Method of improving quality of manufactured modules

• US 6,859,676 B1
• Filed: 04/09/2001
• Issued: 02/22/2005
• Est. Priority Date: 04/09/2001
• Status: Expired due to Term

• Current Assignee: Ciena Corporation
• Original Assignee: Ciena Corporation
• Inventors: Kazemi, Niakam
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US09/827,979
• Time in Patent Office: 1,415 Days
• Field of Search: 700/110, 700/105, 700/109, 700/115, 700/116, 700/104, 700/47, 700/49, 702/184, 702/185, 379/21, 714/26, 714/46, 706 45- 47, 706/61, 706/911, 706/912, 706/916
• US Class Current: 700/110
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35082 Product, feature based modeling, geometric and engineering info
• CPC Class Codes: G05B 2219/35159 With nominal blank and model in memory define tool path and machine workpiece
• CPC Class Codes: G05B 2219/49245 2-5-D pocket machining
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10S 706/912 Manufacturing or machine, e.g. agricultural machinery, machine tool

Abstract

A method of improving the quality of manufactured modules includes logging manufacturing information to a database and utilizing a knowledge base to determine defects of a manufactured module. A quality ticket is issued for defective modules that is used to log and store defect symptom information in the database. Defects may be determined based on the quality ticket and by utilizing the knowledge base. Repair suggestions may be made and logged to the quality ticket based on the defect determination. Repairs are performed and repair actions logged to the quality ticket. Tests are then performed on the repaired modules. Based on the test results, the knowledge base is updated. In other words, the knowledge base learns over time as more modules, symptoms, defects and actions are tracked. The knowledge base aids during troubleshooting by providing a list of repair actions and frequency of such repair actions that successfully repaired the defect identified in the quality ticket. Alternatively, the knowledge base may provide a list of defects and defect frequency for the symptom identified in the quality ticket. Using these techniques, the quality of a manufactured item may be improved.

Claims

1. A method of improving the quality of manufactured modules, comprising:

issuing a quality ticket uniquely identifying a defective module and a symptom thereof;

storing the quality ticket in a database;

determining a defect of the defective module based on the quality ticket stored in the database and by utilizing a knowledge base stored in the database;

logging, by an operator, a repair suggestion in the quality ticket based on said defect determination;

performing a repair action intended to repair the defective module based on the logged repair suggestion contained in the quality ticket;

logging the repair action to the defective module in the quality ticket;

testing the repaired module to determine if the defect has been corrected; and

updating the knowledge base according to said testing.

2. The method according to claim 1,

wherein the knowledge base utilized in said determining step provides a list of repair actions that successfully repaired the defect identified in the quality ticket.

3. The method according to claim 1, wherein the knowledge base utilized in said determining step provides a list of repair actions that successfully repaired the defect identified in the quality ticket and the frequency of the repair actions.

4. The method according to claim 1,

wherein the knowledge base utilized in said determining step provides a list of defects and defect frequency for the symptom identified in the quality ticket.

5. The method according to claim 1, further comprising:

associating a process with the detected symptom;

said issuing a quality ticket including identifying the defective module, the symptom, and the process associated with the detected symptom.

6. The method according to claim 1, further comprising:

associating a process and a process step with the detected symptom;

said issuing a quality ticket including identifying the defective module, the symptom, the process associated with the detected symptom, and the process step associated with the detected symptom.

7. The method according to claim 1,

said logging the repair suggestion including logging module component identification information and the repair action taken for each module component repaired or replaced.

8. The method according to claim 1,

repeating said determining, said logging the repair suggestion, said repairing, said logging the repair action and said testing if said testing determines that the defect has not been corrected.

9. The method according to claim 1,

utilizing a graphical user interface to perform said issuing, said determining, said logging the repair suggestion, and said logging the repair action.

10. The method according to claim 1,

said storing the quality ticket storing the quality ticket in a networked database.

11. The method of claim 1, wherein the quality ticket is represented by a graphical interface.

12. A system for improving the quality of manufactured modules, comprising:

a network;

a database operatively connected to said network, said database storing a knowledge base and a quality ticket uniquely identifying a defective module and a symptom thereof;

a workstation operatively connected to said database via said network, said workstation usable by an operator to determine a defect of the defective module based on the quality ticket and by utilizing the knowledge base stored in said database;

said workstation also usable by the operator to log a repair suggestion in the quality ticket based on the defect determination and view the logged repair suggestion to aid in the repair of the defective module;

said workstation further usable by the operator to log a repair action to the defective module in the quality ticket;

said workstation further usable by the operator to provide feedback as to whether the defect has been corrected based on testing of a repaired module; and

said knowledge base being updated according to the feedback.

13. The system according to claim 12,

said knowledge base providing to said workstation a list of repair actions that successfully repaired the defect identified in the quality ticket.

14. The system according to claim 12,

said knowledge base providing to said workstation a list of repair actions that successfully repaired the defect identified in the quality ticket and the frequency of the repair actions.

15. The system according to claim 12,

said knowledge base providing to said workstation a list of defects and defect frequency for the symptom identified in the quality ticket.

16. The system according to claim 12,

said database associating a process with the identified symptom;

said workstation usable to identify the defective module, the symptom, and the process associated with the symptom.

17. The system according to claim 12,

said database associating a process and a process step with the identified system;

said workstation usable to identify the defective module, the symptom, the process associated with the symptom, and the process step associated with the symptom.

18. The system according to claim 12,

said workstation usable to log repairs including logging module component identification information and repair actions taken for each module component repaired or replaced.

19. The system according to claim 12,

said workstation utilizing a graphical user interface.

20. The method of claim 12, wherein the quality ticket is represented by a graphical interface.