Virtual Material Tracking Across Multi-Facility Manufacturing
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Solution Overview
Problem
In manufacturing processes, tracking the location of materials across multiple facilities is challenging due to the removal of identifiers during processes like CNC operations 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, generates and updates tracking information for materials, and uses image-based data from cameras to maintain accurate material tracking, even in non-automation sections where log data is not generated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ID is imprinted on a material in an initial stage and the material passes through a CNC facility, then the tracking is interrupted because almost all of the ID is removed, but if an ID is imprinted on a material, then the material can be tracked through that facility
Solution Approach 1:
The system performs preliminary actions by generating tracking information and assigning IDs to materials before they enter processing facilities. The server creates virtual logs and tracking records in advance, so that even when physical IDs are removed during CNC operations, the tracking information already exists in the system and can be correlated with subsequent processing steps.
Solution Approach 2:
The system creates a virtual copy of the tracking information that persists even when the physical ID is removed. The server generates virtual logs that replicate the tracking function without requiring the physical ID to survive processing. This virtual tracking copy allows continuous monitoring throughout the manufacturing process.
2Reliability
If an imprinting of the ID is required every time when a material is output from a facility, then the tracking can be maintained, but the process time increases
Solution Approach 1:
The system replaces the mechanical process of physical ID imprinting with an information-based virtual logging system. Instead of mechanically re-applying IDs at each facility output, the server automatically generates and updates virtual log entries, eliminating the time-consuming physical imprinting operations while maintaining tracking continuity.
Solution Approach 2:
The tracking system serves itself by automatically generating and updating tracking information without requiring external intervention or repeated physical ID application. The server autonomously correlates logs from different facilities and maintains continuous tracking records without manual ID re-imprinting at each stage.
3Device complexity
If inspection is conducted only in a main point and a final inspection, then the inspection process is simplified, but many defective products are reported by consumers even if products pass the final inspection
Solution Approach 1:
The system implements continuous tracking and monitoring throughout the entire manufacturing process rather than intermittent inspections at discrete points. The virtual logging system continuously records material movement and processing information, enabling ongoing quality verification without disrupting production flow or requiring complex inspection infrastructure at multiple stages.
Data Source
AI summary
A server and a controlling method therefor are provided. The server includes a communicator, a memory, and a processor configured to receive first log information related to a first material generated in a first facility among facilities, the first facility belonging to a first process 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 pieces of second log information generated in a second facility among the 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 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.