Patent Number: 
Section: description

The invention relates generally to the use of information technology in industrial processes and more specifically to mass manufacturing processes. The problem addressed by the present invention is errors in mass manufacturing processes. Minimizing costs and improving product quality is a goal of any company developing products. To the manufacturer one of the most costly aspects in a product's life cycle is servicing product defects after the product has left manufacturing. Present methods use quality control tests on a manufactured item that are done by a single department such as a quality control department. Such tests are expensive to perform and it is also expensive and difficult to use the results. One present technology is Orthogonal Defect Classification (ODC) which addresses software defects found during development and by customers, but only software, not hardware and only defects found during development. Another known method is Orthogonal Problem Classification (OPC), which addresses software problems reported by customers, but does not address mass manufacturing industry, it only addresses software. Another technology, Warranty Management Solutions (WMS) facilitates handling by management of warranty related data but provides no feedback to modify production. Quality Control testing products before product release provide no feedback mechanism back to production and design facilities. In their report B. Freimut, C. Denger, and M Ketter, “An Industrial Case Study of Implementing and Validating Defect Classification for Process Improvement and Quality Management,” Proceedings of the 11th IEEE Software Metrics Symposium (METRICS 2005), Sep. 19-22, 2005, pages 19-29), provide a general description of a consulting-like engagement where they provide suggestions to a production organization based on an analysis of product defects. They do not provide any specifics of either their defect classifications or their analysis methods. In his report, Jack Silberman, “Robot Orthogonal Defect Classification Towards an In-Process Measurement System for Mobile Robot Development,” doctoral dissertation, Tech. Report CMU-RI-TR-99-05, Robotics Institute, Carnegie Mellon University, January, 1998, describes how the ODC methodology can be extended to determine and provide production process modification suggestion to an organization creating mobile robots, these robots including both hardware and software. He does not provide any description of how the ODC methodology can be used to support mass manufacturing of products that include both hardware and software. Therefore, there is a need for a solution that overcomes the deficiencies of the prior art. Briefly according to an embodiment of the invention, to solve the above-discussed problems a product service event classification (PSEC) method is used. The computer-implemented PSEC method of optimizing one or more of the production or testing processes in a mass manufacturing industry comprises steps of: collecting error data relating to a product at a plurality of points along its production and distribution chain; classifying the error data into categories of defects to provide classified error data; analyzing relationships among the classified error data; and suggesting modifications to one or more of the production or testing processes based on the analysis. The foregoing and other aspects, features, and advantages of the invention will become more apparent from the following description and from the claims. An embodiment of the invention is a method of optimizing the production and testing of products produced by a mass manufacturer, i.e. where many (virtually) identical copies of a given product are produced in exactly the same way. This is in contrast to cases where heroic, unique methods are used each time. The preferred embodiment will describe how the current invention is used to optimize the production and testing processes of a mass manufacturing plant 3010, whose products 1000 are sold by a product dealer 3020 and repaired by a product service provider 3030 (as will be described in detail with references to FIGS. 1-5). FIG. 1 is a component block diagram of an example of the product 1000 produced, sold and serviced in the preferred embodiment. As shown, the product 1000 includes a subsystem 1010, which includes apart 1020. Although only a single subsystem 1010 and a single part 1020 are shown, the current invention is also applicable to products 1000 that include two or more subsystems 1010 and subsystems 1010 that include two or more parts 1020. An example of such a product is a personal computer (product), a communication subsystem (the subsystem), and a chipset (port) according to a protocol such as the Ethernet. FIG. 2 is an illustrative flow diagram of the mass manufacturing industry's production, testing, and delivery processes 2000 according to an embodiment of the invention. As shown, the overall process 2000 begins at step 2010 where the design of the product 1000 is created. Next, in step 2020, the design is reviewed, and, if any errors (defects) are identified, control continues at step 2010, where the identified design error is corrected. Otherwise, in step 2030, an instance of the part 1020 is built, followed by step 2040 where the instance of the part 1020 is tested. If an error is identified, then step 2050 checks whether it is a part error. If so, control continues at step 2030 where the error is corrected. If the error is not a part error, then it must be design error and so control continues at step 2010 where the design is corrected to overcome the error. If no part error is found in step 2040, then control continues at step 2060 where an instance of the subsystem 1010 is built. Next, the instance of the subsystem 1010 is tested in step 2070. If an error is detected, then in step 2080 the error is checked to determine if it one with the subsystem. If so, control continues at step 2060 where the subsystem error is corrected. If the detected error is not one with the subsystem, then control continues at step 2050, which determines how the detected error, either a part or design error, is handled, as described above. If step 2070 does not detect any errors, then step 2090 is executed, where an instance of the product 1000 is built, following which the product 1000 instance is tested in step 2100. If an error is detected, then in step 2110 the error is checked to determine if it one with the product. If so, control continues at step 2090 where the product error is corrected. If the detected error is not one with the product, then control continues at step 2080, which determines how the detected error, either a subsystem, part or design error, is handled, as described above. If step 2100 does not detect any errors, then step 2120 is executed, where an instance of the mass manufactured product 1000 is created using the mass manufacturing process (e.g., including but not limited to an assembly line, and robotics), following which the mass manufactured product 1000 instance is tested in step 2130. If an error is detected, then in step 2140 the error is checked to determine if it one with the mass manufacturing process (e.g., the bolts that hold the wheels on are not being sufficiently tightened). If so, control continues at step 2120 where the mass manufacturing process error is corrected (e.g., wheel bolts are screwed on more tightly). If the detected error is not one with the mass manufacturing process, then control continues at step 2110, which determines how the detected error, either a product, subsystem, part or design error, is handled, as described above. If step 2130 does not detect any errors, then step 2120 is executed, where the instance of the