JP2002251212A - Method for quality control and system for the same and recording medium with its program recorded - Google Patents

Abstract

PROBLEM TO BE SOLVED: To accurately specify the cause of the failure of the quality of high- order component to be manufactured by the combination of the plurality of kinds of low order components. SOLUTION: In a graph 301 of the measured data of a finished article C, the finished article C which is shown with '×' in a normal/defective condition column 311, that is, the finished article C whose name card number is '08' is noticed, and the graph of an assembled article indicating change similar to the change of the measured data of the finished article C before and after the finished article C whose name card number is '08' is retrieved by visually following this downward. In a graphic 303 of an assembled article B, the change of the dimension of the assembled article B used for the finished article C whose name card number is '08' approximates to the change of the finished article C in the graph 301 so that it is possible to specify that the cause of the failure lies in not the assembly process of the finished article C or an assembled article A but the assembled article B. In the same way, the low order components of the assembled article B are retrieved so that it is possible to specify that the cause of the failure lies in components b2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for managing the quality of a lower part or an upper part in a case where a higher part is manufactured by combining a plurality of types of lower parts.

[0002]

2. Description of the Related Art When a certain factory (parts factory) is in charge of producing lower-order parts and another certain factory (assembly factory) is in charge of producing higher-order parts using the lower parts, the latter is used. At the end of the assembly process, the production quality of the upper part is inspected. Various types of conventional quality control systems have been proposed. For example, in the technology disclosed in Japanese Patent Application Laid-Open No. 6-155252, inspection data is acquired for each process, and quality defects of higher-order parts occur. In this case, a method of changing the work condition is considered by matching the work condition at the time of production of the lower part constituting the upper part.

[0003]

However, in an upper part manufactured by combining a plurality of types of lower parts, if the upper part is defective, the cause is that the lower part itself is defective. Even if the lower order parts are acceptable, there may be a problem in the assembly process. In this regard, in the above-described conventional technology, it is necessary to specify whether the cause of the defective quality of the upper part is a defect of each lower part constituting the upper part or whether there is a problem in the assembling process. Was difficult.

Therefore, an object of the present invention is to provide a high-order part manufactured by combining a plurality of types of low-order parts.
An object of the present invention is to provide means for identifying whether the cause of the quality defect of the upper part is a defect of each lower part constituting the higher part or whether there is a problem in the assembling process.

[0005]

A first aspect of the present invention is a method for quality control of an upper part manufactured by combining a plurality of types of lower parts, wherein at least one of the plural kinds of lower parts is controlled. A lower part data detection step of detecting quality data for the upper part data detection step of detecting quality data of the upper part, and comparing the quality data of the upper part with a predetermined upper part defect reference value, A quality management method comprising: an upper component evaluation step of performing an upper component defect determination; and a cause identification step of identifying a cause of a higher component failure based on the quality data of the lower component when the upper component defect determination is performed. It is.

According to the first aspect of the present invention, quality data of at least one of a plurality of types of lower parts is detected, and quality data of an upper part is detected.
Then, the higher-level component quality data is compared with a predetermined higher-level component failure reference value to determine a higher-level component failure.

In the first aspect of the present invention, when a higher-level component failure is determined, the cause of the higher-level component failure is specified based on the quality data of the lower-level component, so that one of the lower-level components is defective. In this case, it is known that the cause of the failure of the upper part is due to the failure of the lower part.If all of the lower parts are acceptable, it is known that there is a problem in the assembly process. The cause of failure can be quickly and accurately identified. In addition, the upper part in the present invention may be a semi-finished product, or may be a final product or a finished product.

[0008] A second aspect of the present invention is the quality control method according to the first aspect of the present invention, wherein the lower-level part quality data of the lower-level part is compared with a predetermined lower-level part defect reference value to determine a lower-level part defect. The evaluation step and the quality data of the lower part, the lower part required measure reference value for specifying the required lower part in the passed lower part which is not a target of the lower part failure determination in relation to the lower part defect reference value The quality control method further includes a necessary action lower-level component extraction step of performing a required action determination as compared with the method.

According to the second aspect of the present invention, lower-order part defect determination is performed by comparing quality data of lower-order parts with a predetermined lower-order part defect reference value. Further, the quality data of the lower part is compared with a lower part required measure reference value for specifying a required part in a passed product which is not a target of the lower part defect determination in relation to the lower part defect reference value, and Perform countermeasure judgment. Therefore, in the second aspect of the present invention, when the lower-level part itself does not reach the defective area, the working condition of the specified lower-order part requiring measures can be improved, and occurrence of a defective part in the lower-level part can be prevented. .

