CN102885392A - Quality monitoring system and method of tobacco primary process - Google Patents
Quality monitoring system and method of tobacco primary process Download PDFInfo
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Abstract
The invention relates to a quality monitoring system and a method of a tobacco primary process. The quality monitoring system of the tobacco primary process comprises an index formulating unit, a data collection unit, a data analysis unit and a result determination unit; the collected data is modeled and analyzed on the basis of a tobacco primary process center control data system, so that the indexes according with current tobacco requirements, device processing capacity and processing direction are obtained, and the indexes are subjected to SPC (statistical process control) tracking determination. According to the technical scheme, the technical problem that a tobacco primary process parameter in the prior art cannot objectively reflect an actual production condition is effectively avoided. The quality monitoring method and the system are capable of monitoring and automatically analyzing the tobacco primary process.
Description
Technical field
The present invention relates to a kind of Quality Monitoring Control System and method, specifically a kind of cigar mill's technology for making tobacco threds Quality Monitoring Control System and method belong to technical field.
Background technology
At cigarette industry, during Primary Processing is most important, and what pay close attention to most in the during Primary Processing is stability and the controllability that guarantees the quality of production, and in whole production process, exist a large amount of parameters that affect tobacco quality, such as environment temperature, atmosphere moisture content, atmospheric pressure etc.At home, although the cigarette industry standard is arranged, because the difference of various places environment, quality of tobacco, capacity of equipment, processing method, there is different control parameters in each enterprise in its fiber tow production process.How according to a large amount of control parameters, more efficient, control the throwing quality accurately, easily, be the major issue that domestic all enterprises face.In actual production process, a large amount of technologists of enterprise cause attending to one thing and lose sight of another owing to needing the data volume of analysis too many.During fiber tow production, by middle control data system during Primary Processing is controlled, this system is at PLC automatically on the basis of control, automatically collects plc data and points out, and transfers data to simultaneously in the PLC control system.Technique person need to carry out walkaround inspection to the data in the throwing flow process, in each production process outlet, pay close attention to craft quality standard, but the supplied materials state for reality can't be judged, because in the production procedure, data volume is huge, and technique person can't accomplish every batch of product is all analyzed, and more can't accomplish each index is carried out horizontal and vertical analysis.
In order to solve the during Primary Processing complicated difficult with the problem of control and analysis, disclose a kind of method that improves parameter control effect in silk making technology among the Chinese patent literature CN102090703A, having comprised: the steady state data and the unstable state data that gather the technological parameter in the silk producing procedures; Calculate the Measure of Process Capability of technological parameter according to the steady state data of technological parameter; Respectively Measure of Process Capability and the unstable state data of technological parameter are changed, obtained the process capability evaluation value of technological parameter steady state data and unstable state data; Judge whether the steady state data of technological parameter and the process capability evaluation value of unstable state data reach respectively each self-corresponding predetermined threshold value, if the process capability evaluation value that does not reach predetermined threshold value is wherein arranged, then this technological parameter is carried out adjusting operation.In this technical scheme by the calculating to process capability evaluation value corresponding to steady-state process and the technological parameter in unstable state stage, investigated the quality condition of technological parameter comprehensively, for follow-up parameter optimization provides more realistic more comprehensively foundation, can improve the control effect after the optimization.But, this technical scheme takes the division of steady state data and unstable state data to carry out technological parameter in the during Primary Processing, the division of steady state data and unstable state data had certain subjectivity herein, some data is being to be unstable state under stable state, the certain state under certain state, therefore the method can not objectively reflect the actual state in the during Primary Processing, can not well instruct the throwing production process.
Summary of the invention
Technical problem to be solved by this invention is that the technology for making tobacco threds parameter control method can not objectively reflect actual production situation, can not well instruct the throwing production process in the prior art, can monitor technology for making tobacco threds quality control method and system with automatic analysis to the fiber tow production process thereby provide a kind of.
For solving the problems of the technologies described above, the present invention is achieved by the following technical solutions: a kind of technology for making tobacco threds quality control method comprises the steps:
(1) analyze in historical data in the control data system, obtain affect the index of technology for making tobacco threds quality, formulate the mark post value of each index, this index S PC(statistical Process Control is set) upper and lower bound controlled;
(2) set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
(3) the described desired value that collects is analyzed, compared with the mark post value of this index that obtains in the described step (1), exceed the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, carry out alarm indication;
(4) after this silk producing procedures is finished, carry out SPC and judge, form the SPC result of determination.
