CN113609698A - Process reliability analysis method and system based on process fault database - Google Patents
Process reliability analysis method and system based on process fault database Download PDFInfo
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- CN113609698A CN113609698A CN202110941604.6A CN202110941604A CN113609698A CN 113609698 A CN113609698 A CN 113609698A CN 202110941604 A CN202110941604 A CN 202110941604A CN 113609698 A CN113609698 A CN 113609698A
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- G06—COMPUTING; CALCULATING OR COUNTING
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- G06F30/20—Design optimisation, verification or simulation
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- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
Abstract
The invention discloses a process reliability analysis method and system based on a process fault database, and relates to the field of process reliability analysis. The method comprises the following steps: calling a process fault form prestored in a process fault database according to a fault pre-judgment request instruction before the process design process starts; in the process of process design, inquiring faults occurring in the process of process design; after the process design process is finished, counting faults occurring in the process design process; and analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value. The method is suitable for analyzing and evaluating the process reliability of products with complex production process and more faults in the production process, establishes a reliability analysis and evaluation system, improves the process reliability in the production process, and further ensures the quality and the reliability of the products.
Description
Technical Field
The invention relates to the field of process reliability analysis, in particular to a process reliability analysis method and system based on a process fault database.
Background
The quality and reliability of the product are formed by design and manufacture, and are closely related to the design reliability and the process reliability of the product.
The traditional method for controlling the process reliability of the product is as follows: by adopting a post analysis method, after a fault occurs, products are repaired or reworked without pre-prevention, a systematic process fault database is not formed, and a reliability analysis and evaluation system is not established, so that the problems of influencing the delivery cycle of the products, repeatedly occurring faults and the like are easily caused.
Disclosure of Invention
The invention aims to solve the technical problem of the prior art and provides a process reliability analysis method and system based on a process fault database.
The technical scheme for solving the technical problems is as follows:
a process reliability analysis method based on a process fault database comprises the following steps:
before the process design process starts, acquiring a fault pre-judgment request instruction, and calling a process fault table pre-stored in a process fault database according to the fault pre-judgment request instruction;
in the process of process design, inquiring faults occurring in the process of process design according to the process fault list;
after the process design process is finished, counting faults occurring in the process design process to generate a process PPM value and a product PPM value;
and analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
Another technical solution of the present invention for solving the above technical problems is as follows:
a process reliability analysis system based on a process fault database comprises:
the system comprises an acquisition unit, a fault pre-judgment unit and a fault pre-judgment unit, wherein the acquisition unit is used for acquiring a fault pre-judgment request instruction before the process design process starts, and calling a process fault form prestored in a process fault database according to the fault pre-judgment request instruction;
the query unit is used for querying faults occurring in the process design process according to the process fault list in the process design process;
the statistical unit is used for counting faults occurring in the process design process after the process design process is finished to generate a process PPM value and a product PPM value;
and the analysis unit is used for analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
The invention has the beneficial effects that: the method and the system for analyzing the process reliability are suitable for analyzing and evaluating the process reliability of products with complex production process and many faults in the production process, the faults which possibly occur in the process are predicted by pre-establishing a process fault database, a process fault list is generated and pre-stored in the process fault database, and the faults in the process can be pre-judged in the process design process, so that a technologist and a field operator can optimize a process file, develop preventive measures and supplement inspection contents according to the list, and finally the reliability of the process design process is analyzed through a process PPM value and a product PPM value, so that a reliability analysis and evaluation system is established, the process reliability of the production process is improved, and the quality and the reliability of the products are further ensured.
Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
FIG. 1 is a schematic flow chart diagram provided by an embodiment of a process reliability analysis method of the present invention;
FIG. 2 is a schematic diagram of a PFMEA form provided by an embodiment of the method for process reliability analysis according to the present invention;
FIG. 3 is a failure statistics presentation provided by an embodiment of the process reliability analysis method of the present invention;
FIG. 4 is a diagram of a PPM form provided by an embodiment of the method for analyzing process reliability according to the present invention;
FIG. 5 is a schematic operational flow diagram of a process reliability analysis method according to another embodiment of the present invention;
FIG. 6 is a block diagram of a process reliability analysis system according to an embodiment of the present invention.
Detailed Description
The principles and features of this invention are described below in conjunction with the following drawings, which are set forth to illustrate, but are not to be construed to limit the scope of the invention.