mass manufactured product 1000 is transported to the Product Dealer 3020 (described in detail with reference to FIG. 3). Once delivered, mass manufactured product 1000 instance is tested in step 2160. If an error is detected, then in step 2170 the error is checked to determine if it one with the transportation process (e.g., the product's paint scratched by the vehicles that carry the product to the Product Dealer 3020). If the error is one with the transportation process, control continues at step 2150 where the transportation process error is corrected (e.g., the products are covered with a protective wrap before being shipped). If the detected error is not one with the transportation process, then control continues at step 2140, which determines how the detected error, either a mass manufacturing process, product, subsystem, part or design error is handled, as described above. Skilled artisans will appreciate that any of test processes other than Design Review 2020 (i.e., Part Test 2040, Subsystem Test 2070, Product Test 2100, Mass Manufacturing Test 2130 and Transportation Test 2160) could include stress testing (i.e., operating a given component [i.e., part, subsystem or product] up to or beyond one or more of its specified maximum limits) and environmental testing (i.e., testing a given component in one or more of is specified maximally adverse conditions). So, for example, the Part Test 2040 for tires could include running the inflated tires repeatedly of a series of bumps (for stress testing). Similarly for environmental testing, the Manufacturing Test 2130 could include driving each car (cars being the product) through 110 degree (Fahrenheit) heat. FIG. 3 depicts a network topology 3000 providing an execution environment implementing the functionality of a system for the current embodiment. The network topology 3000 includes: a Mass Manufacturing Plant 3010; a Product Dealer 3020; a Product Service Provider 3080; a Client D 3130, and a PSEC Server 3050. The Mass Manufacturing Plant 3010 comprises a location, including, but not limited to a building, or set of buildings, co-located or geographically distributed, wherein a Client A 3100 and an instance of mass manufactured product 1000 (MMP1 3060) is located. This location 3010 is where instances of the mass manufactured product 1000 are created. The Product Dealer 3020 comprises a location, including, but not limited to a building, or set of buildings, co-located or geographically distributed, wherein a Client B 3110 and an instance of mass manufactured product 1000 (MMP2 3070) is located. This location 3020 is where instances of the mass manufactured product 1000 are sold. The Product Service Provider 3030 depicts a location, including, but not limited to a building, or set of buildings, co-located or geographically distributed, wherein a Client C 3120 and an instance of mass manufactured product 1000, MMP3 3080 are located. This location 3030 is where instances of the mass manufactured product 1000 are repaired or serviced. Each of Clients A-D 3100-3130 and the PSEC Server 3050 are able to communicate with each other via a network 3090. The network 3090 comprises: the Internet, an internal intranet, or a public or private wireless or wired telecommunication network. Skilled artisans will appreciate that although only one each of the Mass Manufacturing Plant 3010, the Product Dealer 3020 and the Product Service Provider 3030 are depicted in FIG. 2, other embodiments are also applicable to cases where there are a greater number of one or more of these entities 3010-1030. Skilled artisans will also appreciate that other embodiments are also applicable to cases where the three entities 3010-3030 are co-located. Each of Clients A-D 3100-3130 enable an authorized user to interact with the PSEC Server 3050 (as will be discussed in further detail below) with reference to FIGS. 3-5. An example of a platform that supports the Clients A-D 3100-3130 includes any computing node that can act as web client (i.e., runs a web browser application and can communicate with the PSEC Server 3050 via the network 3090). Such software comprises Microsoft's Internet Explorer®. Still another example of a platform that supports the Clients A-D 3100-3130 includes, but is not limited to: an IBM ThinkPad running on a Windows based operating system such as Windows XP, or like operating system. Other contemplated operating systems include Linux, UNIX, and the like. Clients A-D 3100-3130 may also include network-connectable mobile (i.e., portable) devices such as some cellular telephones (i.e., devices which function as a cellular telephone and execute network applications, like web browsers). Although only four Clients A-D 3100-3130 are shown in FIG. 1, the current invention is also applicable to any number of client nodes greater than or equal to 1. Further, while the preferred embodiment includes a Web-based (i.e., HTTP) client 3100-3130, other forms of network communication are also applicable, such as a sockets-based client/server architecture, e.g., implementing secure sockets layer (SSL) or like network communications protocols. Skilled artisans will appreciate that the current invention is also applicable to cases where there is only a single client node, which resides on the same machine as the PSEC Server 3050, thereby eliminating the need for any network communication at all. FIG. 4 is a block diagram of the PSEC Server 3050. The PSEC Server 3050 is a computing node that acts as an HTTP server. The PSEC Server 3050 includes a CPU 4000, a network interface 4010, and a storage device 4020 such as a disk or data access storage device (DASD), and memory 4030, such as RAM. The network interface 4010 allows the PSEC Server 3050 to communicate with other network connected nodes via the network 3090. Such interfaces include, but are limited to: Ethernet, and wireless IP (Internet Protocol, e.g., LEAP, CDMA or WAP). In the present embodiment, the PSEC Server 3050 also includes PSEC Server logic 4040, which is embodied as computer executable code that is loaded into memory 4030 (for execution by CPU 4000) from a remote source (e.g., over the network 3090 via the network interface 4010), local permanent optic (CD-ROM), or from the storage device 4020 (e.g. disk or DASD). The PSEC Server logic 4040 stored in the memory 4030 includes an HTTP Server Handler 4050, which includes a PSEC Client Applet 4060 and a PSEC Client Interface Servlet 4070. The PSEC Server logic 4040 further includes a Defect Data Collection Handler 4080, a Defect Data Classification Handler 4090, an Analysis Handler 4100, a Suggested Actions Report Handler 4110, and a PSEC Server Database 4120. The HTTP Server Handler 4050 is an application that can respond to HTTP communications, comprising: the WebSphere™ product sold by IBM. The PSEC Client Applet 4060 and PSEC Client Interface Servlet 4070 together enable an authorized end-user to communicate with the Defect Data Collection Handler 4080, Defect Data Classification Handler 4090, Analysis Handler 4100, and Suggested Actions Report Handler 4110. When the end-user wants to interact with the PSEC Server 3050, the end-user first downloads the PSEC Client Applet 4060 to a web browser running on their client, Clients A-D 3100-3130. To download the PSEC Client Applet 4060, the end-user must provide sufficient credentials (e.g., user ID and password). After the PSEC Client Applet 4060 has been downloaded and enabled, the PSEC Client Applet 4060 communicates directly with the PSEC Client Interface Servlet 4070, which is executing in the HTTP Server Handler 4050. The HTTP Server Handler 4050, in turn, communicates locally with the other handlers 4090-4110 executing on the server 4050. Skilled artisans will recognize that this