Productivity Map Display for Suction Step Fault Isolation
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Solution Overview
Problem
In manufacturing facilities, identifying the cause of abnormalities in the suction step is time-consuming due to the involvement of multiple constituent elements, such as nozzles, headers, and feeders, leading to reduced production efficiency and product quality.
Innovation Solution
A display device that displays productivity indicators for combinations of constituent elements on a grid map, allowing for easier identification of poor-performing elements by calculating and displaying productivity metrics based on manufacturing log information, facilitating quicker handling and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple constituent elements (nozzle, header, feeder, components) are involved in the suction step, then the manufacturing process can be completed, but it becomes difficult to identify the specific cause of abnormalities
Solution Approach 1:
The patent segments the manufacturing process into discrete steps (suction step, mounting step, etc.) and further segments each step into individual constituent elements (nozzle, header, feeder). By assigning unique identifiers to each element and tracking their performance separately, the system can pinpoint exactly which element is causing abnormalities, transforming a complex undifferentiated problem into manageable segmented units for analysis
Solution Approach 2:
The patent introduces an intermediary information processing system that collects data from multiple constituent elements, processes this data centrally, and generates visual displays showing the relationship between elements and their performance. This intermediary system acts as a mediator between the complex manufacturing facility and the operator, translating raw data into actionable insights about which specific element is causing problems
2Measurement precision
If time is spent identifying the cause of abnormalities among multiple constituent elements, then accurate diagnosis can be achieved, but production efficiency is reduced
Solution Approach 1:
The patent implements preliminary action by pre-establishing a data collection framework that continuously monitors and records performance data from all constituent elements before abnormalities occur. The system pre-organizes this data by step and element, so when an abnormality is detected, the analysis is already prepared and can be immediately displayed, eliminating the need for time-consuming manual investigation while maintaining high diagnostic accuracy
Solution Approach 2:
The patent replaces the manual mechanical process of investigating abnormalities with an automated information processing system. Instead of operators physically checking each component to identify problems, the system automatically collects, processes, and displays diagnostic information, substituting automated computational analysis for manual mechanical inspection and significantly reducing diagnosis time
3Measurement precision
If detailed tracking of each constituent element is implemented, then productivity indicators can be accurately calculated, but system complexity increases
Solution Approach 1:
The patent applies universality by designing a standardized data collection and processing framework that handles multiple constituent elements (nozzles, headers, feeders) and multiple process steps (suction, mounting) through a single unified system. The same information processing logic and display methods are applied universally across all elements, reducing the need for element-specific complex handling while maintaining precise tracking of each individual component's performance
Data Source
AI summary
A display device that displays productivity of a manufacturing facility that performs processes to manufacture products, wherein the manufacturing facility includes constituent element groups, each including constituent elements, constituent elements selected from the constituent element groups perform a corresponding one of the processes. The display device includes: an obtainer that obtains manufacturing log information from the manufacturing facility; a calculator that calculates an indicator showing productivity of each combination of a first constituent element and a second constituent element, based on the manufacturing log information; and a display that displays the indicator showing the productivity of each combination at a position of an intersection point corresponding to the combination on a productivity indicator map including a vertical axis along which first constituent elements are arranged and a horizontal axis along which second constituent elements are arranged.