As shown in fig. 1, a schematic flow chart provided by an embodiment of the process reliability analysis method of the present invention is implemented based on a process fault database, and includes:
s1, before the process design process starts, acquiring a fault pre-judgment request instruction, and calling a process fault form pre-stored in a process fault database according to the fault pre-judgment request instruction;
it should be noted that the process reliability analysis method provided in this embodiment may be implemented by a process reliability analysis system, and a product process reliability analysis system based on a process failure database may be developed based on a CAPP system of an existing B/S architecture. The CAPP (Computer Aided Process Planning) refers to a Process for machining parts by using a Computer to perform functions such as numerical calculation, logical judgment, inference and the like by means of Computer software and hardware technology and supporting environment. By means of the CAPP system, the problems of low efficiency, poor consistency, unstable quality, difficulty in optimization and the like of manual process design can be solved.
Illustratively, basic constituent modules of the CAPP system may include: the device comprises a control module, a part information input module, a technological process design module, a process decision module, a process step decision module, an NC machining instruction generation module, an output module and an output module, wherein:
the control module is mainly used for coordinating the operation of each module, is a man-machine interaction window, realizes information exchange between man and machine and controls the acquisition mode of part information;
the part information input module is mainly used for realizing the input of the part information when the part information cannot be directly acquired from the CAD system;
the technical process design module is mainly used for making a decision on a processing technical process by the technical process design module and generating a technical process card for a processing and production management department;
the process decision module is mainly used for generating a process card, calculating the size among the processes and generating a process diagram;
the step decision module is mainly used for designing the step content, determining the cutting amount and providing a tool location file required by forming an NC (numerical control) machining control instruction;
the NC machining instruction generation module is mainly used for calling an NC instruction code system according to the tool bit file provided by the step decision module and generating an NC machining control instruction;
the output module is mainly used for outputting a process flow card, a process step card, a process diagram and other documents, outputting various process files which can be called from the existing process file library, and modifying the existing process files by using an editing tool to obtain the required process files;
the main function of the dynamic simulation of the machining process is to simulate the generated machining process and check the correctness of the process.
Based on the understanding, the CAPP system can be deployed on a server, a user can send a fault pre-judgment request instruction through a terminal, the fault pre-judgment request instruction contains fault information, and a process fault table pre-stored in a process fault database can be called in a mode of matching the fault information.
For example, the header fields of a process fault form may include: process names, process inspection characteristics, failure modes, failure effects, failure causes, reason classifications, severity, degree of detection, degree of occurrence, risk priority, precautionary measures, inspection measures, and post-hoc measures of improvement.
The fault anticipation request command may include information such as a process name, a process checking characteristic, and a fault mode, so that a process fault table including corresponding information is matched from the process fault database according to the information.
For example, if the fault anticipation request command input by the user includes a process a, the header fields of all process fault forms including the process a in the process fault database may be searched to generate a process fault form.
In the implementation of the software layer, a "failure pre-judgment" button may be added on the software interface, and the failure pre-judgment function is implemented by clicking the button, for example, when instructing a process designer to perform process compilation based on the established failure database, the "failure pre-judgment" button is clicked, the failure database is automatically invoked, failures possibly related to each process are selected, after confirmation, the "generate PFMEA" button is clicked, a word-form PFMEA is automatically generated, and an accessory automatically used as the process file is uploaded to the system for storage. Technologists and field operators can optimize process files, develop preventive measures and supplement inspection contents according to the PFMEA forms.
An exemplary PFMEA table example is given as shown in fig. 2. Taking the serial number 1 as an example, the process name is hoisting, the process inspection characteristic is redundancy, the fault mode is that redundancy exists on site, the fault influence influences subsequent assembly, the fault reason is human-redundancy is not cleared, the reason is classified as an operation problem, the severity is 2, the detection degree is 1, the occurrence degree is 1, the risk priority index is 2, and the precautionary measure is clearing the redundancy.
S2, in the process of process design, inquiring faults occurring in the process of process design according to the process fault list;
taking fig. 2 as an example, assuming that in the process of process design, the appearance of the product is damaged in the hoisting process, after finding out the PFMEA form, information such as fault cause, fault influence, preventive measures and the like can be quickly found out, so that fault analysis in the process of process design, electronic fault recording in the production process and visual query are realized.