According to a third aspect of the present invention, there is provided the quality control method according to the second aspect of the present invention, further comprising a correcting step of correcting the lower component necessary countermeasure reference value based on the cause of the defect of the upper component. This is a characteristic quality control method.

According to the third aspect of the present invention, the lower-part required countermeasure reference value is corrected based on the upper-part failure cause specified in the cause specifying step. Therefore, in the third aspect of the present invention, the lower component necessity measure reference can be set to an appropriate value.

According to a fourth aspect of the present invention, in the quality control method according to the first aspect of the present invention, the quality data of the upper part is not subjected to the upper part defect judgment in relation to the upper part defect reference value. This quality control method further includes a high-requirement high-priority component extraction step of performing a high-requirement determination by comparing the high-reliability high-value component reference value for specifying the high-requirement high-level component in the passed high-order part.

According to a fourth aspect of the present invention, the quality data of a higher-order part is determined by determining a higher-order part necessary for identifying a higher-order part which requires a higher-order part which is not subject to a higher-order part defect determination in relation to a higher-order part failure reference value. The countermeasure required is determined by comparing with the countermeasure reference value. Therefore, according to the fourth aspect of the present invention, it is possible to improve the working conditions relating to the extracted high-priority parts requiring countermeasures, and prevent occurrence of defective products in the high-order parts.

A fifth aspect of the present invention is the quality control method according to the first or fourth aspect of the present invention, wherein the cause identification step includes at least one of quality data of the lower part and quality data of the upper part. A quality control method including a step of identifying a cause of the failure of the higher-order part based on a change over time in the quality control method.

According to a fifth aspect of the present invention, the cause of the failure of the upper part is specified based on a temporal change in at least one of the quality data of the lower part and the quality data of the upper part. Therefore, in the fifth aspect of the present invention, it is possible to detect a tendency of lowering the quality of the lower part or the upper part, and prevent occurrence of defective products in the upper part.

According to a sixth aspect of the present invention, there is provided the quality control method according to any one of the first to fifth aspects, wherein a producer of the plurality of types of lower-order parts and a producer of the upper-order parts communicate with each other. And transmitting the quality data of the upper-level part and the quality data of the lower-level part so that the producer of the plurality of types of lower-level parts can view the quality data of the lower-level parts by the communication means. It is a quality control method characterized by the following.

In the sixth invention, the quality data of the upper part and the quality data of the lower part are shared by the producer of the lower part and the producer of the upper part. Each effect can be made more effective.

A seventh aspect of the present invention is the quality control method according to the sixth aspect, wherein the communication means transmits quality data of the lower part from a producer of the lower part to a producer of the upper part. Is performed at the time when the lower part reaches the producer of the higher part or at an earlier time.

According to the seventh aspect of the present invention, it is guaranteed that the producer of the upper part can always use the quality data of the lower part when the lower part arrives, which is highly convenient.

According to an eighth aspect of the present invention, there is provided a quality control system for performing quality control of a high-order part manufactured by combining a plurality of types of low-order parts, wherein quality data of at least one of the plurality of types of low-order parts is provided. Lower part data detecting means for detecting the quality of the upper part, upper part data detecting means for detecting the quality data of the upper part, and comparing the quality data of the upper part with a predetermined upper part defect reference value to determine the upper part defect. The quality management system comprises: a high-order component evaluation unit that performs the above-mentioned operations; and a cause specification processing unit that specifies a cause of the high-order component failure based on the quality data of the low-order component when the high-order component failure determination is performed. According to the eighth aspect of the invention, the same effect as that of the first aspect of the invention can be obtained.

According to a ninth aspect of the present invention, there is provided a recording medium recording a quality control program for causing a computer to perform quality control of an upper component manufactured by combining a plurality of types of lower components, wherein the quality control program is A recording medium storing a quality management program characterized by causing the computer to output quality data of at least one of the plurality of types of lower-level parts and quality data of the higher-level parts in association with each other. is there. In the ninth aspect, the present invention can be used as a useful auxiliary means for realizing the effects of the first to eighth aspects.

[0022]

Embodiments of the present invention will be described below with reference to the drawings. In the embodiment shown in FIG. 1, components a1, a2, a3, b1, b are sent from component manufacturers 11, 12, 13, 21, 22, 23 to assembly manufacturers 101, 102.
2 and b3, respectively, and assembling manufacturers 101 and 102
The following shows an example in which the present invention is applied to a case where assembled products A and B are respectively delivered to a finished product maker 201 and a finished product C is manufactured by the finished product maker 201.