Technology for making tobacco threds quality control method of the present invention also comprises step (5), after this batch production is finished, this batch is estimated, and this batch quality is carried out quantification treatment.
Technology for making tobacco threds quality control method of the present invention, in described step (1), when the historical data of centering control data system is analyzed, add up nearly 2 years historical data, all qualified rates of each batch are added up, average level reaches 99% the long-term steadily index that is made as, average level reach between 70%-99% for paying close attention to index, average level is less than 70% be made as and pay close attention to index, described concern index is the index that affects the technology for making tobacco threds quality with paying close attention to index, and the mark post value of described index is the mean value of historical data.
Technology for making tobacco threds quality control method of the present invention, in described step (1), the described index that affects the technology for making tobacco threds quality is carried out weight coefficient calculate the percentage of the shared optimal value A2 of difference of the mean value A1 that described weight coefficient Q is this index and this index optimal value A2.
Technology for making tobacco threds quality control method of the present invention in described step (1), when the upper and lower bound of described index S PC control is set, is made as bound with 3 times of standard deviations of historical normal data.
Technology for making tobacco threds quality control method of the present invention, in described step (5), this batch estimated, and when this batch quality carried out quantification treatment, the method that adopts is as follows: according to resulting index in the step (1), the mark post value of establishing its index is x, and currency is y, then current index score z is (1-|y-x|/x) * 100, and then the higher explanation quality of score is better; Overall score is calculated by the weight coefficient Q (n) of each index in the step 1, and then total points is M=∑ z*Q (n), and n is each index.
A kind of technology for making tobacco threds Quality Monitoring Control System comprises:
Index is formulated the unit: the historical data in the analysis in the control data system, and acquisition affects the index of technology for making tobacco threds quality, formulates the mark post value of each index, and the upper and lower bound of this index S PC control is set;
Data acquisition unit, set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
Data analysis unit is analyzed the described desired value that collects, and compares with the mark post value of this index that obtains in the described step (1), exceeds the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, and carries out alarm indication;
Identifying unit after silk producing procedures is finished, carries out SPC and judges as a result, forms the SPC result of determination.
Technology for making tobacco threds Quality Monitoring Control System of the present invention also comprises evaluation unit, after this batch production is finished, this batch is estimated, and this batch quality is carried out quantification treatment.
Technique scheme of the present invention has the following advantages compared to existing technology:
(1) technology for making tobacco threds Quality Monitoring Control System of the present invention and method, in throwing, control on the basis of data system, setting target is formulated the unit, data acquisition unit, data analysis unit and identifying unit as a result, the data that collect are carried out modeling analysis, met most current pipe tobacco requirement, equipment processing ability, the index of machine direction, and index is carried out SPC follow the tracks of judgement, like this, just can determine production process is monitored and automatic analysis, can also predict bad parameter to the influence degree of pipe tobacco by the gross, and then can take measures in advance, lower road manufacturing procedure is carried out the index adjustment, thereby guarantee by the gross tobacco quality, can also judge according to SPC, the practical capacity of estimating apparatus is before the equipment practical capacity is not up to standard, improve or overhaul, guaranteed that capacity of equipment is sufficient.Technique scheme has effectively been avoided the technical problem that technology for making tobacco threds parameter in the prior art can not objective reaction actual production situation, is a kind ofly can monitor technology for making tobacco threds quality control method and system with automatic analysis to the fiber tow production process.
(2) technology for making tobacco threds Quality Monitoring Control System of the present invention and method, reduced hand labor intensity, improved the operability of PMS, estimated by the method that quantizes, having made things convenient for homogenizes produces analysis, can better guarantee the quality of product.
(3) technology for making tobacco threds Quality Monitoring Control System of the present invention and method, the historical data of introducing central control system is also analyzed, weed out a large amount of parameters that have nothing to do with batch quality, the minimizing technologist proposes the subjectivity of data, reduction staff's the amount of labour, thereby obtain to affect the index of technology for making tobacco threds quality, can better characterize the quality of this technology for making tobacco threds.
