Vehicle Inspection System Reducing Part-Assembly Overlap
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Solution Overview
Problem
In vehicle production lines, overlapping inspection items between part inspections and completed vehicle inspections lead to unnecessary and unreliable inspections, reducing productivity due to lack of man-hours and difficulty in inspecting covered parts.
Innovation Solution
A vehicle inspection method that performs part inspections during manufacturing, stores results, and displays failed items on a completed vehicle inspection terminal, allowing focused inspection on specific failed parts without redundant checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If part inspections are performed for all parts during manufacturing, then inspection reliability is improved, but inspection time and productivity are worsened due to overlapping inspection items with completed vehicle inspections
Solution Approach 1:
The system performs part inspections during the manufacturing process and stores the results in advance. When conducting completed vehicle inspections, the system retrieves these pre-stored results and only performs additional inspections for items that failed or are not covered by part inspections. This preliminary action eliminates redundant inspections and improves productivity while maintaining reliability.
Solution Approach 2:
The inspection process is segmented into part inspections (performed during manufacturing) and completed vehicle inspections (performed after assembly). The system divides the inspection items and processes them in stages, with part inspections handling individual components and completed vehicle inspections handling the assembled vehicle. This segmentation allows for efficient resource allocation and reduces overlapping inspections.
2Reliability
If completed vehicle inspections are performed for all items, then inspection reliability is improved, but inspection time is worsened due to redundant inspections of already inspected parts
Solution Approach 1:
The system implements a feedback mechanism where part inspection results are stored and automatically retrieved during completed vehicle inspections. The completed vehicle inspection terminal accesses the stored part inspection results and uses this feedback information to determine which items require additional inspection. This feedback loop eliminates redundant inspections by avoiding re-inspection of items that have already passed part inspections.
Solution Approach 2:
Instead of performing complete inspections on all items during completed vehicle inspection, the system performs partial inspections only on items that failed part inspections or are not suitable for part inspection (such as covered parts). This partial action approach reduces inspection time while maintaining sufficient reliability by focusing resources on critical areas.
3Productivity
If part inspections are omitted for covered parts, then productivity is improved, but inspection reliability is worsened because covered parts cannot be properly inspected
Solution Approach 1:
The system performs part inspections at an earlier stage when parts are still accessible and can be properly inspected. Covered parts are inspected during the part inspection phase before they are assembled into the completed vehicle where they would be inaccessible. This preliminary inspection ensures that parts which will later be covered are still inspected with full reliability.
Solution Approach 2:
The system changes the temporal dimension of inspection by performing inspections at different stages of the manufacturing process. Parts that will be covered in the final assembly are inspected in the part inspection dimension (earlier stage) when they are accessible. This dimensional approach to inspection timing ensures that covered parts receive appropriate inspection without compromising productivity.
Data Source
AI summary
A vehicle inspection method in a production line of a vehicle includes: performing a part inspection in steps of manufacturing parts of the vehicle, the part inspection in which each of the parts after being manufactured is inspected with an inspection device and which includes one or more inspection items; storing a result of the part inspection in a storage device such that the result is associated with the part; and displaying the result of the part inspection, on a display device used in a completed vehicle inspection for inspecting a completed vehicle serving as the vehicle that is completed, information indicating at least the part of the parts corresponding to a failed item serving as the inspection item which is determined not to be passed in the result of the part inspection stored in the storage device and information indicating the failed item.