The parts makers 11, 12, 13, 21, 21
2, 23 are parts a1, a2, a3, b1, b, respectively.
2 and b3 are manufactured. The part a1 is a front door exterior plate, a part a
2 is a front door interior plate, component a3 is a front door reinforcement frame, component b1 is a rear door exterior plate, component b2 is a rear door interior plate, and component b3 is a rear door reinforcement frame. Assembled product A is part a
1, a2, a3 is a front door manufactured by combining the components, and the assembled product B is a rear door manufactured by combining the components b1, b2, b3. The finished product C is a vehicle body manufactured by assembling the assembled products A and B.

The parts makers 11, 12, 13, 21, 21
Reference numerals 2 and 23 denote measurement data input terminals 31, data processing terminals 32, and printers 34, each of which is a known personal computer, in addition to each production facility.
(Note that these are shown only for the component maker 11). The measurement data input terminal 31
And the data processing terminal 32 may be configured as a single personal computer having both functions.

The assembling maker 101 includes parts a1, a2, a
3 and combine them to produce an assembled product A as a higher-order part. The assembly maker 102
After receiving the delivery of 1, b2 and b3, these are combined to produce an assembled product B as a higher-order part. Each of the assembling manufacturers 101 and 102 includes, in addition to each production facility, a measurement data input terminal 131, a data processing terminal 132, a measurement data reception terminal 133, and a printer 134 (each of which is a known personal computer). Only the assembly maker 101 is shown). Note that a part or all of the measurement data input terminal 131, the data processing terminal 132, and the measurement data reception terminal 133 may be configured as a single personal computer having the same functions.

The finished product maker 201 receives the assembled products A and B and combines them to produce a finished product C as a higher-order part. Each of the finished product manufacturers 201 has a measurement data input terminal 231 and a data processing terminal 23, each of which is a known personal computer, in addition to the production equipment.
2 and a printer 234. Note that the measurement data input terminal 231 and the data processing terminal 232 may be configured as a single personal computer having both functions.

The data processing terminal 32 of the component manufacturer, the data processing terminal 132 and the measurement data receiving terminal 133 of the assembly maker, and the data processing terminal 232 of the finished product maker
Has a well-known web browser installed, and these terminals 32, 132, 133, 232 are connected to the Internet 50 or the intranet 70. For example, a data sharing server 60 installed in a production management section (not shown) Has been made accessible.

The entire data communication system including these terminals, servers, the Internet 50 and the intranet 70 is, for example, an HTTP (HyperText Transfer Protocol).
rotocol).

In this embodiment, the individual parts a1, a2,
a3, b1, b2, b3, assembled products A, B and finished product C
, Name tags on which unique name tag numbers are printed in the order of inspection are created and attached as described later.

Parts manufacturers 11, 12, 13, 21, 22
2, 23, assembling manufacturers 101 and 102, and finished product maker 201, have measuring instruments 35, 135, and 2 for measuring dimensions at predetermined measurement points in parts, assembled products, and finished products.
35 are provided. Further, the data processing terminals 32, 1
32, 232 include measurement data input terminals 31, 131,
A processing program for counting the measurement values transferred from the H.231 is installed. In the data file for inputting each measurement data generated by this processing program, individual parts a1, a2, a3, b1,
b2, b3, assembled products A and B, and finished product C are represented by item and in the order of the name tag number, and the parts and
The processing time and processing conditions corresponding to the assembled product / finished product are written.

As shown in FIG. 2, the measuring points in this embodiment are set at the same height. That is, the measurement points of the parts a1, a2, a3, b1, b2, and b3, the assembled parts A and B, and the completed part C are all on the ii line at the same height from the lower end 41 of the vehicle body. is there.

More specifically, as shown in FIG.
The measurement at 1 is performed for a distance d1 from the predetermined reference plane 43 of the component a1 at a point at a predetermined distance from the right end of the component a1 in the drawing. The measurement on the part a2 is
At a point at a predetermined distance from the right end of the component a2 in the drawing, the processing is performed for the distance d2 from the predetermined reference plane 44 of the component a2. The measurement of the component a3 is performed at an angle d3 between the vertical surface and the horizontal surface of the component a3 in the drawing.

The measurement on the part b1
Is performed at a point at a predetermined distance from the left end in FIG. 4 for a distance e1 from the predetermined reference plane 45 of the component b1. The measurement of the component b2 is performed for a distance e2 from the predetermined reference plane 47 of the component b2 at a point at a predetermined distance from the left end of the component b2 in the drawing. The measurement of the component b3 is performed by measuring the distance e from the predetermined reference plane 46 of the component b3 at a point at a predetermined distance from the left end of the component b3 in the drawing.
3 is performed.