(4) technology for making tobacco threds Quality Monitoring Control System of the present invention and method quantize each index, carry out SPC and judge, and estimate, and adopt mark to characterize each index, obtain intuitively evaluation result by the mode that quantizes.
Description of drawings
For content of the present invention is more likely to be clearly understood, below in conjunction with accompanying drawing, the present invention is further detailed explanation, wherein,
Fig. 1 is the structural representation of technology for making tobacco threds Quality Monitoring Control System of the present invention;
Fig. 2 is throwing of the present invention workshop index name schematic diagram;
Fig. 3 is that throwing workshop index mark post is set schematic diagram;
Fig. 4 is throwing workshop batch tracking data affirmation figure;
Fig. 5 is throwing workshop batch trace analysis SPC figure;
Fig. 6 is throwing workshop batch tracking score browse graph.
The specific embodiment
Embodiment 1:
Technology for making tobacco threds Quality Monitoring Control System of the present invention comprises
Index is formulated the unit: the historical data in the analysis in the control data system, and acquisition affects the index of technology for making tobacco threds quality, formulates the mark post value of each index, and the upper and lower bound of this index S PC control is set;
Data acquisition unit, set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
Data analysis unit is analyzed the described desired value that collects, and compares with the mark post value of this index that obtains in the described step (1), exceeds the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, and carries out alarm indication;
Identifying unit after silk producing procedures is finished, carries out SPC and judges as a result, forms the SPC result of determination.
A kind of technology for making tobacco threds quality control method of the present invention comprises the steps:
(1) historical data in the control data system in the analysis, acquisition affects the index of technology for making tobacco threds quality, formulates the mark post value of each index, and the upper and lower bound of this index S PC control is set;
(2) set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
(3) the described desired value that collects is analyzed, compared with the mark post value of this index that obtains in the described step (1), exceed the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, carry out alarm indication;
(4) after this silk producing procedures is finished, carry out SPC and judge, form the SPC result of determination.
Embodiment 2:
On the basis of embodiment 1 described technology for making tobacco threds Quality Monitoring Control System, also comprise evaluation unit, after this batch production is finished, this batch estimated, this batch quality is carried out quantification treatment.
The described a kind of technology for making tobacco threds quality control method of the present embodiment comprises the steps:
(1) the nearly 2 years historical data in the control data system in the analysis, acquisition affects the index of technology for making tobacco threds quality, as shown in Figure 2.Simultaneously, by Preliminary screening, weed out a large amount of parameters that have nothing to do with batch quality, the minimizing technologist proposes the subjectivity of data, reduction staff's the amount of labour.Then according to the index that affects the technology for making tobacco threds quality that obtains, formulate the mark post value of each index, the upper and lower bound of this index S PC control is set, as shown in Figure 3.
In this step, with all qualified rates of each batch statistics, average level has reached 99%, then is defined as long-term steadily index; Average level reaches 70% and is defined as the concern index; Be less than 70% be defined as and pay close attention to index.Because " long-term steadily index " is stable, and is not the leading indicator of the current quality of impact, so with its rejecting.And " concern index " and " paying close attention to index " are the main cruxs of the current quality of impact, therefore divide these indexs into affect the technology for making tobacco threds quality index.So it is carried out daily tracking, its mark post value is the mean value of historical data.Its weight coefficient Q is the percentage of the shared optimal value of difference of the mean value A1 of this index and this index optimal value A2.Described optimal value herein is the standard value of corresponding index, and for the index of qualification rate equal percentage form, its optimal value is 100%, and for indexs such as temperature, times, its optimal value is the standard value of this index, and described standard value sets in advance according to industry standard.
The computing formula of described weight coefficient Q is: Q=|A2-A1|/A2*100%, and the difference of this formula explanation A2 and A1 is less, illustrates that this index is less to quality influence, and then Q is less.
In this step, judge the calculating of line for SPC, be bound by 3 times of standard deviations of historical normal data.
(2) set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
(3) the described desired value that collects is analyzed, compared with the mark post value of this index that obtains in the described step (1), exceed the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, then be labeled as redness and point out.As shown in Figure 4.
In this step, according to the mark post value and the bound that obtain in the step (1), if go out boundary, then redden and point out, and the mandatory requirement related personnel describes the at that time condition of production.
(4) after this silk producing procedures is finished, carry out SPC and judge, form the SPC result of determination, as shown in Figure 5.
