CN113115978A - Process method for reducing single gram weight deviation of cigarettes - Google Patents
Process method for reducing single gram weight deviation of cigarettes Download PDFInfo
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- CN113115978A CN113115978A CN202110413220.7A CN202110413220A CN113115978A CN 113115978 A CN113115978 A CN 113115978A CN 202110413220 A CN202110413220 A CN 202110413220A CN 113115978 A CN113115978 A CN 113115978A
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
- A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
- A24C5/32—Separating, ordering, counting or examining cigarettes; Regulating the feeding of tobacco according to rod or cigarette condition
- A24C5/34—Examining cigarettes or the rod, e.g. for regulating the feeding of tobacco; Removing defective cigarettes
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
- A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
- A24C5/32—Separating, ordering, counting or examining cigarettes; Regulating the feeding of tobacco according to rod or cigarette condition
- A24C5/34—Examining cigarettes or the rod, e.g. for regulating the feeding of tobacco; Removing defective cigarettes
- A24C5/3424—Examining cigarettes or the rod, e.g. for regulating the feeding of tobacco; Removing defective cigarettes by weighing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The process method for reducing the single gram weight deviation of the cigarettes belongs to the technical field of tobacco manufacturing, and comprises the following steps: for each link of a measuring system and a process flow related to the single-gram weight deviation of the cigarettes in the manufacturing process of the selected cigarette type, a FMEA fault mode influence analysis method is adopted to score and compare the potential influence degree and the occurrence frequency of each influence factor on the single-gram weight deviation of the cigarettes, the current control method and the control degree, items needing to be improved are screened out, the screened improved items are verified one by adopting a statistical analysis method, and finally, the factors which have the greatest influence on the single-gram weight deviation of the cigarettes are identified as the cut stem thickness, the 20 cigarette weights and the single-box stem rejection amount; step two: and (3) searching reasonable parameter collocation aiming at each influence factor: step three: and (4) making a control plan aiming at each influence factor, and requiring a worker to execute the control plan strictly. The invention can reduce the deviation of single gram weight of the cigarette from 19.91mg to 18mg and improve the stability of the cigarette.
Description
Technical Field
The invention belongs to the technical field of cigarette manufacturing, and particularly relates to a process method for reducing the single gram weight deviation of cigarettes.
Background
The single gram weight deviation of the cigarettes is used as a key index for monitoring the process quality to carry out long-term daily monitoring. The single-gram-weight deviation of the cigarette is the absolute value of the weight difference value between the actual gram weight of the sample cigarette and the single-gram-weight of the standard cigarette in the production process. The method is used for measuring the degree that the single cigarette weight value is close to the design central value. The smaller the deviation of the single gram weight of the cigarette is, the closer the cigarette weight is to the design central value. By counting the deviation of the single gram weight of the cigarette of good cats (golden monkey king) in 1-7 months in 2020, as shown in the following table,
statistics of single gram weight deviation of cigarette in 1-7 months in 2020
The cigarette weight control is unstable, the maximum value of the single gram weight deviation is 20.95mg, the average value is 19.91mg, and a certain distance is left between the maximum value and the standard index required by a company, so that the single gram weight deviation of the cigarette is inevitably reduced.
Disclosure of Invention
The technical problems solved by the invention are as follows: the invention provides a process method for reducing the single gram weight deviation of cigarettes, which researches relevant factors of the stability of the cigarette weight through stages of measurement, analysis, improvement, control and the like, and performs parameter configuration and improved control, thereby reducing the single gram weight deviation of the cigarettes from 19.91mg to 18mg and improving the stability of the cigarettes.
