Hierarchical Quality Control for Defect Cause Traceability
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Solution Overview
Problem
In complex products composed of multiple components, identifying the specific element causing a quality defect is challenging due to the lack of effective tools that integrate test values, assembling management information, and step-related data to pinpoint defect causes.
Innovation Solution
A quality control apparatus that acquires and integrates test values, assembling management information, and step-related information to display a hierarchical configuration diagram, highlighting combinations of components and production steps likely causing defects based on deviation analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If test values, assembling management information, and step-related information are integrated and analyzed, then defect cause identification accuracy is improved, but system complexity increases
Solution Approach 1:
The system segments the complex quality control task into three distinct information acquisition units: test value acquisition unit, assembling management information acquisition unit, and step-related information acquisition unit. Each unit independently collects specific types of data, which are then integrated by the defect cause identification unit. This segmentation reduces system complexity by organizing functions into modular, manageable components while maintaining comprehensive defect analysis capability.
2Reliability
If comprehensive data integration is performed to identify defect causes, then quality control effectiveness is improved, but information processing time increases
Solution Approach 1:
The system performs preliminary actions by pre-collecting and organizing test values, assembling management information, and step-related information into structured databases before defect analysis is needed. The information acquisition units continuously gather and store data in readiness, so when a defect occurs, the defect cause identification unit can immediately query and analyze the pre-organized information without time-consuming data collection, thus maintaining high quality control effectiveness while minimizing processing time.
3Loss of information
If hierarchical configuration diagram with defect paths is displayed, then defect visualization is improved, but data processing complexity increases
Solution Approach 1:
The system transforms complex defect data relationships into a visual hierarchical configuration diagram that adds a spatial dimension to defect analysis. The display unit presents product configuration hierarchies with overlaid defect paths, allowing operators to visually trace defect propagation through assembly levels. This dimensional transformation converts complex tabular data relationships into intuitive graphical representations, improving defect visualization while the automated path generation algorithm handles the processing complexity.
Data Source
AI summary
A quality control apparatus includes: a test value acquisition unit that acquires test values of respective components that constitute a product; an assembling management information acquisition unit that acquires assembling management information that is information concerning assembling of the product and the components; a step-related information acquisition unit that acquires step-related information that is information related to a production step; and a display that displays a configuration diagram of the product that is hierarchically constituted by the components and shows a combination of elements that are assumed to be likely to have caused a quality defect of the product on the configuration diagram on a basis of the test values, the assembling management information, and the step-related information.