S3, after the process design process is finished, counting faults occurring in the process design process to generate a process PPM value and a product PPM value;
it should be understood that PPM refers to parts per million failure rate, and can be used for reliability evaluation of the process, and can be obtained by statistical data of faults occurring in the process design process.
As shown in fig. 3, an exemplary fault statistics table example is presented. The header includes the process name, process inspection characteristics, failure mode, failure impact, failure detection method, severity, detection level, occurrence level, risk priority number, and post-event improvement measures.
And S4, analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
For example, as shown in fig. 4, the PPM value may be displayed in the form of a PPM form, the header of which includes: the process name, the process inspection characteristic serial number, the process inspection characteristic name, the total detection point number, the defective point number, the process PPM, the operator and the operation time.
The smaller the value of PPM, the higher the reliability of the process or product.
The process reliability analysis method provided by the embodiment is suitable for process reliability analysis and evaluation of products with complex production processes and many faults in the production process, the faults which are possibly generated in the process are predicted by pre-establishing a process fault database, a process fault table is generated and pre-stored in the process fault database, and the faults in the process can be pre-judged in the process design process, so that a technologist and a field operator can optimize a process file, develop preventive measures and supplement inspection contents according to the table conveniently, and finally, the reliability of the process design process is analyzed through a process PPM value and a product PPM value, a reliability analysis and evaluation system is established, the process reliability of the production process is improved, and the quality and the reliability of the products are further ensured.
Optionally, in some possible embodiments, the table header fields of the process fault table pre-stored in the process fault database include: process names, process inspection characteristics, failure modes, failure effects, failure causes, reason classifications, severity, degree of detection, degree of occurrence, risk priority, precautionary measures, inspection measures, and post-hoc measures of improvement.
Optionally, in some possible embodiments, the method further includes:
in the process of process design, when unknown faults occurring in the process design process are not inquired in the process fault table, correlation inquiry is carried out in the process fault database according to the process names, the inspection characteristics and the fault modes of the unknown faults, and if the correlated faults are not inquired, the unknown faults are taken as new faults and are stored in the process fault table of the process fault database according to the format of the table header field.
For example, the process name may be first used as a first-level query keyword, and if the corresponding process name is not queried in the process fault database, the unknown fault may be directly used as a new fault;
if the corresponding process name is inquired in the process fault database, the inspection characteristic is continuously used as a second-level inquiry keyword, the inquiry is continuously carried out under the corresponding process name, and if the corresponding inspection characteristic is not inquired, the unknown fault is directly used as a new fault under the current process;
if the corresponding checking characteristic is inquired, the fault mode is continuously used as a third-stage inquiry keyword, inquiry is continuously carried out under the corresponding process name, and if the corresponding fault mode is not inquired, the unknown fault is directly used as a new fault under the current process.
By adding the new fault into the process fault database, the process fault database can be updated in real time, the process fault database can be combed according to the hierarchical relationship, the addition position suitable for the fault can not be found due to waste of a lot of time, or the fault can be edited due to waste of a long time, so that the process fault database does not need to be maintained uniformly after a certain period like a traditional reliability analysis method, and the real-time performance and the practicability of reliability analysis are improved.
Optionally, in some possible embodiments, the process PPM value is calculated according to the following formula:
NG＝C×n
wherein, PPMwIndicates the PPM value of the process, DGTotal number of defects, P, indicating the detection of process inspection characteristicsiIndicates the number of defects detected by the process inspection characteristics i, i is 1,2, n, n is the number of process inspection characteristics, KiRepresenting the severity weighting factor, N, corresponding to the process inspection characteristic iGIndicates the total number of process inspection characteristics, and C indicates the number of products to be checked.
Optionally, in some possible embodiments, the product PPM value is calculated according to the following formula:
wherein, PPMpIndicating the PPM value of the product, DjNumber of defects, N, representing all inspection characteristics detected in the jth processjThe total number of the characteristics of the jth procedure is shown, j is 1, 2.