The technical scheme adopted by the invention is as follows: the process method for reducing the single gram weight deviation of the cigarettes comprises the following steps:
the method comprises the following steps: for each link of a measuring system and a process flow related to the single-gram weight deviation of the cigarettes in the manufacturing process of the selected cigarette type, a FMEA fault mode influence analysis method is adopted to score and compare the potential influence degree and the occurrence frequency of each influence factor on the single-gram weight deviation of the cigarettes, the current control method and the control degree, items needing to be improved are screened out, the screened improved items are verified one by adopting a statistical analysis method, and finally, the factors which have the greatest influence on the single-gram weight deviation of the cigarettes are identified as the cut stem thickness, the 20 cigarette weights and the single-box stem rejection amount;
step two: and (3) searching reasonable parameter collocation aiming at each influence factor:
(1) cutting the stem thickness: under the condition that other conditions are not changed, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thickness is detected, and the optimal stem pressing thickness is determined; verifying the optimal stem pressing thickness through the tobacco shred structure and the physical indexes of a finished product;
(2) weight of 20 cigarettes: carrying out full factor experiments on the left and right room wind pressure by using DOE experiments, and verifying and standardizing parameters obtained by the experiments;
(3) single-box stem rejection: verifying the relation between the wind pressure and the tobacco shred content in the stem by regression analysis, and finding the optimal parameter and standardizing;
step three: a control plan is made according to each influence factor, and workers are required to execute the control plan strictly;
(1) cutting the stem thickness: counting the thickness of the cut stems in the working process, and drawing a process operation control chart;
(2) weight of 20 cigarettes: arranging inspectors for inspection according to the requirements of relevant process technical standards, and bringing the inspectors into evaluation and assessment according to inspection results;
(3) single-box stem rejection: controlling the single-box stem sliver removing amount by using a quality control chart; and (4) strengthening the inspection, and finding that the single box of stem rejecting amount is not in a specified range and is included in evaluation and assessment.
In the second step, when the thickness of the cut stem is 0.8mm and the thickness of the cut stem is 0.12mm, the cigarette weight is closest to the set value, the standard deviation is 0.006, and the cigarette weight is most stable.
In the second step, the wind pressures of the left and right chambers with the weight of 20 cigarettes stabilized within the standard required range of 17.6 ± 0.3 are as follows: in the case of eliminating the interaction, the left pressure was 7100Pa and the right pressure was 8000 Pa.
In the second step, the wind-dividing wind pressure in the single-box stem sliver removing amount is 4.5 mm. .
Compared with the prior art, the invention has the advantages that:
1. according to the scheme, relevant factors of cigarette weight stability are researched through stages of measurement, analysis, improvement, control and the like, and parameter configuration and improvement are carried out, so that the single gram weight deviation of the cigarette is reduced from 19.91mg to 18mg, and the stability of the cigarette is improved;
2. according to the method, the FMEA fault mode influence analysis is applied, potential fault modes in the process can be accurately and quickly found out, risk quantitative evaluation is carried out on the found fault modes according to a corresponding evaluation system, fault causes are listed, and prevention and improvement measures are searched.
Drawings
FIG. 1 is a report of the C3 gauge of the present invention;
FIG. 2 is a graph of the efficacy of a single sample t-test of the present invention;
FIG. 3 is a box diagram showing the moisture content and the cigarette weight in the present invention;
FIG. 4 is a probability plot of water cut in the present invention;
FIG. 5 is a probability chart of cigarette weights in the present invention;
FIG. 6 is an examination chart of the equal variance of the moisture content and the cigarette weight in the present invention;
FIG. 7 is a graph of the efficacy of the two-sample t-test of the present invention;
FIG. 8 is a graph of the efficacy of a single sample t-test of the present invention;
FIG. 9 is a box diagram of the cut stem thickness cigarette weight in the present invention;
FIG. 10 is a box diagram of cut stem thickness-1 and cigarette weight-1 in the present invention;
FIG. 11 is a probability chart of cigarette weights in the present invention;
FIG. 12 is an isometric variance test chart of cigarette weight, cigarette weight-1, and cigarette weight-2 in accordance with the present invention;
FIG. 13 is an equivalent test chart of the cigarette weight mean value in the present invention;
FIG. 14 is a graph of dual sample T-test data in accordance with the present invention;
FIG. 15 is a boxplot of class A, B, C in accordance with the present invention;
FIG. 16 is a probability chart of class A, B and C in the present invention;
FIG. 17 is a graph of the variance test for 20 cigarette weights in the present invention;
FIG. 18 is a graph of the residual error of 20 cigarette weights in the present invention;
FIG. 19 is a boxplot of the 20 cigarette weights of the present invention;
FIG. 20 is a single value graph of shift versus weight for 20 cigarettes in accordance with the present invention;
FIG. 21 is a probability chart of the machines No. 1,3, 6, and 7 of the present invention;
FIG. 22 is a diagram of the test of the variance of a single-box stem removing quantity machine according to the present invention;
FIG. 23 is a sectional view of the amount of single box of rejected stems and the machine table in the present invention;
FIG. 24 is a single-valued graph of the single-bin stem culling amount in the present invention;
FIG. 25 is a residual error diagram of the machine tables No. 1,3, 6, and 7 for the single-box stem removing amount in the present invention;
FIG. 26 is a boxed line graph of the single-box stem rejection amount in the present invention;
FIG. 27 is a normal graph of the normalized effect of the present invention;
FIG. 28 is a graph of the residual weight of 20 cigarettes in the present invention;
FIG. 29 is a graph showing the main effect of 20 cigarettes in the present invention;
FIG. 30 is a graph showing the interaction of the weight of 20 cigarettes in the present invention;
FIG. 31 is a curved view of the weight of 20 cigarettes and the left and right wind pressures in the present invention;
FIG. 32 is a contour line graph of the weight of 20 cigarettes and the left and right wind pressures in the present invention;
FIG. 33 is a diagram showing a comparison of the contour lines of the weight of 20 cigarettes and the left and right wind pressures in the present invention;
FIG. 34 is a fitting line graph of the single-box stem culling amount in the present invention;
FIG. 35 is a residual error diagram of the single-box stem culling amount in the present invention;
FIG. 36 is a comparison graph of deviation of single gram weights of cigarettes before and after improvement in the present invention;
FIG. 37 is a probability chart of cigarette weights in accordance with the present invention;
FIG. 38 is a chart showing the control of cigarette weight I-MR in the present invention;
FIG. 39 is a summary report of the cigarette weights in accordance with the present invention;
FIG. 40 is a diagram of the examination of the equal variance of the C14 cigarette weight in accordance with the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-40, embodiments of the present invention are described in detail.