The measurement of the assembled product A
At a point at a predetermined distance from the right end in FIG. The measurement of the assembly B is performed by measuring the distance f of the component b1 from the reference plane 45 at a point at a predetermined distance from the left end of the assembly B in the drawing.
2 is performed.

The measurement of the finished product C is performed for a distance g1 from the reference plane 45 of the part b1 at a point at a predetermined distance from the right end of the assembled product A in the drawing.

An example of the quality control processing according to the present embodiment configured as described above will be specifically described. As described above, in the present embodiment, the component manufacturers 11, 12, 1
From 3, 21, 22, 23, assembling manufacturers 101, 102
To the finished product maker 201 from the assembling manufacturers 101 and 102 to the finished product maker 201.
Manufactures finished products, while parts manufacturers 11,
Measurement data of parts a1, a2, a3, b1, b2, b3 manufactured in 12, 13, 21, 22, 23, measurement data of assembled parts A, B manufactured by assembly manufacturers 101, 102, and The measurement data of the finished product C manufactured by the finished product maker 201 is finally transmitted to and stored in the data sharing server 60 via one or both of the Internet 50 and the intranet 70. Then, the stored measurement data is transmitted to the component manufacturers 11, 12,
The data sharing server 60 stores the information so that it can be accessed at any time from the manufacturers 21, 21, 22, 23, the assembling manufacturers 101, 102, and the finished product manufacturer 201.

FIG. 4 is a flowchart showing a processing example in this embodiment. In the figure, the upper row (steps S10 to S10)
50) shows the flow of objects, and the lower part (steps S110 to S154) shows the flow of measurement data. First,
In the parts manufacturers 11, 12, 13, 21, 22, 23, the parts a1, a2, a3, b1, b2, b3
The measurement is performed for each of the above measurement points (S10). This measurement is performed by the measuring device 35 on the parts extracted by the periodic sampling. This extraction may be performed every predetermined number of days or may be performed every predetermined number of productions.

Next, the measured data of each measured part is
The data is input to the measurement data input terminal 31 (S110). This input is performed by an input operation of an operator or an input operation in which an automatic measuring machine or the like and an automatic input program software are combined. Specifically, the individual components a1, a2, a
3, b1, b2, and b3, the measured value of the part having the name tag number, the processing time and the processing condition corresponding to the part having the name tag number are associated with each other,
The data is sequentially written to the table format data file.

Next, the parts a1, a
2, a3, b1, b2, and b3 are pasted with name tags of the respective name tag numbers, respectively.
It is transported by a truck or the like (S20). Parts a1, a
2 and a3 are provided to the assembling maker 101 for parts b1, b2 and b3.
Is transported to the assembly maker B.

On the other hand, the components a1, a2, a3, which were previously input to the measurement data input terminal 31 in step S110.
The data file containing the measurement data of b1, b2, and b3 is transmitted from the data processing terminal 32 to the measurement data receiving terminal 133 of the assembling manufacturers 101 and 102 via the Internet 50 (S120). This transmission is performed by transmitting an e-mail attached with the data file. Here, the measurement data of the components a1, a2, and a3 is transmitted to the measurement data receiving terminal 133 of the assembly maker 101, and the measurement data of the components b1, b2, and b3 is transmitted to the measurement data reception terminal of the assembly maker 102. 133. In addition, this transmission is performed when the part is assembled by the assembly maker 101,
This processing is performed at the time when the part reaches 102 or earlier, for example, when the loading of the component on the truck is completed. Since transmission / reception by e-mail is generally completed within a few minutes, by the time the parts reach the assembling manufacturers 101 and 102, the assembling manufacturers 101 and 102 must have received the measurement data of the parts. become.

Next, in the assembling manufacturers 101 and 102, the parts a1, a2, a3 and the parts b1, b2, b3 with the name tags are collected and assembled respectively, and the assembled parts A, For B, measurement is performed for each of the above measurement points by the measuring instrument 135 (S30).

On the other hand, the components a1, a2, a3, b1, b2, b3 previously received by the measurement data receiving terminal 133
Is transferred to the data processing terminal 132. Then, the measured data of the assembled products A and B measured by the assembling manufacturers 101 and 102 are additionally input to this data file (S13).
2). This input is performed by an operator's input operation to the measurement data input terminal 131 or an input operation in which an automatic measuring machine or the like and an automatic input program software are combined. Specifically, the individual components a1, a2, a3, b1 ,
At the end of the lines b2 and b3, the columns of the processing time of the assembled products A and B, the processing conditions, and the measured values are additionally written, and the respective data are entered.