applet/servlet paring is well known in the art (e.g., see Jason Hunter with William Crawford, Java Servlet Programming (Sebastopol, Calif.: O'Reilly & Associates, Inc., 1988), pp. 277-337). Skilled artisans will also appreciate that the communication between the Clients A-D 3100-3130 and the handlers 4090-4110, in other embodiments can be implemented using other socket-based applications. The PSEC Server Database 4120 allows the PSEC Server 3050 to store, modify, and delete data related to misinformation, usage patterns, users, and online community servers. A detailed description of the information maintained by the PSEC Server Database 4120 is given below. The PSEC Server Database 4120 can be implemented using database tools such as the DB/2 product sold by IBM, and like database platforms. One with skill in the art will appreciate that in other embodiments, the PSEC Server Database 4120 can be a service that runs on another server and is accessed by the PSEC Server 3050 via the network 3090. The Defect Data Collection Handler 4080 enables the current invention to gather a set of defect data regarding the mass manufactured product 1000 and the processes of its production, testing and delivery 2000. This data includes but is not limited to:                Defects founds during product 1000 development, such as design defects discovered during the design review 2020,        Defects found in instances of the product 1000 after manufacturing 2110, but before delivery, such as cases where the mass manufacturing process 2120 has failed to tighten the bolts that hold the wheels on.        Defects that occur as a result of the transportation process 2150, such as paint being chipped during shipping due insufficient secure restraints in the delivery vehicle, and        Defects found at the Product Service Provider 3030, such as a case where an unreliable tire is identified by the fact that many instances of the product 1000 are brought in where one or more of the tires has burst during operation.Note that this data comes from in-process and post delivery. All such data is stored in the PSEC Server Database 4120.         The Defect Data Classification Handler 4090 takes all of the stored defects and either types or adds types to each defect, storing results in the PSEC Server Database 4120. This set of attributes categories and associated values is called the PSEC scheme. It is it uses some of the categories and values of the ODC scheme, as well as adding new categories and new values. In the current invention there are two types of defect attributes: opener data, that which is known when the defect is first discovered, and closer data, which is only available after a given defect has been resolved. In the current invention, the opener data associated with each that is stored in the PSEC Server Database 4120 comprises:                Unique ID, which can be used to distinguish one defect from all others.        VIN (Vehicle Identification Number), which, in the preferred embodiment is the unique encoded alphanumeric string that every automobile has assigned to, this string not only including a unique ID (serial number) for the car, but also indication the car's make, model, and manufacturing plant (for details, see http://en.wikipedia.org/wiki/VIN).        Ownership Duration indicates long the product was owned before the defect occurred. In one embodiment of the current invention these revealing conditions include, but are not limited to (note that they are listed in order of shortest to longest):                    Short—Year or less,            Medium—1 to 5 years,            Long—5 years to disposal.                        One skilled in the art will appreciate that the current invention also includes embodiments in which the Ownership Duration attribute has more or less than 3 values, and in which the values differ from those above (values applicable for the automotive industry). Such alternatives are needed for other mass manufacturing industries, such as the aeronautics industry, whose product: planes are owned and used for well over 5 years, on average. Thus the Long value would have to be greater than 5. Such values are also necessary because different industries have warranty periods of different length.        Conditions Revealing Defect, indicates must be done to product for the defect to occur. In one embodiment of the current invention these revealing conditions include (but are not limited to):                    Single Function: execution of single feature, e.g., windshield wipers don't work correctly at any speed.            Single Function with Option: execution of a single with some option, e.g. windshield wipers don't work at “slow.”            Interaction, execution of multiple functions exposes the defect            Sequencing: execution of multiple functions in a specific order.            Workload/Stress: operating the entire product 1000 at extreme conditions.            Recovery/Exception: testing product's reaction to crashes, e.g., airbags didn't deploy.            Startup/Restart: e.g., restarting product 1000.            Environmental: executing product in specific environmental condition.            Stress: testing extremes at a part 1020 level                        Open Date indicates when the defect was reported.        In-Process indicates whether or not the given defect occurred while the product was being developed.        Product Impact indicates the most pronounced impact the defect had on the products. One embodiment of the current invention includes the following (note that they are listed in order or greatest to least importance):                    Fire            Theft            Product Inoperable/Damaged            Safety Impairment            Function Inoperable/Damaged            Diminished Aesthetics (looks)            Diminished Performance                        Non Product Impact indicates the most pronounced impact the given defect had on non-product entities. One embodiment of the current invention includes the following Note that values are listed from most to least important):                    Death—Death occurred due to defect            Personal Injury—Personal Injury occurred due to defect            Safety Impairment—Product Unsafe to operate            Property Damage—Property Damaged occurred due to defect            None                         In the current embodiment, the closer data associated with each that is stored in the PSEC Server Database 4120 comprises:                Phase Found indicates where the defect should have been caught. One embodiment of the current invention includes the following. (Note that the values are listed from earlier to later in the overall mass manufacturing process 2000):                    Design Review 2020,            Part test 2040,            Subsystem test 2070,            Product test 2100,            Mass Manufacturing test 2130, and            Transportation test 2160.                        Close Date indicates when the defect was finally corrected        Repair Cost indicates how much it cost to fix the given defect. An example of values used by the preferred embodiment includes:                    Low—Less than $100, e.g., for simple part 1020 replacements and repairs,            Medium—$100-$1,000, e.g., for subsystem 1010 replacements and repairs,            High—$1,000-$100,000, e.g. for product 1000 replacement, repair and redesign, and            Extreme—Greater than $100,000, e.g. for retooling and redesign of mass manufacturing or transportation processes.                        