The process method for reducing the single gram weight deviation of the cigarettes comprises the following steps:
the method comprises the following steps: and (3) grading and comparing the potential influence degree and the occurrence frequency of each influence factor on the single-gram-weight deviation of the cigarettes, the current control method and the control degree by adopting an FMEA fault mode influence analysis method for each link of a measurement system and a process flow related to the single-gram-weight deviation of the cigarettes in the manufacturing process of the selected cigarette type, and screening out items to be improved.
The specific screening process is as follows:
1. screening of measurement systems relating to cigarette single-gram weight deviation
Taking the single gram weight deviation of good cat (gold monkey king) cigarettes as an example, sampling, measuring and analyzing the plan,
measurement system analysis
Analysis data table of measuring system
| simple | opera | Zhongliang | | opera | Zhongliang | |
| 1 | 1 | 878 | 1 | 2 | 879 | |
| 2 | 1 | 906 | 2 | 2 | 905 | |
| 3 | 1 | 871 | 3 | 2 | 871 | |
| 4 | 1 | 877 | 4 | 2 | 870 | |
| 5 | 1 | 861 | 5 | 2 | 863 | |
| 6 | 1 | 913 | 6 | 2 | 916 | |
| 7 | 1 | 900 | 7 | 2 | 900 | |
| 8 | 1 | 879 | 8 | 2 | 878 | |
| 9 | 1 | 890 | 9 | 2 | 891 | |
| 10 | 1 | 918 | 10 | 2 | 926 | |
| 1 | 1 | 878 | 1 | 2 | 879 | |
| 2 | 1 | 905 | 2 | 2 | 907 | |
| 3 | 1 | 872 | 3 | 2 | 870 | |
| 4 | 1 | 877 | 4 | 2 | 870 | |
| 5 | 1 | 862 | 5 | 2 | 862 | |
| 6 | 1 | 913 | 6 | 2 | 916 | |
| 7 | 1 | 900 | 7 | 2 | 900 | |
| 8 | 1 | 879 | 8 | 2 | 878 | |
| 9 | 1 | 890 | 9 | 2 | 891 | |
| 10 | 1 | 916 | 10 | 2 | 926 |
By studying the R & R-anova, as shown in figure 1,
two-factor ANOVA including interaction
Alpha 0.05 for deleting interaction item
Measuring tool R & R
Variance component
Gauge evaluation
Number of distinguishable categories 9
From the above analysis results of the measurement system, the main difference of the measurement system is from the sample (component variance component is 103.432), and the variance contribution rate of the gauge is 2.83% < 10%; the fluctuation of the measurement system accounts for 13.69% < 30% of the overall fluctuation of the process; the precision of the measuring system accounts for 2.83 percent to less than 30 percent of the tolerance; the distinguishable category number is 9 & gt 4, namely the instrument resolution meets the requirement, and the measurement system is effective.
2. Taking good cat (gold monkey king) as an example to analyze the process flow
The technical process of the good cat (golden monkey king) is combed, the details are known, a flow chart is drawn, and the research scope of the invention is clear and mainly focused on the silk making and wrapping parts.
