Production Process Testing with Adaptive Measurement Frequency
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Solution Overview
Problem
Existing methods for quality and process measurement in production processes fail to adapt to the changing stability of the process, leading to unnecessary costs in stable processes and inadequate detection of defects in unstable processes.
Innovation Solution
A method that defines a primary characteristic with a higher test frequency and secondary characteristics with a lower test frequency, using IoT technologies for continuous measurement and analysis, and adjusts the test frequency based on stability criteria to optimize measurement effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If measurements are performed frequently on all characteristics, then defect detection capability is improved, but measurement costs and time consumption increase
Solution Approach 1:
The patent segments characteristics into primary characteristics (measured continuously at high frequency) and secondary characteristics (measured less frequently). This segmentation allows focused monitoring of critical parameters while reducing overall measurement burden, resolving the contradiction between comprehensive defect detection and measurement time consumption.
Solution Approach 2:
The patent dynamically adjusts measurement frequencies based on process stability assessment. When the process is stable, measurement frequency is reduced; when instability is detected, measurement frequency increases. This dynamic adaptation optimizes the balance between defect detection capability and measurement time consumption according to actual process conditions.
2Reliability
If measurements are performed frequently on all characteristics, then defect detection capability is improved, but measurement costs increase
Solution Approach 1:
The patent segments characteristics into primary and secondary categories, measuring only primary characteristics continuously while measuring secondary characteristics less frequently. This reduces the total number of measurements required, thereby lowering measurement costs while maintaining adequate defect detection capability through focused monitoring of critical parameters.
Solution Approach 2:
The patent dynamically adjusts measurement frequencies based on process stability. During stable periods, measurement frequency is reduced to minimize costs; during unstable periods, frequency increases to ensure defect detection. This dynamic approach optimizes the balance between defect detection capability and measurement costs.
3Loss of energy
If measurements are performed infrequently, then measurement costs are reduced, but defect detection capability deteriorates
Solution Approach 1:
The patent segments characteristics into primary characteristics (critical for defect detection) and secondary characteristics. Primary characteristics are measured continuously at high frequency to maintain defect detection capability, while secondary characteristics are measured less frequently to reduce costs. This selective measurement strategy ensures adequate defect detection while minimizing measurement costs.
Solution Approach 2:
The patent dynamically adjusts measurement frequencies based on process stability assessment. When process instability is detected, measurement frequency increases to ensure defects are not missed; when stable, frequency decreases to reduce costs. This dynamic adaptation maintains defect detection capability while optimizing measurement costs according to actual process conditions.
4Reliability
If high test frequency is applied to all characteristics, then process stability monitoring is improved, but productivity decreases
Solution Approach 1:
The patent segments characteristics into primary characteristics (measured continuously) and secondary characteristics (measured less frequently). This segmentation enables effective process stability monitoring through continuous measurement of critical parameters while reducing the overall measurement burden that would otherwise hinder production efficiency.
Solution Approach 2:
The patent dynamically adjusts measurement frequencies based on process stability. During stable production phases, measurement frequency is reduced to minimize interference with production efficiency; during unstable phases, frequency increases to ensure proper monitoring. This dynamic approach maintains productivity while ensuring process stability is adequately monitored when needed.
5Productivity
If low test frequency is applied to reduce measurement effort, then productivity is improved, but process stability monitoring deteriorates
Solution Approach 1:
The patent segments characteristics into primary characteristics (critical for stability monitoring) and secondary characteristics. Primary characteristics are measured continuously to maintain adequate process stability monitoring, while secondary characteristics are measured less frequently to improve productivity by reducing measurement effort. This selective approach ensures critical monitoring is maintained while overall measurement burden is reduced.
Solution Approach 2:
The patent dynamically adjusts measurement frequencies based on process stability assessment. When process instability is detected, measurement frequency increases to ensure proper stability monitoring; when stable, frequency decreases to maximize productivity. This dynamic adaptation maintains process stability monitoring capability while optimizing productivity according to actual process conditions.
Data Source
AI summary
A method for testing a production process for components, wherein at least the components or a manufacturing facility used for producing the components have a plurality of metrologically measurable characteristics, wherein at least one characteristic is defined as a major characteristic and at least one further characteristic as a minor characteristic; comprising at least the following steps: a) defining a test plan for recording at least one major characteristic and at least one minor characteristic by tests, wherein the at least one major characteristic is measured with a first test frequency and the at least one minor characteristic with a second test frequency; wherein at least one stability criterion is defined for the at least one major characteristic; b) manufacturing the components and simultaneously executing the test plan to generate test results, wherein only the at least one major characteristic is tested with the first test frequency;c) Evaluate the test results obtained; and, if at least one test result for at least one main characteristic violates the stability criterion, d) continue the execution of the test plan, whereby at least one secondary characteristic is also tested.