In this step, the SPC judgment basis is [GB/T 4091-2001 idt.ISO8258:1991], and herein [GB/T 4091-2001 idt.ISO8258:1991] is national standard.
(5) after this batch production is finished, this batch estimated, this batch quality is carried out quantification treatment, as shown in Figure 6.
In this step, for resulting index in the step (1), establishing its index mark post value is x, and currency is defined as y, and (1-|y-x|/x) * 100 is defined as current index score z, and then the higher explanation quality of score is better.During the calculated population score, weight coefficient Q (n) by the n of index described in the step 1 calculates again, total points M=∑ z*Q (n) then, and n is each index, Q (n) is the weight system of index n, and described index n is each index that affects the technology for making tobacco threds quality in the described step (1).
Obviously, above-described embodiment only is for example clearly is described, and is not the restriction to embodiment.For those of ordinary skill in the field, can also make other changes in different forms on the basis of the above description.Here need not also can't give all embodiments exhaustive.And the apparent variation of being extended out thus or change still are among the protection domain of the invention.
Claims (8)
1. a technology for making tobacco threds quality control method is characterized in that, comprises the steps:
(1) historical data in the control data system in the analysis, acquisition affects the index of technology for making tobacco threds quality, formulates the mark post value of each index, and the upper and lower bound of this index S PC control is set;
(2) set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
(3) the described desired value that collects is analyzed, compared with the mark post value of this index that obtains in the described step (1), exceed the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, carry out alarm indication;
(4) after this silk producing procedures is finished, carry out SPC and judge, form the SPC result of determination.
2. technology for making tobacco threds quality control method according to claim 1 is characterized in that, also comprises step (5), after this batch production is finished, this batch is estimated, and this batch quality is carried out quantification treatment.
3. technology for making tobacco threds quality control method according to claim 2, it is characterized in that, in described step (1), when the historical data of centering control data system is analyzed, add up nearly 2 years historical data, all qualified rates of each batch are added up, average level reaches 99% the long-term steadily index that is made as, average level reach between 70%-99% for paying close attention to index, average level is less than 70% be made as and pay close attention to index, described concern index is the index that affects the technology for making tobacco threds quality with paying close attention to index, and the mark post value of described index is the mean value of historical data.
4. technology for making tobacco threds quality control method according to claim 3, it is characterized in that, in described step (1), the described index that affects the technology for making tobacco threds quality is carried out weight coefficient calculate the percentage of the shared optimal value A2 of difference of the mean value A1 that described weight coefficient Q is this index and this index optimal value A2.
5. according to claim 1 and 2 or 3 or 4 described technology for making tobacco threds quality control methods, it is characterized in that, in described step (1), when the upper and lower bound of described index S PC control is set, 3 times of standard deviations of historical normal data are made as bound.
6. technology for making tobacco threds quality control method according to claim 4, it is characterized in that, in described step (5), this batch estimated, and when this batch quality carried out quantification treatment, the method for employing was as follows: according to resulting index in the step (1), if the mark post value of its index is x, currency is y, and then current index score z is (1-|y-x|/x) * 100, and then the higher explanation quality of score is better; Overall score is calculated by the weight coefficient Q (n) of each index in the step 1, and then total points is M=∑ z*Q (n), and n is each index.
7. a technology for making tobacco threds Quality Monitoring Control System is characterized in that, comprising:
Index is formulated the unit: the historical data in the analysis in the control data system, and acquisition affects the index of technology for making tobacco threds quality, formulates the mark post value of each index, and the upper and lower bound of this index S PC control is set;
Data acquisition unit, set to follow the tracks of produce batch, in during Primary Processing, therefrom control the described desired value that gathers described batch products in the data system;
Data analysis unit is analyzed the described desired value that collects, and compares with the mark post value of this index that obtains in the described step (1), exceeds the upper limit of SPC control of described index or in limited time lower when the described desired value that collects, and carries out alarm indication;
Identifying unit after silk producing procedures is finished, carries out SPC and judges as a result, forms the SPC result of determination.
8. technology for making tobacco threds Quality Monitoring Control System according to claim 3 is characterized in that: also comprise evaluation unit, after this batch production is finished, this batch estimated, this batch quality is carried out quantification treatment.
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