Visual Inspection Reliability Evaluation With Weighted Human Factors

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Solution Overview

Problem

Current methods for estimating human error in visual inspections of production systems, particularly in the aerospace industry, are subjective and do not account for the dynamic, multi-variable environment, leading to inaccurate assessments and potential quality issues.

Innovation Solution

A method and system that incorporate human factors engineering to identify and weight variables such as task factors, time, stressors, experience, and ergonomics, using a computer system to calculate the reliability of human inspections and provide recommendations for improvement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If current subjective estimation methods are used to assess human error in inspections, then the process is simple and quick, but the accuracy and reliability of the assessment deteriorates

Engineering Contradiction:
Improveinspection reliability assessmentVSAvoidevaluation system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent transforms subjective estimation into objective measurement by changing the parameters from qualitative judgments to quantitative inputs. The system collects specific data about inspection conditions (lighting, time, complexity of parts) and uses these measurable parameters to calculate reliability scores, replacing vague subjective estimates with concrete, measurable factors that directly influence human performance.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical process of manual subjective estimation with an automated computational system. Instead of relying on human judgment and experience to assess inspection reliability, the system uses computer algorithms that process input data through defined mathematical models, eliminating the variability and bias inherent in manual estimation processes.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If detailed multi-variable analysis is performed to account for environmental factors, then the accuracy of human error estimation improves, but the time and complexity of the evaluation process increases

Engineering Contradiction:
Improvehuman error estimation precisionVSAvoidevaluation time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent divides the complex evaluation into discrete, manageable segments. Instead of attempting to analyze all possible factors simultaneously, the system breaks down the inspection environment into specific categories (lighting conditions, time of day, part complexity, inspector experience level) and evaluates each separately. This segmentation allows for comprehensive analysis while maintaining organizational structure that facilitates efficient processing.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary actions by pre-defining the variables and weightings before the actual evaluation. The system comes pre-configured with the complete list of factors to consider and their relative importance, so that during actual use, the evaluator simply needs to input data for these pre-identified variables rather than conducting a comprehensive analysis from scratch each time.

Inventive Principle:
Principle #10Preliminary action

3Reliability

If inspection frequency is increased to compensate for human error, then the reliability of inspection improves, but the productivity and cost of the manufacturing process deteriorates

Engineering Contradiction:
Improveinspection reliabilityVSAvoidmanufacturing throughput
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent implements feedback by continuously monitoring inspection outcomes and using this information to adjust future evaluations. The system tracks actual detection rates and compares them against predicted reliability scores, allowing for iterative improvement. This feedback mechanism enables the system to optimize inspection frequency and intensity based on actual performance data rather than relying on conservative estimates that would require excessive inspection frequency.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS20250307735A1Inspection Reliability Evaluation System
Publication Date: 2025.10.02 THE BOEING CO
  • US20250307735A1 patent drawing
  • US20250307735A1 patent drawing
  • US20250307735A1 patent drawing

AI summary

A method, system and computer program product for estimating reliability of a human inspection of a production system. Human inspection variables specific to the human inspection and the environment the inspection was conducted in are identified through human factors engineering research. The identified human inspection variables are weighted. Environment input or feedback about the inspection is received. The environment input received is also weighted. An assessment of the reliability of the human inspection is calculated using the human inspection variables and the received environment input.