Next, a name tag is attached to the assembled products A and B to be measured, and the products are transported to the finished product maker 201 by a truck or the like (S40). On the other hand, a data file containing the measurement data of the parts and the assembled product is transmitted from the data processing terminal 132 to the data sharing server 60 via the intranet 70 (S140).

Next, in the finished product maker 201, assembled products A and B with name tags are collected and assembled, and the manufactured finished product C is measured by the measuring device 235 at the above measurement points. The measurement is performed (S150).

The measurement data is input at the measurement data input terminal 231 to a data file containing the measurement data of the parts and the assembled product by an operator's operation input or an input operation combining an automatic measuring machine or the like with an automatic input program software. Is entered. Thereby, a data file of a set of measurement data in a format in which the name tag number of each completed product C and the time, processing condition, and measured value of the processing of the completed product C are associated with each other is created. This data file is transmitted to the data sharing server 60 via the data processing terminal 232 (S152).

Then, the data sharing server 60 receives the data files including the measurement data from the assembling manufacturers 101 and 102 and the finished product maker 201, performs macro processing on them, associates the respective data, and makes a graph. Output (S142). This graph is output as a file in the form of a hypertext or the like generated by the data sharing server 60 according to a CGI (Common Gateway Interface) program, is stored in a hard disk device (not shown) of the data sharing server 60, and has a component maker / assembly maker and a completed Product manufacturer's data processing terminal 3
2, 132, 232.

The graph output and stored in this way is as shown in FIG. 5, for example. That is, first, the graphs 301, 302, and 303 of the measurement data relating to the finished product C, the assembled product A, and the assembled product B are arranged vertically, and the finished product C manufactured at a specific date and time is used for the manufacture. The measurement data with the assembled products A and B are displayed in an up-down relation.

For each measurement data, a defect reference value α, which is a discrimination value between a part / assembled product / finished product whose dimensions are within the standard and a defective product which is out of the standard, is set in advance. , The failure reference value α of each measurement data is represented by graphs 301 and 3.
02 and 303 are indicated by dashed lines. If the measured data exceeds the failure reference value α by an absolute value, “×” is displayed in the pass / fail column 311 of the graph.

Further, for each measurement data,
The standard value β required to identify the parts that need to be improved in the manufacturing conditions among the parts, assembled products, and finished products whose dimensions are within the standard is set in advance. The data required countermeasure reference value β is represented by graphs 301, 302, 30
3 is indicated by a dashed line. If the measured data is within the defective reference value α and exceeds the required countermeasure reference value β in absolute value, “△” is displayed in the pass / fail column 311 of the graph, and the measured data is displayed in absolute value. If it is within the required action reference value β, “○” is displayed in the pass / fail column 311 of the graph.

Then, the quality control personnel calculates the graph 30
Among the 1, 302, and 303, pay attention to the completed product C in which “×” is displayed in the pass / fail column 311 in the measurement data graph 301 of the completed product C, that is, the completed product C with the name tag number “08”. The graph of the assembled product showing a change similar to the change in the measurement data of the completed product C before and after the completed product C with the name tag number “08” is searched for by visually following down.

As a result, in the example of FIG. 5, in the graph 302 of the assembled product A, although the change in dimensions before and after the assembled product A used for the completed product C having the name tag number “08” is slight. On the other hand, in the graph 303 of the assembled product B, the name tag number “08” is displayed.
It can be seen at a glance that the change in dimensions before and after the assembled product B used for the finished product C is similar to the change in the graph 301 of the finished product C. Therefore, the quality control personnel considers that the cause of the defect of the finished product C having the name tag number “08” is
It can be specified that the finished product C is not in the assembly process or in the assembled product A but is in the assembled product B.

