Server Material Tracking via Image Correlation
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Solution Overview
Problem
In manufacturing processes, tracking the location of materials through facilities is challenging due to the removal of identifiers during processes like CNC and heat/chemical treatments, making it difficult to identify the cause of defects in products.
Innovation Solution
A server system that collects log information from various facilities and generates tracking information using correlation, including virtual logs from image data in non-automation sections, to consistently track material locations and identify potential defect causes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an ID is imprinted on a material in an initial stage and the material passes through a CNC facility, then the tracking system can identify the material, but almost all of the ID is removed
Solution Approach 1:
The system performs preliminary actions by capturing images of the material at each facility stage before processing occurs. These images are stored and correlated to maintain tracking information even when physical identifiers are removed during CNC or heat/chemical processes.
Solution Approach 2:
Instead of relying on physical IDs that can be removed, the system creates digital copies through image capture. These image-based records serve as permanent tracking identifiers that persist even when physical marks are eliminated during manufacturing processes.
2Ease of manufacture
If the material passes through heat/chemical process, then the material is processed, but the ID can be removed
Solution Approach 1:
The system captures images of the material before heat/chemical processing occurs, storing the tracking information in advance. This preliminary image capture ensures that identification data is preserved even though the physical ID may be removed during the thermal or chemical treatment processes.
Solution Approach 2:
The system replaces vulnerable physical identifiers with robust digital image copies. These digital records are immune to the effects of heat and chemical processes that can eliminate traditional physical markings, thereby maintaining continuous tracking capability throughout the manufacturing process.
3Measurement precision
If an imprinting of the ID is required every time when a material is output from a facility, then the material can be tracked, but the process time increases
Solution Approach 1:
The system performs image capture and tracking data generation as preliminary actions at each facility stage, so that tracking information is already available before material transfer. This eliminates the need for time-consuming re-imprinting operations at each subsequent facility.
Solution Approach 2:
The system uses digital image copying instead of physical re-imprinting at each facility. Once an ID is captured in image form, it can be digitally replicated and associated with the material throughout the manufacturing process without requiring physical reapplication, significantly reducing process time while maintaining tracking accuracy.
4Device complexity
If inspection is conducted only in a main point and final inspection, then the production process is simplified, but many defective products are reported by consumers
Solution Approach 1:
The system implements continuous feedback by capturing images at each facility stage and making tracking data available in real-time. This enables quality issues to be detected early in the manufacturing process rather than only at final inspection, allowing for immediate corrective action while maintaining a relatively simple inspection infrastructure.
Solution Approach 2:
The system performs preliminary quality assessment through continuous image capture and tracking at each manufacturing stage. This preliminary detection capability identifies defects early in the process, preventing defective products from advancing to final inspection and reducing the need for complex post-manufacturing inspection systems.
Data Source
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AI summary
A server and a controlling method thereof are provided. The server includes a communicator, a memory configured to store computer executable instructions, and a processor configured to, by executing the computer executable instructions, receive first log information related to a first material generated in a first facility among a plurality of facilities, the first facility belonging to a first process among a series of processes for manufacturing a product through the communicator, generate an identifier (ID) regarding the first material, generate tracking information on the first material based on the first log information, assign the ID to the tracking information, receive a plurality of pieces of second log information generated in a second facility among the plurality of facilities, the second facility belonging to a second process following the first process through the communicator, identify second log information corresponding to the first material among the plurality of pieces of second log information based on the first log information included in the tracking information, and update the tracking information based on the identified second log information.