Part Hierarchy indicates an identification hierarchy for the defective element. One embodiment of the current invention uses the automobile part hierarchy from NHSTA TREAD:                    Body            body:exterior            body:exterior:decals            body:exterior:exterior trim/moldings            body:exterior:paint            body:exterior:paint:paint-bumper            body:exterior:paint:paint-door            body:exterior:paint:paint-fender            body:exterior:paint:paint-hood            body:exterior:paint:paint-moldings/trim            body:exterior:paint:paint-quarterpanel            body:exterior:paint:paint-roof            body:exterior:paint:paint-tailgate            body:exterior:paint:paint-truck bed/box            body:exterior:paint:paint-trunk/hatch            body:glass            body:glass:backglass            body:glass:backglass:fixed backglass sealing            body:glass:backglass:heated backglass elements            body:glass:backglass:liftgate hinges and sealing            body:glass:mirrors            body:glass:mirrors:exterior mirrors            body:glass:mirrors:interior mirrors            body:glass:side glass            body:glass:windshield            body:glass:windshield:windshield sealing            body:interior            body:interior:carpet/floor mats            body:interior:headlining            body:interior:instrument panel/console/glove box            body:interior:interior trim/panels            body:locks/latches            body:locks/latches:door            body:locks/latches:door:door-front            body:locks/latches:door:door-rear            body:locks/latches:fuel door            body:locks/latches:fuel door:remote release            body:locks/latches:glove box/console/storage compartment            body:locks/latches:hood            body:locks/latches:hood:remote release            body:locks/latches:ignition lock and cylinder            body:locks/latches:power locks/rke            body:locks/latches:tailgate            body:locks/latches:tailgate:remote release            body:locks/latches:trunk/hatch            body:locks/latches:trunk/hatch:remote release            body:restraints            body:restraints:airbags            body:restraints:airbags:airbag module/sensors            body:restraints:airbags:clock spring            body:restraints:airbags:driver airbag            body:restraints:airbags:horn switch and assy            body:restraints:airbags:passenger airbag            body:restraints:airbags:side airbag/curtain            body:restraints:seat belts            body:restraints:seat belts:buckles            body:restraints:seat belts:child seats            body:restraints:seat belts:front belts            body:restraints:seat belts:pretensioners            body:restraints:seat belts:rear belts            body:restraints:seat belts:retractors            body:seating            body:seating:covers/pads            body:seating:headrests            body:seating:seat frame            body:seating:track/tilt            body:seating:track/tilt:manual seat            body:seating:track/tilt:power seat            body:structure/sheetmetal            body:structure/sheetmetal:bumpers            body:structure/sheetmetal:cowl            body:structure/sheetmetal:door            body:structure/sheetmetal:door: door and sideglass sealing            body:structure/sheetmetal:door:door-front            body:structure/sheetmetal:door:door-rear            body:structure/sheetmetal:fenders            body:structure/sheetmetal:floorpan            body:structure/sheetmetal:hood            body:structure/sheetmetal:hood:liftcylinders            body:structure/sheetmetal:quarterpanels            body:structure/sheetmetal:roof            body:structure/sheetmetal:roof:convertible            body:structure/sheetmetal:roof:removable/hardtop            body:structure/sheetmetal:roof:roof rack/bed accessories            body:structure/sheetmetal:roof:sun/moonroof            body:structure/sheetmetal:roof:t-top            body:structure/sheetmetal:tailgate            body:structure/sheetmetal:tailgate:tailgate sealing            body:structure/sheetmetal:truck bed/box            body:structure/sheetmetal:trunk/hatch            body:structure/sheetmetal:trunk/hatch:liftcylinders            body:structure/sheetmetal:trunk/hatch:trunk/hatch sealing            body:structure/sheetmetal:unibody            body:structure/sheetmetal:unibody:static metal sealing            body:window mechanisms            body:window mechanisms:manual mechanisms            body:window mechanisms:power mechanisms            chassis            chassis:axle (solid)            chassis:axle (solid):front axle            chassis:axle (solid):rear axle            chassis:differential            chassis:driveshaft/halfshaft            chassis:driveshaft/halfshaft:driveshaft (in-line)            chassis:driveshaft/halfshaft:driveshaft (in-line):front driveshaft            chassis:driveshaft/halfshaft:driveshaft (in-line):rear driveshaft            chassis:driveshaft/halfshaft:halfshaft            chassis:driveshaft/halfshaft:halfshaft:front halfshaft            chassis:driveshaft/halfshaft:halfshaft:rear halfshaft            chassis:frame            chassis:parking brakes            chassis:service brakes            chassis:service brakes:abs/traction control            chassis:service brakes:abs/traction control:abs module            chassis:service brakes:abs/traction control:hydraulic control unit            chassis:service brakes:abs/traction control:sensors/tone rings            chassis:service brakes:air brake system            chassis:service brakes:brake lines/hoses            chassis:service brakes:brake pedal            chassis:service brakes:caliper/wheel cylinder            chassis:service brakes:hub/wheel bearings            chassis:service brakes:master cylinder/booster/hydroboost            chassis:service brakes:pads/shoes/linings            chassis:service brakes:rotor/drum            chassis:steering            chassis:steering:steering column            chassis:steering:steering gear/rack            chassis:steering:steering lines/hoses            chassis:steering:steering linkage            chassis:steering:steering pump/reservoir            chassis:steering:steering wheel            chassis:suspension            chassis:suspension:active suspension            chassis:suspension:air suspension            chassis:suspension:alignment            chassis:suspension:alignment:front suspension            chassis:suspension:alignment:rear suspension            chassis:suspension:shock absorbers/struts            chassis:suspension:shock absorbers/struts:front suspension            chassis:suspension:shock absorbers/struts:rear suspension            chassis:suspension:spindles/supports            chassis:suspension:spindles/supports:front suspension            chassis:suspension:spindles/supports:rear suspension            chassis:suspension:springs            chassis:suspension:springs:front suspension            chassis:suspension:springs:rear suspension            chassis:suspension:stabilizers            chassis:suspension:stabilizers:front suspension            chassis:suspension:stabilizers:rear suspension            chassis:transfer case            chassis:transfer case:bearings            chassis:transfer case:case and housing            chassis:transfer case:controls            chassis:transfer case:gears            chassis:transfer case:seals and gaskets            chassis:transfer case:shafts            chassis:wheel assy            chassis:wheel assy:lugs and studs            chassis:wheel assy:spare tire and stowage            chassis:wheel assy:tire change/repair            chassis:wheel assy:tire change/repair:jack            chassis:wheel assy:tire change/repair:lug wrench            chassis:wheel assy:tire change/repair:tire repair kit            chassis:wheel assy:tire