According to the technical flow chart of good cats (gold monkey king), deep thinking is carried out from the aspects of human, machine, material, method, ring, measurement and the like, potential causes are searched, and FMEA analysis is carried out as follows:
scoring and grading according to the potential influence degree of the important factors on the single cigarette weight deviation of the project, the occurrence frequency, the current control method, the control degree and the like, and finally confirming the improved process and the important potential factors, wherein the table is shown in the specification:
| flow path | Important latent factor | Score value |
| Cut tobacco drying procedure | Water content ratio | 216 |
| Stalk pressing procedure | Thickness of stem pressing | 216 |
| Rolling and connecting process | Single box stem pick removing quantity | 192 |
| Rolling and connecting process | Cigarette with unstable weight | 224 |
The FMEA fault mode influence analysis is applied in the process, the method can find out potential fault modes in the process, risk quantitative evaluation is carried out on the found fault modes according to a corresponding evaluation system, fault causes are listed, and prevention and improvement measures are searched.
3. And verifying the screened improved items one by adopting a statistical analysis method in order to prove whether the determined reason is correct.
(1) Cut tobacco drying procedure verification
The stability of the moisture content of the cut tobacco drying process is directly related to the stability of the moisture content of the finished cut tobacco.
The moisture content of cut tobacco drying is not in accordance with the requirement, the moisture content is larger or smaller, the result is that the moisture content does not reach the standard, and whether the moisture content of a cut tobacco drying machine is a main reason influencing the single gram weight deviation of cigarettes is researched.
First, we establish a null hypothesis and an alternative hypothesis from the data we analyze:
h0: μ 1 ═ μ 2 ═ μ 3H 1: mu 1, mu 2, mu 3 are not all equal
1) Determining the number of samples as shown in figure 2,
efficacy and number of samples
Single sample t test
Mean value of being tested is zero (and is not equal to zero)
Mean value of calculated efficacy is zero + difference value
α -0.05 assumed standard deviation-0.14
Results
From the above, as long as the number of samples is greater than 28, the target efficacy can reach 0.95 or more, so the number of samples is determined to be 30.
2) And drawing a box line graph as shown in fig. 3, wherein the difference of the moisture content of the cut tobacco has no influence on the single gram weight of the cigarettes under the confidence interval of 95 percent.
3) The normality test is shown in FIGS. 4 and 5, the P value is greater than 0.05, and the data distribution conforms to the normal distribution.
4) Equal variance test, as shown in FIG. 6
95% Bonferroni standard deviation confidence interval
Single confidence level 99.1667%
P is 0.278 >0.05, so samples are equal in variance.
5) The T-test is shown in figure 7,
efficacy and number of samples
Double sample t-test
Mean of ongoing examination 1 ═ mean 2 (and ≠)
Calculate mean 1 efficacy-mean 2+ difference
α -0.05 assumed standard deviation-0.05
Results
The number of samples refers to each group.
And (4) checking and concluding: since the P value is 0.005, the original assumption cannot be rejected, which indicates that the cut tobacco moisture content is not a main cause.
(2) Cut stem thickness verification
1) The number of samples is determined and, as shown in figure 8,
efficacy and number of samples
Single sample t test
Mean value of being tested is zero (and is not equal to zero)
Mean value of calculated efficacy is zero + difference value
α -0.05 assumed standard deviation-0.01
Results
From the above, as long as the number of samples is greater than 16, the target efficacy can reach 0.95 or more, so the number of samples is determined to be 20.
2) Box plots are drawn, as shown in figures 9 and 10,
it is shown that the difference of the thickness of cut stems has influence on the single gram weight of the cigarette.
3) The normality test, as shown in figure 11,
p > 0.483 >0.05, indicating that the data fit into a normal distribution.
4) The equal variance test, as shown in figure 12,
checking the equal variance, namely, the thickness of cut stems _1, the thickness of cut stems _2 and the weight of cigarettes _2
Method
All variances of the original hypothesis are equal
Alternative assumptions have at least one variance difference
Significance level α ═ 0.05
The Bartlett method has been used. This method is only applicable to normal data.
95% Bonferroni standard deviation confidence interval
Single confidence level 98.3333%
Examination of
P0 is less than 0.05, so the original hypothesis is rejected, indicating that at least one variance is different at different cut stem thicknesses.
5) The equivalence test, as shown in figure 13,
efficacy and number of samples
Double sample t-test
Mean of ongoing examination 1 ═ mean 2 (and ≠)
Calculate mean 1 efficacy-mean 2+ difference
α -0.05 assumed standard deviation-0.021
Results
The number of samples refers to each group.
Efficacy curves for two-sample t-test
The results show that the cigarette weights are different under different stem cutting thicknesses, which indicates that the stem cutting thickness is the reason for influencing the single gram weight of the cigarette. The significant difference of different stem cutting thicknesses to the single gram weight of the cigarette is shown.