As shown in fig. 5, a more specific operation flow is provided for the operation flow diagram provided by the other embodiment of the process reliability analysis method of the present invention, and the method comprises the steps of firstly entering a process file structured editing, generating a process fault table, establishing a process fault database, then clicking a "fault pre-judgment" button on a software interface to enter a fault analysis module, selecting possible fault modes of each process based on the process fault database to form a PFMEA table, completing process content and inspection content according to the PFMEA table, forming a process file and a production process record card according to the process and the inspection content, issuing a workshop for production and inspection by an operator, judging whether the process and the product are qualified, if so, completing production, otherwise, reentering the process file structured editing, clicking a "fault query" on the software interface to enter a fault query module, judging whether relevant faults and improvement suggestions exist or not, if yes, improving, if not, supplementing a fault database, counting faults in the production process to form a fault statistical table, and calculating a PPM value according to the fault statistical table to form a PPM form.
It is to be understood that some or all of the various embodiments described above may be included in some embodiments.
As shown in fig. 6, a structural framework diagram provided for an embodiment of the process reliability analysis system of the present invention is implemented based on a process fault database, and includes:
the acquiring unit 10 is configured to acquire a fault pre-judgment request instruction before a process design process starts, and call a process fault table pre-stored in a process fault database according to the fault pre-judgment request instruction;
the query unit 20 is used for querying faults occurring in the process design process according to the process fault list in the process design process;
the statistical unit 30 is used for counting faults occurring in the process design process after the process design process is finished, and generating a process PPM value and a product PPM value;
and the analysis unit 40 is used for analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
The process reliability analysis system provided by the embodiment is suitable for process reliability analysis and evaluation of products with complex production processes and many faults in the production process, the faults which possibly occur in the process are predicted by pre-establishing a process fault database, a process fault table is generated and pre-stored in the process fault database, and the faults in the process can be pre-judged in the process design process, so that a technologist and a field operator can optimize a process file, develop preventive measures and supplement inspection contents according to the table conveniently, and finally, the reliability of the process design process is analyzed through a process PPM value and a product PPM value, a reliability analysis and evaluation system is established, the process reliability of the production process is improved, and the quality and the reliability of the products are further ensured.
Optionally, in some possible embodiments, the table header fields of the process fault table pre-stored in the process fault database include: process names, process inspection characteristics, failure modes, failure effects, failure causes, reason classifications, severity, degree of detection, degree of occurrence, risk priority, precautionary measures, inspection measures, and post-hoc measures of improvement.
Optionally, in some possible embodiments, the query unit 20 is further configured to perform, in the process design process, when an unknown fault occurring in the process design process is not queried in the process fault table, a correlation query in the process fault database according to the process name, the inspection characteristic, and the fault mode of the unknown fault, and if the correlation fault is not queried, store the unknown fault as a new fault in the process fault table of the process fault database according to the format of the header field.
Optionally, in some possible embodiments, the statistical unit 30 is specifically configured to calculate the process PPM value according to the following formula:
NG＝C×n
wherein, PPMwIndicates the PPM value of the process, DGTotal number of defects, P, indicating the detection of process inspection characteristicsiIndicates the number of defects detected by the process inspection characteristics i, i is 1,2, n, n is the number of process inspection characteristics, KiRepresenting the severity weighting factor, N, corresponding to the process inspection characteristic iGIndicates the total number of process inspection characteristics, and C indicates the number of products to be checked.
Optionally, in some possible embodiments, the statistical unit 30 is specifically configured to calculate the product PPM value according to the following formula:
wherein, PPMpIndicating the PPM value of the product, DjNumber of defects, N, representing all inspection characteristics detected in the jth processjThe total number of the characteristics of the jth procedure is shown, j is 1, 2.
It is to be understood that some or all of the various embodiments described above may be included in some embodiments.
It should be noted that the above embodiments are product embodiments corresponding to previous method embodiments, and for the description of the product embodiments, reference may be made to corresponding descriptions in the above method embodiments, and details are not repeated here.
The reader should understand that in the description of this specification, reference to the description of the terms "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
In the several embodiments provided in the present application, it should be understood that the disclosed apparatus and method may be implemented in other ways. For example, the above-described method embodiments are merely illustrative, and for example, the division of steps into only one logical functional division may be implemented in practice in another way, for example, multiple steps may be combined or integrated into another step, or some features may be omitted, or not implemented.
The above method, if implemented in the form of software functional units and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention essentially or partially contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product stored in a storage medium and including instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: various media capable of storing program codes, such as a usb disk, a removable hard disk, a Read-only memory (ROM), a Random Access Memory (RAM), a magnetic disk, or an optical disk.