pressure monitoring system            chassis:wheel assy:tires            chassis:wheel assy:tires:tire bead            chassis:wheel assy:tires:tire belts            chassis:wheel assy:tires:tire sidewall            chassis:wheel assy:tires:tire tread            chassis:wheel assy:wheels/rims            chassis:wheel assy:wheels/rims:tire valve stem and core            chassis:wheel assy:wheels/rims:wheel balance weights            chassis:wheel assy:wheels/rims:wheel covers/ornaments            electrical            electrical:accessories/entertainment            electrical:accessories/entertainment:anti-theft            electrical:accessories/entertainment:clock            electrical:accessories/entertainment:compass/thermometer            electrical:accessories/entertainment:mobile communication            electrical:accessories/entertainment:navigation system            electrical:accessories/entertainment:powerpoint/lighter            electrical:accessories/entertainment:reverse sensing            electrical:accessories/entertainment:sound system            electrical:accessories/entertainment:sound system:antenna            electrical:accessories/entertainment:sound system:cd player/changer            electrical:accessories/entertainment:sound system:equalizer/amplifier            electrical:accessories/entertainment:sound system:radio            electrical:accessories/entertainment:sound system:sound system remote control            electrical:accessories/entertainment:sound system:speakers            electrical:accessories/entertainment:sound system:subwoofer            electrical:accessories/entertainment:sound system:tape player            electrical:accessories/entertainment:video system            electrical:accessories/entertainment:voice control            electrical:climate control            electrical:climate control:a/c clutch            electrical:climate control:a/c compressor            electrical:climate control:blower motor            electrical:climate control:cables/linkage/ducts            electrical:climate control:controls/relays/switches            electrical:climate control:heater core/cond/evap            electrical:climate control:hoses            electrical:climate control:refrigerant            electrical:driving controls/multifunction switches            electrical:driving controls/multifunction switches:electric tilt steering controls            electrical:driving controls/multifunction switches:hazard light switch            electrical:driving controls/multifunction switches:headlight dimmer switch/auto-lamp            electrical:driving controls/multifunction switches:speed control switches            electrical:driving controls/multifunction switches:turn signal switch            electrical:driving controls/multifunction switches:wiper/washer controls            electrical:instrument/display            electrical:instrument/display:amp/voltage gauge            electrical:instrument/display:boost gauge            electrical:instrument/display:coolant temperature gauge            electrical:instrument/display:coolant temperature gauge:coolant temperature sender/receiver            electrical:instrument/display:fuel gauge            electrical:instrument/display:fuel gauge:fuel gauge sender/receiver            electrical:instrument/display:message center            electrical:instrument/display:message center:fuel computer            electrical:instrument/display:odometer/hour meter            electrical:instrument/display:odometer/hour meter:tripminder            electrical:instrument/display:oil pressure gauge            electrical:instrument/display:oil pressure gauge:oil pressure sender/receiver            electrical:instrument/display:oil temperature gauge            electrical:instrument/display:oil temperature gauge:oil temperature sender/receiver            electrical:instrument/display:speedometer            electrical:instrument/display:speedometer:speedometer sender/receiver            electrical:instrument/display:tachometer            electrical:instrument/display:tachometer:engine speed sensor            electrical:instrument/display:warning chimes/lights            electrical:instrument/display:warning chimes/lights:4wd/range indicator/warning            electrical:instrument/display:warning chimes/lights:abs/traction control warning            electrical:instrument/display:warning chimes/lights:airbag warning            electrical:instrument/display:warning chimes/lights:brake system warning            electrical:instrument/display:warning chimes/lights:charge warning            electrical:instrument/display:warning chimes/lights:check engine light/mil            electrical:instrument/display:warning chimes/lights:coolant temperature warning            electrical:instrument/display:warning chimes/lights:door ajar warning            electrical:instrument/display:warning chimes/lights:lamp out indicator            electrical:instrument/display:warning chimes/lights:low fuel warning            electrical:instrument/display:warning chimes/lights:o/d indicator            electrical:instrument/display:warning chimes/lights:oil pressure/level low warning            electrical:instrument/display:warning chimes/lights:seat belt warning            electrical:lamps/bulbs            electrical:lamps/bulbs:back-up lamps            electrical:lamps/bulbs:brakelamps/himount brakelamp            electrical:lamps/bulbs:cargo/engine compartment lamps            electrical:lamps/bulbs:cornering lamps            electrical:lamps/bulbs:fog lamps            electrical:lamps/bulbs:headlamps/daytime running lights            electrical:lamps/bulbs:instrument illumination            electrical:lamps/bulbs:interior lighting            electrical:lamps/bulbs:license plate lamps            electrical:lamps/bulbs:parking/marker lamps            electrical:lamps/bulbs:puddle/mirror lamps            electrical:lamps/bulbs:turn signal lamps            electrical:start-charge            electrical:start-charge:alternator/generator            electrical:start-charge:battery            electrical:start-charge:ignition switch            electrical:start-charge:ignition switch:starting interlocks            electrical:start-charge:ignition switch:warning chimes            electrical:start-charge:starter            electrical:start-charge:starter:starter relay            electrical:start-charge:starter:starter solenoid            electrical:start-charge:voltage regulator            electrical:unique electric vehicle components            electrical:unique electric vehicle components:ev charging            electrical:unique electric vehicle components:ev propulsion            electrical:unique electric vehicle components:ev storage/batteries            electrical:wiper/washer            electrical:wiper/washer:window washer            electrical:wiper/washer:window washer:rear glass washer            electrical:wiper/washer:window washer:washer pump and reservoir            electrical:wiper/washer:window washer:windshield washer            electrical:wiper/washer:window wipers            electrical:wiper/washer:window wipers:headlight wipers            electrical:wiper/washer:window wipers:rear glass wipers/motor            electrical:wiper/washer:window wipers:windshield wipers/motor            electrical:wiring            electrical:wiring:circuit protection            electrical:wiring:circuit protection:distribution box            electrical:wiring:circuit protection:fuse box            electrical:wiring:circuit protection:fuses/fusible links            electrical:wiring:connectors            electrical:wiring:entertainment/accessory wiring            electrical:wiring:exterior lighting wiring/switches            electrical:wiring:ground