Next, the quality control staff clicks the lower part display button 313 in the graph 303 of the assembled part B in which the existence of the cause of the defect is specified by clicking the mouse input device on the display screen of the data sharing server 60 or the like. By inputting the instruction, the graph 30 of the measurement data relating to the parts b1, b2, and b3, which are the lower parts constituting the assembly B,
4, 305 and 306 are continuously displayed below the graph of the assembled product B. Then, the displayed graphs 304 and 30 are displayed.
By further following 5,306, a graph of a part showing a change similar to the change in the measurement data of the assembled product B before and after the assembled product B is searched. As a result, in the example of FIG. 5, the graph 304 of the component b1 shows a slight change in dimensions before and after the component b1 used in the assembled product B, whereas the graph 305 of the component b2 shows a small change in the dimension. The change in dimensions before and after the part b2 used for the accessory B is
It can be seen at a glance that it is similar to the change in the graph of the assembled product B. Therefore, the quality control personnel determines that the cause of the failure of the assembled product B is the assembling process of the assembled product B or the part b.
1, it can be specified that the part b2 exists.
Here, although the part b2 itself does not reach the defect reference value α, the pattern of the measurement data of the part b2 and the finished product C
The part b2 is specified as a cause of failure based on the closeness to the pattern of the measurement data.

When the cause of the defect is identified in this way, the quality control personnel checks the parts / assembled product or the production facility related to the assembling process related to the identified cause of the defect, and checks the facility. Is instructed to the parts maker / assembly maker or finished product maker that has This instruction is performed, for example, by sending an e-mail to a part maker / assembly maker or a finished product maker via the intranet 70 or the Internet 50.

The parts maker / assembly maker or the finished product maker receiving the instruction performs an inspection of the production equipment and an appropriate correction of the work setting contents. The work settings to be checked or corrected include, for example, the position and shape of the positioning jig,
There are current supply time related to welding, replacement period of welding tip, coating condition, adhesive discharge amount, and operation timing of various robot facilities. In addition to the inspection and correction of the production equipment, the inspection and correction of storage and transport conditions may be performed.

When the cause of the failure cannot be visually identified by the quality control personnel, the cause of the failure can be determined by using a separate failure cause analysis program (so-called AI) installed in the data sharing server 60, for example. May be analyzed statistically.

The cause of the defect is specified by the quality control personnel operating the data sharing server 60, and the parts makers 11, 12, 13, 21, 22, 2,
3. Assembly maker 101, 102 or finished product maker 20
1 is assigned to a data processing terminal 32, 1
By using the data files of the data sharing server 60 by using the data files 32 and 232, the processing may be performed independently.

As described above, in this embodiment, the finished product C
Are determined, the parts a1, a2, a3,
Since the cause of the failure of the finished product C is specified based on the measurement data of b1, b2, b3 or the assembled products A and B, if any part or the assembled product is defective, the finished product C It can be seen that the cause of the defect is the defect of the part / assembled product. If all of the plurality of parts / assembled products are acceptable products, it is understood that there is a problem in the assembly process of the finished product C. Therefore, the cause of the defect of the finished product C can be quickly and accurately specified.

Also, in the present embodiment, the component manufacturers 11,
12, 13, 21, 22, 23 and the assembling maker 101,
102 and the finished product maker 201 on the Internet 5
0 and the intranet 70 to transmit the data, and hold the respective data in the data sharing server 60 so that the component manufacturer can view the measurement data of the assembled product and the assembly manufacturer can view the measurement data of the component. . Therefore,
By sharing the assembled product quality data and the component quality data, the cause of the defect can be more effectively specified.

In this embodiment, the parts manufacturers 11, 1
From 2,13,21,22,23, assembly maker 101,1
02 is transmitted at the time when the part reaches the assembling maker 101 or 102 or at an earlier time, the assembling maker always sends the part data of the part when the arriving part arrives. The availability of quality data is guaranteed and the convenience is high. Also, the parts manufacturers 11, 1
In 2,13,21,22,23, the shipment of the part and the processing of the measurement data relating to the part can be performed in parallel. Therefore, by transmitting the measurement data as a part of the part shipment confirmation work, the measurement data is transmitted. It is guaranteed that the data is transmitted without forgetting, and the assembling manufacturers 101 and 102 on the receiving side can process a large number of data in a time series with a time margin.

In the present embodiment, since the necessary countermeasure reference value β is provided in addition to the defective reference value α, the parts a1, a2, a
Appropriate measures can be taken for 3, b1, b2, b3, assembled products A, B and finished products C before defective products occur. Particularly, in the past, only the defective reference value was set only for the completed product C, and when the measured value of the completed product C exceeded the defective reference value in absolute value, the manufacturing process of the lower part was inspected and corrected. When a defective product of the finished product C occurs, a number of lower-level parts are manufactured, and many man-hours and days are required to correct and deliver the product. Then, if the measured value of the finished product C (or the higher-order part or assembled product) exceeds the required standard value β in absolute value as a result of setting the required standard value β, In addition, since the production conditions of lower parts (or lower assembly parts) can be checked and corrected, occurrence of defective products in the finished product C can be prevented beforehand, and conversely, lower parts (or lower assembly parts) can be prevented. If the measured value of the product exceeds the required countermeasure reference value β in absolute value Because can check and modify the manufacturing conditions of the lower part at that time, it can prevent the occurrence of defective products in the lower part in advance.