(3) Verification of weight of 20 cigarettes
The cigarette weight does not meet the requirement, the cigarette is overweight and ultralight, the result is that the cigarette weight does not meet the requirement, and whether the weight of 20 cigarettes is the main reason for influencing the single gram weight deviation of the cigarette is researched.
First, we establish a null hypothesis and an alternative hypothesis from the data we analyze:
h0: μ 1 ═ μ 2 ═ μ 3H 1: mu 1, mu 2, mu 3 are not all equal
1) The number of samples is determined and, as shown in figure 14,
from the above, as long as the number of samples is greater than 27, the target efficacy can reach 0.95 or more, so the number of samples is determined to be 30.
2) A box plot is drawn, as shown in figure 15,
the effect of 20 cigarette weights on the deviation of single gram weight of cigarettes is shown.
3) The normality test is carried out, if the data is not normal, normal conversion is carried out, as shown in figure 16,
from the above figure, the p-value is greater than 0.05, and thus, conforms to a normal distribution.
4) Equal variance test, as shown in FIG. 17
From the above figure, Bartlett tests have p values greater than 0.05 and therefore, equal variance assumptions are met.
5) One-factor analysis of variance
One-factor ANOVA C12 and C13
S0.2308R-Sq 29.77% R-Sq 28.15%
Single set of 95% confidence intervals for mean (based on combined standard deviation)
Combined standard deviation of 0.231
Grouping information using Tukey method
There is a significant difference between the means that do not share letters.
All pairwise comparisons between C13 levels
Single confidence level 98.06%
C13 ═ 1, reduced from:
c13 ═ 2 subtracted from:
as shown in detail in fig. 18-10
And (4) conclusion: the residual error is normally distributed, the mean value is 0, the variance is constant, the P value is less than 0.05, and the original hypothesis is rejected, so that at least one level of 20 cigarettes with stable weight is indicated. As can be seen from the single-factor analysis of variance, the cigarette weights of the two levels of the first class and the third class have no significant difference, and have significant difference with the second class.
(4) The single-box cut stem removing amount is verified,
1) determining the number of samples
Regarding different machines as a factor, the factors are respectively: 1#, 3#, 5#, 6#, 7#, determine α is 0.05, β is 0.1, and then determine the sample quantity according to the cigarette single gram weight deviation counted in the definition stage:
efficacy and number of samples
One-factor analysis of variance
The number of samples is referred to per level.
According to the difficulty of data collection, 6 data are determined to be collected at each level.
2) The normality check is shown in figure 21,
from the p value, the data p of six levels of 5 machines is all larger than 0.05 and obeys normal distribution.
3) Equal variance test
Method
All variances of the original hypothesis are equal
Alternative assumptions have at least one variance difference
Significance level α ═ 0.05
95% Bonferroni standard deviation confidence interval
Examination of
As shown in fig. 22, the Levene test p-value is greater than 0.05, indicating equal variance.
4) One-factor analysis of variance
One- factor ANOVA 1,3,5,6,7
Method
All means of the original hypothesis are equal
Alternative assumptions that not all means are equal
Significance level α ═ 0.05
Equal variance has been assumed for this analysis.
Factor information
Model summary
Combined standard deviation of 0.145285
As shown in figures 23-26 of the drawings,
and (4) conclusion: the residuals are normally distributed with a mean of 0 and a constant variance, so there is not enough reason to reject the model. The P value is more than 0.05, the original assumption is rejected, and the rejection quantity of the single-box stems in at least one horizontal box is stable. The single box stem rejection level between different machine stations has obvious difference.
4. Reason verification result
Through the verification of the screened reasons, the main reasons are reconfirmed:
| serial number | Name (R) | Status of state | Whether or not to improve |
| 1 | Water content in cut tobacco drying process | Is not significant | Whether or not |
| 2 | Thickness of cut stem | Is remarkable in that | Is that |
| 3 | 20 cigarettes in weight | Is remarkable in that | Is that |
| 4 | Single box stem pick removing quantity | Is remarkable in that | Is that |
Finally, determining that the factors which have the greatest influence on the single-cigarette gram weight deviation are the cut stem thickness, the 20-cigarette weight and the single-box stem rejection amount;
step two: and (3) searching reasonable parameter collocation aiming at each influence factor:
(1) cutting the stem thickness: under the condition that other conditions are not changed, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thickness is detected, and the optimal stem pressing thickness is determined; and verifying the optimal stem pressing thickness through the tobacco shred structure and the physical indexes of the finished product.