wires            electrical:wiring:instrument panel wiring            electrical:wiring:main body wiring            electrical:wiring:start-charge wiring            electrical:wiring:trailer tow wiring            powertrain            powertrain:aux/pto            powertrain:engine            powertrain engine:accel pedal/linkage/controls            powertrain:engine:accessory drive            powertrain:engine:accessory drive:belts            powertrain:engine:accessory drive:pulley/tension            powertrain:engine:air induction            powertrain:engine:air induction:air cleaner assembly            powertrain:engine:air induction:intake manifold            powertrain:engine:air induction:supercharger            powertrain:engine:air induction:throttle body            powertrain:engine:air induction:turbocharger            powertrain:engine:base engine            powertrain:engine:base engine:block            powertrain:engine:base engine:crankshaft/damper/bearings            powertrain:engine:base engine:flywheel            powertrain:engine:base engine:pistons and pins            powertrain:engine:base engine:rods            powertrain:engine:base engine:seals and gaskets (not oil pan or head gasket)            powertrain:engine:cooling system            powertrain:engine:cooling system:cooling fan and motor            powertrain:engine:cooling system:cooling hoses/tubes            powertrain:engine:cooling system:level/temp indicator            powertrain:engine:cooling system:radiator            powertrain:engine:cooling system:reservoir            powertrain:engine:cooling system:thermostat            powertrain:engine:cooling system:water pump            powertrain:engine:cylinder head            powertrain:engine:cylinder head:cylinder head gasket            powertrain:engine:cylinder head:head body            powertrain:engine:electronic engine control            powertrain:engine:electronic engine control:diagnostics            powertrain:engine:electronic engine control:engine control actuators            powertrain:engine:electronic engine control:module            powertrain:engine:electronic engine control:sensors            powertrain:engine:emissions            powertrain:engine:emissions:air pump            powertrain:engine:emnissions:egr system            powertrain:engine:eemissions:pcv system            powertrain:engine:exhaust            powertrain engine:exhaust:attachment            powertrain:engine:exhaust:catalytic convertor            powertrain:engine:exhaust:exhaust manifold            powertrain:engine:exhaust:exhaust pipe            powertrain:engine:exhaust:heat shields            powertrain:engine:exhaust:muffler/resonator            powertrain:engine:fuel system            powertrain:engine:fuel system:attachment            powertrain engine:fuel system:carburetor            powertrain:engine:fuel system:evaporative system            powertrain:engine:fuel system:filler neck/cap            powertrain:engine:fuel system:fuel filter            powertrain:engine:fuel system:fuel hoses/tubes            powertrain:engine:fuel system:fuel pump            powertrain:engine:fuel system:fuel rail            powertrain:engine:fuel system:fuel tank            powertrain:engine:fuel system:injector/seals            powertrain:engine:fuel system:roll-over valve            powertrain:engine:fuel system:tank selector            powertrain:engine:ignition system            powertrain:engine:ignition system:coil wire and plug wires            powertrain:engine:ignition system:distributor            powertrain:engine:ignition system:ignition coil            powertrain:engine:ignition system:ignition module            powertrain:engine:ignition system:spark/glow plugs            powertrain:engine:miscellaneous controls            powertrain:engine:miscellaneous tubes and hoses            powertrain:engine:miscellaneous vacuum components            powertrain:engine:mounts/dampers            powertrain:engine:oil system            powertrain:engine:oil system:level indicator/dipstick            powertrain:engine:oil system:oil cap            powertrain:engine:oil system:oil filter            powertrain:engine:oil system:oil pan and crank sealing            powertrain:engine:oil system:oil pump            powertrain:engine:timing system            powertrain:engine:timing system:camshaft            powertrain:engine:timing system:tensioner/guides            powertrain:engine:timing system:timing belt/chain            powertrain:engine:timing system:timing gear/sprocket/aux. drive shaft            powertrain:engine:valve train            powertrain:engine:valve train:rocker arms and support            powertrain:engine:valve train:seal—valve guide            powertrain:engine:valve train:tappets and push rods            powertrain:engine:valve train:valves            powertrain:transmission            powertrain:transmission:automatic            powertrain:transmission:automatic:bands and servos            powertrain:transmission:automatic:case and housing            powertrain:transmission:automatic:clutch and sun gears            powertrain:transmission:automatic:control valve assembly            powertrain:transmission:automatic:cooler and tubes            powertrain:transmission:automatic:differential and bearings            powertrain:transmission:automatic:electronic trans controls            powertrain:transmission:automatic:indicator/dipstick/filler tube            powertrain:transmission:automatic:linkage/shift lever            powertrain:transmission :automatic:output shaft            powertrain:transmission:automatic:pan/gaskets/seals            powertrain:transmission:automatic:parking pawl            powertrain:transmission:automatic:planetary assembly            powertrain:transmission:automatic:speedo drive            powertrain:transmission:automatic:torque converter            powertrain:transmission:automatic:trans fluid pump            powertrain:transmission:automatic:vent area            powertrain:transmission:clutch            powertrain:transmission:clutch:clutch disc            powertrain:transmission:clutch:clutch pedal and linkage            powertrain:transmission:clutch:hub and bearing            powertrain:transmission:clutch:pressure plate            powertrain:transmission:manual            powertrain:transmission:manual:bearings            powertrain:transmission:manual:case and housing            powertrain:transmission:manual:differential and bearings            powertrain:transmission:manual:electronic trans controls            powertrain:transmission:manual:gaskets and seals            powertrain:transmission:manual:gears            powertrain:transmission:manual:linkage/shift lever            powertrain:transmission:manual:shafts            powertrain:transmission:manual:speedo drive            powertrain:transmission:manual:synchronizer assembly            Publications            publications:labels            publications:owner's manual            publications:scheduled maintenance guide                        Target, indicates the overall type of the defect.                    