation with quality maintenance.
Solution Approach 2:
The system automatically resets allowable ranges of other elements when a deviation is detected, without requiring manual intervention. This self-service capability maintains quality while preserving the simplicity of the control interface, as operators do not need to manually recalculate or adjust ranges.
Data Source
AI summary
A method to be performed in a production support system configured to process a raw material and to produce a product. And the method includes: acquiring a plurality of element values relating to production elements of the product; determining whether the element values are within allowable ranges in which a quality of the product meets a predetermined allowed quality; resetting the allowable ranges of one or a plurality of other element values to the allowable ranges in which the quality of the product meets the predetermined allowed quality, upon determining that at least one element value exceeds the allowable range; and outputting information about the reset allowable ranges.