The thickness of cut stems is a target value, unqualified cigarettes can be produced when the thickness is too large or too small, and the single gram weight deviation of the cigarettes is influenced. The thickness of the cut stem is limited by the thickness of the pressed stem, so the thickness of the pressed stem is tested.
1) The thickness of the pressed stems is respectively set to be 0.7mm, 0.8mm and 0.9mm, the thickness of the cut stems is 0.12mm, the weight of the cigarettes is detected, and the results are as follows:
from the results, it is understood that, assuming that the stem pressing thickness and the stem cutting thickness are 0.8mm and 0.12mm, respectively, among the stem cutting thicknesses, the cigarette weight is closest to the set value and is biased to 0.006, so that the cigarette weight is most stable.
2) Adjusted results analysis
Tobacco shred structure
The average cut tobacco shred finishing rate after the first test is 78.3 percent, the average cut tobacco shred finishing rate after the second test is 78.3 percent, the average cut tobacco shred finishing rate after the third test is 78.2 percent, and the cut tobacco shred finishing rate is basically unchanged; the broken filament rate and the filling value are stable and basically unchanged.
Physical index of finished cigarette
The stem pressing thickness test detects and analyzes the dust content, the end cut tobacco quantity and the cigarette resistance of the finished cigarette. The end content after the first test is 1.32, the end content after the second test is 1.22, and the end content after the second test is 1.3; the filament drop of the end part after the primary test was 4.2, the filament drop of the end part after the secondary test was 3.8, and the filament drop of the end part after the tertiary test was 4.1; the standard deviation of the cigarette after the first test is 40, the standard deviation of the cigarette after the second test is 32, and the standard deviation of the cigarette after the third test is 46; the tobacco powder content, the end tobacco shred dropping amount and the suction resistance standard deviation are all reduced most obviously after the second test, which shows that the second test parameters can most meet the requirements of the finished cigarette products.
(2) Weight of 20 cigarettes: carrying out full factor experiments on the left and right room wind pressure by using DOE experiments, and verifying and standardizing parameters obtained by the experiments;
1) design of DOE experiment
The project group discusses how to stabilize the relevant equipment parameters of the cigarette weight, and the optimal values of the parameters are found by searching a relational expression through experimental design, so that the weight of 20 cigarettes is stabilized within a standard requirement range (17.6 +/-0.3), the wind pressure of the left wind chamber and the right wind chamber is set, and the weight of the left wind chamber: 7 × 100Pa, 9 × 100 Pa; a right air chamber: 7 × 100Pa, 9 × 100 Pa. Selecting full factor test and arranging 4 central point test, using MINITAB software to generate 2 factor 2 horizontal 4 central point full factor test design scheme, and randomizing the test sequence to make the central point approximately at the beginning, middle and end of the test, and testing according to the test scheme.
| Standard sequence | Sequence of operation | Center point | Block of medicine | Left side of | |
| 3 | 1 | 1 | 1 | 7 | 9 |
| 6 | 2 | 0 | 1 | 8 | 8 |
| 8 | 3 | 0 | 1 | 8 | 8 |
| 1 | 4 | 1 | 1 | 7 | 7 |
| 5 | 5 | 0 | 1 | 8 | 8 |
| 2 | 6 | 1 | 1 | 9 | 7 |
| 7 | 7 | 0 | 1 | 8 | 8 |
| 4 | 8 | 1 | 1 | 9 | 9 |
a. Analysis of influence of right wind pressure on weight of 20 cigarettes under interaction
Fitting factors weight and positive and negative pressure
Estimated effect and coefficient of weight (coded unit)
Standard error T P of coefficient of term effect
Constant 0.9080000.001555584.090.000
Positive pressure-0.010000-0.0050000.001555-3.220.049
Negative pressure 0.0250000.0125000.0015558.040.004
Positive pressure and negative pressure 0.0010000.0005000.0015550.320.769
Ct Pt -0.002500 0.002198 -1.14 0.338
S＝0.00310913 PRESS＝*
R-Sq ═ 96.22% R-Sq (predicted) —% R-Sq (adjusted) — 91.18%
Weight analysis of variance (coded units)
Source degree of freedom Seq SS Adj MS F P
Main effect 20.000725000.000725000.0003625037.500.008
Positive pressure 10.000100000.000100000.0001000010.340.049
Negative pressure 10.000625000.000625000.0006250064.660.004
Factor interaction 10.000001000.000001000.000001000.100.769
Positive pressure and negative pressure 10.000001000.000001000.000001000.100.769
Bend 10.000012500.000012500.000012501.290.338
Residual error 30.000029000.000029000.00000967
Pure error 30.000029000.000029000.00000967
Aggregate 70.00076750
Under the left and right wind pressure, the data of the weight are subjected to variance analysis, and the result shows that: under the condition of no interaction, P [0.008, 0.049, 0.004] < alpha, which shows that the main effect, the positive pressure and the negative pressure difference have obvious influence on the cigarette weight; under the interaction, P0.769, 0.769 > alpha indicates that the probability of each test mean value is very large, and the cigarette weight difference is not obvious under different positive pressure and negative pressure, and the interaction is not obvious. Therefore, the main effect is significant, the interactive effect is not significant, and the interactive item can be removed.