Mechanical            Electrical            Software/Firmware/Logic                        Scope of Fix                    Part            Subsystem            Product            Manufacturing-related equipment            Transportation-related equipment                        Corrective Action indicates what was done to overcome the defect. IN the preferred automobile-related embodiment of the current invention, these actions comprise:                    Replace, Replace an existing part with a new part            Adjust/Lubricate, Make adjustment or lubrications to existing parts            Reflash, Reprogram a part            Appearance Fix, Correct problem with product's external finish (e.g., paint)            Install-New, Install a new part that was not in the design            Remove, Remove a part previously installed            Reassemble, Re-Install the same part            Install-Missing, Install a new part that was missing and included in the design                        Responsible Agent indicates the owner of the process that the caused problem. In the present automobile-related embodiment of the current invention this comprises:                    Tier 3, Parts Supplier            Tier 2, Subsystem Supplier            Tier 1, Product Developer            OEM's Manufacturing Department            OEM's Transportation Department                        Part # indicate the manufactures ID for the given defective effective part        Charge Type indicates whether or not the charge for the repair of the given defect was covered by warranty or not. A skilled artisan will appreciate that in many cases it is possible for this attribute to be automatically computed by, e.g., by comparing the Ownership Duration to the Open Date.         In addition to openers and closers, there are mapped attributes whose values for a given defect are computed from other attributes for the given defects. M-Symptoms-Reveal Conditions                Part History indicates when defect was introduced. This is derived from the Part# and product VIN, which indicates the product's date and location of construction. These values comprise:                    Earlier, Part used in prior make/model/years            New, First time part used in a make/model/year            Engineering Change, Part used in make/model, noted engineering change            Bad Fix, Previous fix did not address defect.                        Test Type indicates the type of test that should have caught the given defect. An example list from an embodiment follows:                    Part Testing, Smallest definable unit            Subsystem Testing, Combination of Parts            Product Testing, Combination of Subsystems            (Vehicle) Safety Testing, Crash, Roll-Over, Skid, Fire, Airbags, Seat Belts, Look at Safety Features on Vehicle, Bumper Dents            (Vehicle) Road Testing, Road test is like a final integration or system test of the vehicle            (Vehicle) Manufacturing Testing, Manufacturing tests of the vehicle, done on each build                        The Test Type attribute can be determined from a given defect's conditions-revealing-defect and ownership-duration. An example of a set of mappings for the preferred embodiment is as follows:         TABLE 1Test TypeRevealing ConditionsOwnership DurationPart TestingCoverageLongVariationLongStressLongSubsystem TestingInteractionLongSequenceLongProduct TestingStartup/RestartLongWorkload/StressLongSafety TestingRecovery/ExceptionLongRoad TestingEnvironmentalLongDriving ConditionsLongSensory InspectionLongManufacturing TestingHardware ConfigurationShortSoftware ConfigurationShortSensory InspectionShortCoverageShortVariationShort There are also derived attributes whose values for a given defect can only be computed when all of the defects and all other attributes have been computed                # Units Affected, indicates the total number of product instances that have suffered from this same defect. It is derived by counting the number of defects that identical part # and corrective action value.        Phase of Defect Injection indicates the process in which the given defect was created. This attribute can be determined from a given defect's scope of fix, corrective action and # of units. An example of a set of mappings for the preferred embodiment are as follows:         TABLE 2Phasesof Defect InjectionScope of FixCorrective Action# of UnitsDesignPartRemoveAny number(Requires in-depthComponentRemoveAny numberanalysis to determinePartInstall-NewAny numberroot of defect -part,ComponentInstall-NewAny numbersubsystem or product)Part(s)Replace>1000ComponentReplace>1000PartAdjust/Lubricate>1000ComponentAdjust/Lubricate>1000Sub SystemReplaceAny numberSystem(s)ReplaceAny numberPart(s)ReflashAny numberComponentReflashAny numberSub SystemReflashAny numberSystem(s)ReflashAny numberManufacturing-BodySystemAdjustAny numberManufacturing-PaintPartAppearance Fix>1000SubsystemAppearance Fix>1000ProductAppearance Fix>1000Manufacturing-AssemblyPart(s)Replace1-1000ComponentReplace1-1000PartAdjust/LubricateAny numberComponentAdjust/Lubricate1-1000Sub SystemAdjust/LubricateAny numberSystemAdjust/LubricateAny numberPart(s)Install-MissingAny numberComponentInstall-MissingAny numberPart(s)ReassembleAny numberComponentReassembleAny numberPost Production Build &PartAppearance Fix1-1000Package/TransportationSubsystemAppearance Fix1-1000ProductAppearance Fix1-1000Post ProductionPartInstall-NewAny numberDealershipComponentInstall-NewAny numberOptionsA skilled artisan will appreciate that the current invention also covers the phase at which a given product's requirements are determined as a Phase of Defect Injection. Every defect is classified with each of the attributes above with all of the data stored in the PSEC Server Database 4120. Note that the PSEC Scheme includes data concerning not only software, but hardware and electronics as well (e.g., in the Parts Hierarchy). Further, note that the PSEC Scheme also includes data and analysis techniques targeting mass manufacturing production processes (e.g., Test Type:Manufacturing Test and Phase of Defect Injection: Manufacturing). As is described in detail with reference to FIG. 6, the Analysis Handler 4100 uses the classified defect data stored in the PSEC Server Database 4120 to provide data for and answers to questions related to the production and testing process of the mass manufacturer. As is described in detail with reference to FIG. 6, the Suggested Actions Reports handler 4110 compiles the charts and text results stored in the PSEC Server Database 4120 to generate a report containing suggested modification to one or more production or testing processes in the mass manufacturing industry's production, testing, and delivery processes. Such suggestions can include, but are not limited to the addition of a new test phase, or an indication of whether or not a given product is ready for public sale. In addition to textually described suggestions, the report can also include graphical charts justifying the given suggestions, often more than two or more such graphical charts per suggestion. A skilled artisan will appreciate that the current invention also includes a PSEC scheme that includes the service context in which a given defect was found as an attribute, with values including but not limited to:scheduled maintenance, nonscheduled maintenance, and product recall. A skilled artisan will further appreciate that the current invention also includes a PSEC scheme that includes the attributes that indicate the complexity level—e.g., indicated numerically—of other attributes. Examples include, but not limited to Condition Revealing Defect Complexity:                1 for Single Function        2 for Single Function with Option        3 for Interaction and Sequencing        4 for Workload/Stress, Recovery/Exception, Startup/Restart, Environmental, and Stress.         