In this embodiment, the measured value 320 of the part b2 corresponding to the completed product C having the name tag number “08” in which the defect has occurred has not reached the defect reference value α in absolute value.
As the post-processing in the present embodiment, the defect reference value α for the component b2 may be corrected or reset. That is, when a defect is found in the finished product C and the component b2 is specified as the cause of the defect, the defect reference value α may be corrected so as to be lower than the measured value 320 of the specified component b2. . In this case, after this correction, the component b2 can be determined to be defective on condition that the measured value of the component b2 exceeds the corrected defective reference value α by an absolute value, and the defective reference value is set to an appropriate value. In addition, by setting this value to "x" in the pass / fail column 311 of the graph 305, when a defect occurs in the finished product C, the graph of the part b2 can be quickly referred to visually, or each graph can be set. Can be easily specified by the search that traverses the line.

Further, when such a correction of the defective reference value α is performed, the required reference value β may be corrected in conjunction therewith. In this case, the required reference value β may be appropriately adjusted. Value can be set.

Further, in the present embodiment, the measured value itself is compared with the defect reference value α or the countermeasure reference value β to determine the defect or the countermeasure, but instead of such a configuration, In addition to such a configuration, parts a1, a
2, a3, b1, b2, b3, a failure of the assembled products A, B or the completed product C based on a change over time in at least one of the measured values of the assembled products A, B and the completed product C. The cause may be specified. That is, for example, when the amount of change in the measured value in each measurement exceeds a predetermined reference value, or when the amount of change in the measured value exceeds the predetermined reference value continuously for a predetermined number of times (for example, three times) or more. Alternatively, it is also possible to adopt a configuration in which a determination is made on the necessity of countermeasures. Also in this case, it is possible to detect a tendency of deterioration in the quality of the component or the assembled product, and to prevent the occurrence of a defective assembled product.

In this embodiment, the measurement data is obtained for all of the plurality of types of components and used to specify the cause of the defect. However, in the present invention, the measurement is performed for some of the plurality of types of components. It may be configured to acquire data. That is, based on the measurement data of the finished product C and the measurement data of one of the components (for example, the assembled product A), it is determined whether the failure of the finished product C is caused by the defect of the component or another component. It is possible to specify whether or not there is a defect in the assembly process. Some of these parts may be one type or a plurality of types.

In this embodiment, the measurement data relating to the dimensions is used. However, the present invention can be applied to other qualities such as performance, vibration, noise, and exhaust components.

In this embodiment, the quality control personnel visually identifies the similarity between the pattern of the measurement data of the finished product C and the pattern of the measurement data of each part / assembly. Alternatively, the similarity may be specified only by statistical processing (for example, pattern matching using normalized correlation) without performing the visual specification.

Further, in this embodiment, an example in which the present invention is applied to the determination of the cause of a defect in the finished product C has been described.
It may be a semi-finished product. That is, the present invention specifies the cause of failure of a higher-order part or a finished product in consideration of measurement data of a lower-order part, and such a configuration belongs to the scope of the present invention.

Also, in this embodiment, electronic mail is used for transmitting measurement data from the component maker to the assembly maker and from the assembly maker to the finished product maker. A configuration in which a measurement data input form is held in a computer accessible from the assembling maker and the finished product maker, for example, the data sharing server 60, and measurement data is input to the component maker, the assembling maker, and the finished product maker at any time, or A configuration in which the data is transferred to a recording medium or the like may be adopted.

In the present embodiment, the graph of the measured data is configured as a data file held in the data sharing server 60, and the data file is viewed from the data sharing server 60 and the data processing terminals 32, 132, and 232. ,
Instead of such a configuration, a configuration may be adopted in which a graph having a layout similar to that of FIG. 5 is output to a paper medium, and the cause of the failure is identified by using the graph.

In the present embodiment, the computer program used to configure the data file in the data sharing server 60 may be recorded on a known recording medium such as a CD-ROM. That is, the program is a recording medium recording a quality control program for causing a computer to perform quality control of a high-order part manufactured by combining a plurality of types of low-order parts, and the quality control program stores the quality control program in the computer. The present invention can be traded as a recording medium recording a quality management program characterized in that quality data of at least one of a plurality of types of lower parts and quality data of the upper part are output in association with each other. Can be used as a useful auxiliary means for realizing the effect.

