Systems and methods for assuring and improving process quality

A system for evaluating at least one state of an assembly process of a work piece, the system comprising:

• a processor configured to segment the assembly process on a spatial basis into a plurality of process segments;
• one or more sensors configured to capture information related to each process segment of the plurality of process segments generated by the processor, the information comprising a plurality of samples captured during the assembly process at a predetermined temporal frequency;
• wherein the processor is further configured to:
• process the plurality of samples related to each process segment of the plurality of segments such that numerical data associated with each sample is generated,
• perform a statistical analysis on the numerical data to generate a plurality of process values wherein each process value is associated with one of the samples,
• determine whether the process values exceed a threshold value;
• determining one or more physical defects in the work piece as a result of the assembly process when one or more process values exceeds a threshold value;
• and
• in response to a determination that one or more of the plurality of process values exceeds the threshold, label the work piece for disposal as having failed the assembly process, based on the one or more physical defects determined.

A system for evaluating at least one state of an assembly process of a work piece, the system comprising:

• a processor configured to segment the assembly process on a spatial basis into a plurality of process segments;
• one or more sensors configured to capture information related to each process segment of the plurality of process segments generated by the processor, the information comprising a plurality of samples captured during the assembly process at a predetermined temporal frequency, wherein a trigger between process start/stop and data capture start/stop initiates and synchronizes a position of the work piece and said process segments;
• wherein the processor is further configured to:
• process the plurality of samples related to each process segment of the plurality of segments such that numerical data associated with each sample is generated,
• perform a statistical analysis on the numerical data to generate a plurality of process values wherein each process value is associated with one of the samples,
• determine whether the process values exceed a threshold value;
• determining one or more physical defects in the work piece as a result of the assembly process when one or more process values exceeds a threshold value;
• and
• in response to a determination that one or more of the plurality of process values exceeds the threshold, label the work piece for disposal as having failed the assembly process, based on the one or more physical defects determined, wherein a position of a said one or more physical defects on said work piece is determined based on said synchronization of position and data capture.