While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (10)
1. A process reliability analysis method based on a process fault database is characterized by comprising the following steps:
before the process design process starts, acquiring a fault pre-judgment request instruction, and calling a process fault table pre-stored in a process fault database according to the fault pre-judgment request instruction;
in the process of process design, inquiring faults occurring in the process of process design according to the process fault list;
after the process design process is finished, counting faults occurring in the process design process to generate a process PPM value and a product PPM value;
and analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
2. The process reliability analysis method based on the process fault database according to claim 1, wherein the table header fields of the process fault table pre-stored in the process fault database comprise: process names, process inspection characteristics, failure modes, failure effects, failure causes, reason classifications, severity, degree of detection, degree of occurrence, risk priority, precautionary measures, inspection measures, and post-hoc measures of improvement.
3. The process reliability analysis method based on the process fault database according to claim 2, further comprising:
in the process of process design, when an unknown fault occurring in the process design process is not inquired in the process fault table, performing correlation inquiry in the process fault database according to the process name, the inspection characteristic and the fault mode of the unknown fault, and if the correlation fault is not inquired, storing the unknown fault as a new fault in the process fault table of the process fault database according to the format of the header field.
4. The process reliability analysis method based on process fault database according to any of claims 1 to 3, wherein the process PPM value is calculated according to the following formula:
NG＝C×n
wherein, PPMwIndicates the PPM value of the process, DGTotal number of defects, P, indicating the detection of process inspection characteristicsiIndicates the number of defects detected by the process inspection characteristics i, i is 1,2, n, n is the number of process inspection characteristics, KiIndicating process check characteristic i correspondenceSeverity of (N)GIndicates the total number of process inspection characteristics, and C indicates the number of products to be checked.
5. The process reliability analysis method based on process fault database according to any of claims 1 to 3, characterized in that the product PPM value is calculated according to the following formula:
wherein, PPMpIndicating the PPM value of the product, DjNumber of defects, N, representing all inspection characteristics detected in the jth processjThe total number of the characteristics of the jth procedure is shown, j is 1, 2.
6. A process reliability analysis system based on a process fault database, comprising:
the system comprises an acquisition unit, a fault pre-judgment unit and a fault pre-judgment unit, wherein the acquisition unit is used for acquiring a fault pre-judgment request instruction before the process design process starts, and calling a process fault form prestored in a process fault database according to the fault pre-judgment request instruction;
the query unit is used for querying faults occurring in the process design process according to the process fault list in the process design process;
the statistical unit is used for counting faults occurring in the process design process after the process design process is finished to generate a process PPM value and a product PPM value;
and the analysis unit is used for analyzing the reliability of the process design process according to the procedure PPM value and the product PPM value.
7. The process reliability analysis system based on the process fault database according to claim 6, wherein the pre-stored header fields of the process fault table in the process fault database comprise: process names, process inspection characteristics, failure modes, failure effects, failure causes, reason classifications, severity, degree of detection, degree of occurrence, risk priority, precautionary measures, inspection measures, and post-hoc measures of improvement.
8. The system of claim 7, wherein the query unit is further configured to perform, in a process design process, association query in the process fault database according to a process name, an inspection characteristic, and a fault mode of an unknown fault when the unknown fault occurring in the process design process is not queried in the process fault table, and if the associated fault is not queried, store the unknown fault as a new fault in the process fault table of the process fault database according to the format of the header field.
9. The process reliability analysis system based on the process fault database according to any of the claims 6 to 8, wherein the statistical unit is specifically configured to calculate the process PPM value according to the following formula:
NG＝C×n
wherein, PPMwIndicates the PPM value of the process, DGTotal number of defects, P, indicating the detection of process inspection characteristicsiIndicates the number of defects detected by the process inspection characteristics i, i is 1,2, n, n is the number of process inspection characteristics, KiRepresenting the severity weighting factor, N, corresponding to the process inspection characteristic iGIndicates the total number of process inspection characteristics, and C indicates the number of products to be checked.
10. The process reliability analysis system based on a process fault database according to any of the claims 6 to 8, wherein the statistical unit is specifically configured to calculate the product PPM value according to the following formula:
wherein, PPMpIndicating the PPM value of the product, DjNumber of defects, N, representing all inspection characteristics detected in the jth processjThe total number of the characteristics of the jth procedure is shown, j is 1, 2.
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