(2) Analysis of influence of positive pressure and negative pressure on cigarette weight without interaction
Fitting factors weight and positive and negative pressure
Estimated effect and coefficient of weight (coded unit)
Standard error T P of coefficient of term effect
Constant 0.9080000.001369663.110.000
Positive pressure-0.010000-0.0050000.001369-3.650.022
Negative pressure 0.0250000.0125000.0013699.130.001
Ct Pt -0.002500 0.001936 -1.29 0.266
S＝0.00273861 PRESS＝0.000112
R-Sq ═ 96.09% R-Sq (predicted) ═ 85.41% R-Sq (adjusted) ═ 93.16%
Weight analysis of variance (coded units)
Source degree of freedom Seq SS Adj MS F P
Main effect 20.000725000.000725000.0003625048.330.002
Positive pressure 10.000100000.000100000.0001000013.330.022
Negative pressure 10.000625000.000625000.0006250083.330.001
Bend 10.000012500.000012500.000012501.670.266
Residual error 40.000030000.000030000.00000750
Simulation losing 10.000001000.000001000.000001000.100.769
Pure error 30.000029000.000029000.00000967
Aggregate 70.00076750
Analysis shows that under the condition of removing interaction, main effect, positive pressure and negative pressure P [0.002, 0.022 and 0.001] < alpha are obvious in each coefficient, which shows that main effect, positive pressure and negative pressure difference have obvious influence on cigarette weight; bending and distortion P [0.266, 0.769] >0.05, which shows that the data has no bending and distortion.
As shown in the figures 27-33 of the drawings,
fitting value
Argument of new observed value
New concept
1 8.01 7.4
And (3) obtaining a predicted value by demodulating the optimal value into an analysis prediction, wherein the predicted response to the weight at the new design point is in a 95% prediction interval, and the weight value is between (17.431, 17.808), so that the cigarette weight is stable and is controlled to be at a desired target.
And (3) extracting 3 groups of data to verify the difference of the cigarette weights, wherein the left pressure of the cigarette unit is 7100Pa, and the right pressure of the cigarette unit is 8000 Pa. It can be seen that the weight values all fall into the prediction interval, which proves that the selected model is effective and the cigarette weight is stable.
Therefore, it is determined that the left and right chamber wind pressures at which the 20 cigarette weights are stabilized within the standard required range of 17.6 ± 0.3 are: in the case of the removal interaction, the left pressure was 7100Pa and the right pressure was 8000 Pa.
(3) Single-box stem rejection: verifying the relation between the wind pressure and the tobacco shred content in the stem by regression analysis, and finding the optimal parameter and standardizing;
the size of the primary air pressure can directly influence the cut tobacco content in the stems, the size of the cut tobacco rejection amount is recorded by measuring an air pressure meter on 5 cigarette making machines, and whether the change of the air pressure value can influence the cut tobacco content in the stems is determined by a regression analysis tool. Since the data of the data field Y of X belongs to continuous data, regression analysis is selected to clarify the relationship between two variables. Wind pressure values on 5 cigarette making machines were collected and regression analysis was performed using MINITAB. As shown in figures 34 and 35 of the drawings,
The regression equation is
3＝-0.5047+1.558 C10
Model summary
Analysis of variance
It is considered that the relationship between the output variable and the input variable is large when the value of R-Sq is 0.7 or more, R-Sq is 80.78%, R-Sq (adjustment) is 75.98%,
the S value was 0.06, indicating that the residual error was very small, and R-Sq was 79.6%, R-Sq
The two values are very close, the residual map is normal, and the entire model is valid (adjustment) 78.6%. Meanwhile, the independent variable P-Value is 0.005 and is less than 0.05, so that the air pressure Value can be considered to have a remarkable influence on the rejection quantity of the stems. The air pressure of the air in the single box of the stem removing amount is confirmed to be 4.5 mm.