FIG. 5 is a detailed flow diagram of the operation of the PSEC Server logic 4040. In step 5010, the HTTP Server Handler 4050 awaits an HTTP request. When such a request arrives, step 5020 checks whether it is a request for the Defect Data Collection Handler 4080. If so, this handler 4080 is invoked following which control continues at step 5010. If the request is not for the Defect Data Collection Handler 4080, then step 5040 checks whether it is a request for the Defect Data Classification Handler 4090. If so, this handler 4090 is invoked following which control continues at step 5010. If the request is not for the Defect Data Classification Handler 4090, then step 5050 checks whether it is a request for the Analysis Handler 4100. If so, this handler 4100 is invoked following which control continues at step 5010. If the request is not for the Analysis Handler 4100, then step 5040 checks whether it is a request for the Suggested Actions Report Handler 4110. If so, this handler 4110 is invoked following which control continues at step 5010. If the request is not for the Actions Report Handler 4110, then a miscellaneous handler, beyond the scope of the current invention, is called in step 5070, following which control continues at step 5010. Referring to FIG. 6, a flow diagram 5000 of the operation of the current embodiment is shown. In particular, a case involving an automobile manufacturer is given. First, in step 6010 all defect data for a particular make (e.g., Ford) and model (e.g., Corvette) of car is collected, this data being using the Defect Data Collection Handler 4080 from any of Clients A-D 3100-3130 via the PSEC Client Applet 4060. Skilled artisans will appreciate that any additions could be made manually (i.e. by a human typing information into a computer running the PSEC Client Applet 4060 via a web browser, or by an automatic data collection program, also which communicates with the PSEC server 3050 via the PSEC Client Applet 4060. Thus, the current embodiment allows a given mass manufacturing industry to automate its defect data collection. Skilled artisans will appreciate that this defect data includes in-process production data (e.g., data from the Mass Manufacturing Plant 3010), as well as post-sales, service data (e.g., from the Product Dealer 3020, or the Product Service Provider 3030). Next, in step 6020, the defect data is classified using the Defect Data Classification Handler 4090, again via accesses from Clients A-D 3100-3130. Skilled artisans will appreciate that although the classifications may be made by employees of the manufacturing organization (e.g., Ford), including but not limited to domain experts, a service organization could also provide one or more of the classifications. A skilled artisan will appreciate that if a given mass manufacturing organization obtained its parts 120 or subsystems 1010 from another given component supplier, and if that given component supplier used to current invention to analyze its defects, then the mass manufacturing organization could use the PSEC scheme-based classified defect data for its own defect analysis. Next, in step 6030, using the Analysis Handler 4100, relationships amongst the classified data are sought to answer questions relevant to the mass manufacturer (e.g., which production process(es) is(are) producing the defects that drive the majority of the warranty costs?). This research can also provide indications of salient problems. For example, suppose that a chart displaying the number of defects that escape from (i.e., are not caught by) each of the test processes 2020, 2040, 2070, 2100, 2130 and 2160 shows that vast majority come from the Part testing phase 2040. Then, if the goal of the given mass manufacturer is to save money, more attention and/or resources (e.g., time, and personnel) should be spent on Part testing 2040, so as to keep these defects from escaping to the later stages where they are more expensive to overcome. The Analysis Handler 4100 also includes rules that test the classified data to answer specific questions. Skilled artisans will appreciate that one or more of these rules can be provided when the current invention is first provided to a given organization (e.g., mass manufacturer). An example of such a rule would be one that reviews the Product Impact of the defects and then specifies the given product's reliability:e.g., “high” returned if none of the defects made the product inoperable, “average” if only a few did, and “low” if most defects did. Finally, in step 6040, the current invention compiles a charts and results into a report using the Suggested Actions Report Handler 4110. Skilled artisans will appreciate that Suggested Actions Report Handler 4110 could either of following methods:                Automatic compilation of all charts and results generated by the Analysis Handler 4100 and stored in the PSEC Server Database 4120, or        Allowing an end-user to select the charts and results they wish to include and then compiling only entities into the final report.A skilled artisan will appreciate that one or more members of a service organization could provide the chart and result selection described above instead of an employee of the mass manufacturer,         A skilled artisan will also appreciate that the current invention could be executed multiple times by a given organization, e.g., periodically, say once a year, or to every new version of a given product. By doing this and comparing the results of each execution (e.g., comparing the reports produced in step 6040) the benefits realized by the given organization could include:                Verifying that they are overcoming problem indicated in earlier reports, e.g., by checking the previous problems either vanish or are less severe in later reports.;        Verifying that their product are becoming more stable, reliable, or safe, e.g., by comparing the respective levels of stability, reliability, and safety between reports; or        Verifying that are maintaining a sufficient level of production and testing quality, e.g., by verifying that no new or higher severity problems are reported in later reports.         A skilled artisan will further appreciate that PSEC analysis reports from different organizations could be compared so as to judge the strengths and weaknesses of the organizations. A skilled artisan will also appreciate that by using the both Charge Type attribute (i.e., whether or not the defect's repair was covered by warranty) and the Repair Cost attributes, the analysis provided by the Analysis Handler 4100 and reported by the Suggested Actions Report Handler could include consideration of each defect's warranty cost. Thus, a given organization interested in reducing their warranty-related costs could use the current invention to indicate relevant problems and to suggest corrective modifications to their production and testing processes. A skilled artisan will also appreciate that by comparing and analyzing the classified defects data, especially using the In-Process attribute, the current embodiment can be used to compare defects that escaped (i.e., were created and yet not caught) the product's development and production to those that occurred our in the field. A skilled artisan will finally appreciate that the current embodiment could be provided as a service by a service organization to the mass manufacturer. This service could include the service organization collecting the defects, classifying the defects, analyzing the classified defects and generating the report summarizing the analysis. This service could be offered on a continuing basis, e.g., the service organization could analyze and provide an analysis report to the mass manufacturer each year. The service could also include modifications and updates to the PSEC scheme used to analyze the given mass manufacturer. A skilled artisan will further appreciate that variations, modifications, and other implementations of what is described herein may occur to those of ordinary skill in the art without departing from the spirit and scope of the invention. Accordingly, the invention is defined by the following claims and not to be defined only by the preceding illustrative description.