In the present embodiment, the present invention is applied to a plurality of component manufacturers 11, 12, 13, 21, 21 which are different producers.
An example is shown in which the present invention is applied to production management among the manufacturers 22 and 23, the assembly manufacturers 101 and 102, and the finished product manufacturer 201. However, the present invention relates to production management between a plurality of processes in a single producer. Of course, it can also be applied.

[Brief description of the drawings]

FIG. 1 is a functional block diagram showing connection states of a component maker, an assembled product maker, a completed product maker, and a data sharing server according to an embodiment of the present invention, and their interrelationships.

FIG. 2 is an explanatory diagram showing parts, assembled products, finished products, and measurement points.

FIG. 3 is a sectional view showing a part, an assembled product, a finished product, and measurement points in detail.

FIG. 4 is a flowchart showing an outline of a production management process.

FIG. 5 is an explanatory diagram showing a graph including measurement data.

[Explanation of symbols]

11, 12, 13, 21, 22, 23 Parts manufacturer, 3
1, 131, 231 measurement data input terminals, 32, 13
2,232 data processing terminals, 34,134,234
Printer, 35, 135, 235 measuring instrument, 50 Internet, 60 data sharing server, 70 intranet, 101, 102 assembly maker, 201 completed product maker, a1, a2, a3, b1, b2, b3 parts,
A, B assembled product, C finished product, α defective standard value, β required standard value.

Claims (9)

[Claims] 1. A method for quality control of an upper part manufactured by combining a plurality of types of lower parts, the lower part data detection detecting quality data of at least one of the plurality of types of lower parts. A high-level component data detection step of detecting quality data of the high-level component; a high-level component evaluation step of comparing the quality data of the high-level component with a predetermined high-level component failure reference value to determine a high-level component failure; And a cause identification step of identifying a cause of failure of the upper part based on the quality data of the lower part when the upper part defect determination is performed. 2. The quality management method according to claim 1, wherein the lower part evaluation step of comparing the quality data of the lower part with a predetermined lower part defect reference value to determine a lower part defect; The lower part quality data of the lower part is compared with the lower part required measure reference value for specifying the lower part required measure in the passed lower part which is not a target of the lower part defect determination in relation to the lower part defect reference value, A quality control method characterized by further comprising a necessary action lower-level part extracting step of making an action required determination. 3. The quality management method according to claim 2, further comprising: a correction step of correcting the lower-part required countermeasure reference value based on the cause of the failure of the upper-level part. Method. 4. The quality control method according to claim 1, wherein the quality data of the higher-order part is determined for a pass upper-level part that is not subject to the upper-level part failure determination in relation to the upper-level part failure reference value. A quality control method, further comprising a high-measures high-parts extraction step of performing a high-measurement determination by comparing with a high-level parts necessary measure reference value for specifying the high-measures high-part. 5. The quality control method according to claim 1, wherein the cause identification step includes a time-dependent change in at least one of the quality data of the lower part and the quality data of the upper part. A quality control method comprising a step of identifying a cause of a defect of the upper part based on the information. 6. The quality control method according to claim 1, further comprising a step of connecting a producer of the plurality of types of lower-level parts and a producer of the upper-level parts by communication means. Quality, wherein the communication means transmits the quality data of the higher-order part so that the producers of the plurality of types of lower-order parts can view the quality data of the lower-order parts. Management method. 7. The quality management method according to claim 6, wherein the transmission of the quality data of the lower part from the producer of the lower part to the producer of the upper part by the communication means includes:
A quality control method, wherein the quality control is performed at a time when the lower order part reaches a producer of the higher order part or earlier. 8. A quality management system for managing quality of an upper part manufactured by combining a plurality of types of lower parts, wherein the lower part detects quality data of at least one of the plurality of types of lower parts. A data detection unit, a high-order component data detection unit that detects quality data of the high-order component, and a high-order component evaluation that compares the quality data of the high-order component with a predetermined high-order component failure reference value to determine a high-order component failure A quality management system, comprising: means; and cause identification processing means for identifying a cause of failure of the upper component based on the quality data of the lower component when a higher component defect determination is made. 9. A recording medium recording a quality management program for causing a computer to perform quality control of a higher-order part manufactured by combining a plurality of types of lower-order parts, wherein the quality management program stores the quality control program in the computer. Quality data for at least one of the multiple types of lower parts, and quality data for the upper parts,
And a quality control program for causing the quality control program to output them in association with each other.