Systems and methods for improved manufacturing diagnostics

A system for identifying potential component manufacturing issues, the system comprising:

• a processor;
• and
• a memory including instructions that, when executed by the processor, cause the processor to:
• identify, for a first component, a first set of calibration values corresponding to the first component;
• flash, during a manufacturing phase, a controller associated with the first component with the first set of calibration values;
• perform, during the manufacturing phase, at least one diagnostic test on the first component using an on-board diagnostic system of a controller associated with the first component, wherein the controller associated with the first component is disposed within a vehicle;
• in response to receiving at least one diagnostic flag resulting from the at least one diagnostic test, determine whether the at least one diagnostic flag includes a false positive response;
• in response to a determination that the at least one diagnostic flag includes a false positive response, selectively adjust, during the manufacturing phase, at least one calibration value of the first set of calibration values;
• in response to selectively adjusting the at least one calibration value of the first set of calibration values, perform at least one subsequent diagnostic test on the first component using the adjusted first set of calibration values;
• in response to receiving at least one subsequent diagnostic flag resulting from the at least one subsequent diagnostic test, further adjust, during the manufacturing phase and responsive to a determination that the at least one subsequent diagnostic flag includes a false positive response, the adjusted first set of calibration values;
• and
• in response to a determination that the at least one diagnostic flag does not include a false positive response, flash the controller associated with the first component with a first set of production calibration values, wherein a diagnostic sensitivity of the first set of calibration values is greater than the first set of production calibration values, wherein the first set of production calibration values are used during a production use of the first component, and wherein the production use of the first component occurs after the first component exits the manufacturing phase.

An apparatus for identifying potential component manufacturing issues, the apparatus comprising:

• a processor;
• and
• a memory including instructions that, when executed by the processor, cause the processor to:
• identify, for a first component, a first set of calibration values corresponding to the first component;
• flash, during a manufacturing phase, a controller associated with the first component with the first set of calibration values;
• perform, during the manufacturing phase, at least one diagnostic test on the first component using an on-board diagnostic system of a controller associated with the first component, wherein the controller associated with the first component is disposed within a vehicle;
• in response to receiving at least one diagnostic flag resulting from the at least one diagnostic test, determine whether the at least one diagnostic flag includes a false positive response;
• in response to a determination that the at least one diagnostic flag includes a false positive response, selectively decrease, during the manufacturing phase, a diagnostic sensitivity of at least one calibration value of the first set of calibration values;
• in response to selectively decreasing the at least one calibration value of the first set of calibration values, performing at least one subsequent diagnostic test on the first component using the decreased first set of calibration values;
• in response to receiving at least one subsequent diagnostic flag resulting from the at least one subsequent diagnostic test, further decreasing, during the manufacturing phase and responsive to a determination that the at least one subsequent diagnostic flag includes a false positive response, the decreased first set of calibration values;
• in response to a determination that the at least one diagnostic flag does not include a false positive response, flash the controller associated with the first component with a first set of production calibration values, wherein a diagnostic sensitivity of the first set of calibration values is greater than the first set of production calibration values, wherein the first set of production calibration values are used during a production use of the first component, and wherein the production use of the first component occurs after the first component exits the manufacturing phase;
• and
• in response to a determination that the result of the at least one diagnostic test includes no diagnostic flags, selectively increase the diagnostic sensitivity of at least one calibration value of the first set of calibration values and generate the first set of production calibration values based on the first set of calibration values.