(4) Verification of improvements
As can be seen from the improvement effect fig. 36, the improvement effect is significant and reaches the target value.
(2) Hypothesis test is carried out on the significance of the single gram weight deviation of the improved cigarettes
The problems are as follows: whether the single gram weight deviation of the improved cigarette reaches the target value 18
The target is as follows: reaches the target value 18
Suppose that: h0: mu 1 is less than or equal to 18 mu 2 is more than 18
The statistical test method comprises the following steps: since σ is unknown, a single sample t-test was chosen.
Alpha is 0.05 and beta is 0.1
A single sample T:
examination of mu-18 and >18
As shown in figure 37 of the drawings,
p0.483 >0.05, the data fit to the normality distribution.
Process stability determination, as shown in FIGS. 38-40
And (4) conclusion: the p value is more than 0.05, so the original hypothesis is rejected, and the deviation of the single gram weight of the improved cigarette is less than 18 mg.
Step three: a control plan is made according to each influence factor, and workers are required to execute the control plan strictly;
(1) cutting the stem thickness: counting the thickness of the cut stems in the working process, and drawing a process operation control chart;
(2) weight of 20 cigarettes: arranging inspectors for inspection according to the requirements of relevant process technical standards, and bringing the inspectors into evaluation and assessment according to inspection results;
(3) single-box stem rejection: controlling the single-box stem sliver removing amount by using a quality control chart; and (4) strengthening the inspection, and finding that the single box of stem rejecting amount is not in a specified range and is included in evaluation and assessment.
In conclusion, the invention researches relevant factors of cigarette weight stability through stages of measurement, analysis, improvement, control and the like, and performs parameter configuration and improved control, thereby reducing the single gram weight deviation of the cigarette from 19.91mg to 18mg and improving the stability of the cigarette.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (4)
1. The process method for reducing the single gram weight deviation of the cigarettes is characterized by comprising the following steps of: the method comprises the following steps:
the method comprises the following steps: for each link of a measuring system and a process flow related to the single-gram weight deviation of the cigarettes in the manufacturing process of the selected cigarette type, a FMEA fault mode influence analysis method is adopted to score and compare the potential influence degree and the occurrence frequency of each influence factor on the single-gram weight deviation of the cigarettes, the current control method and the control degree, items needing to be improved are screened out, the screened improved items are verified one by adopting a statistical analysis method, and finally, the factors which have the greatest influence on the single-gram weight deviation of the cigarettes are identified as the cut stem thickness, the 20 cigarette weights and the single-box stem rejection amount;
step two: and (3) searching reasonable parameter collocation aiming at each influence factor:
(1) cutting the stem thickness: under the condition that other conditions are not changed, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thickness is detected, and the optimal stem pressing thickness is determined; verifying the optimal stem pressing thickness through the tobacco shred structure and the physical indexes of a finished product;
(2) weight of 20 cigarettes: carrying out full factor experiments on the left and right room wind pressure by using DOE experiments, and verifying and standardizing parameters obtained by the experiments;
(3) single-box stem rejection: verifying the relation between the wind pressure and the tobacco shred content in the stem by regression analysis, and finding the optimal parameter and standardizing;
step three: a control plan is made according to each influence factor, and workers are required to execute the control plan strictly;
(1) cutting the stem thickness: counting the thickness of the cut stems in the working process, and drawing a process operation control chart;
(2) weight of 20 cigarettes: arranging inspectors for inspection according to the requirements of relevant process technical standards, and bringing the inspectors into evaluation and assessment according to inspection results;
(3) single-box stem rejection: controlling the single-box stem sliver removing amount by using a quality control chart; and (4) strengthening the inspection, and finding that the single box of stem rejecting amount is not in a specified range and is included in evaluation and assessment.
2. The process method for reducing the single gram weight deviation of cigarettes according to claim 1, characterized in that: in the second step, when the thickness of the cut stem is 0.8mm and the thickness of the cut stem is 0.12mm, the cigarette weight is closest to the set value, the standard deviation is 0.006, and the cigarette weight is most stable.
3. The process method for reducing the single gram weight deviation of cigarettes according to claim 1, characterized in that: in the second step, the wind pressures of the left and right chambers with the weight of 20 cigarettes stabilized within the standard required range of 17.6 ± 0.3 are as follows: in the case of eliminating the interaction, the left pressure was 7100Pa and the right pressure was 8000 Pa.
4. The process method for reducing the single gram weight deviation of cigarettes according to claim 1, characterized in that: in the second step, the wind-dividing wind pressure in the single-box stem sliver removing amount is 4.5 mm.
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