CN114897397A - Quality evaluation method in silk making production process - Google Patents
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Abstract
The invention relates to a quality evaluation method in a silk making production process, which comprises a systematic orthogonal experiment of a silk making line, sensory quality evaluation and characteristic value calculation, inherent processing quality level evaluation and process control of an online monitoring device of the silk making line. The operation process of the on-line monitoring equipment for the silk making thread is effectively controlled by carrying out quality identification of core procedures and quality weight calculation of processing procedures, and the validity of data acquisition data participating in quality management and quality evaluation is ensured, so that a new batch quality management and silk making thread processing level evaluation mode for checking according to procedure weights is established. The mode effectively identifies quality fluctuation of the core key processing procedure process, finely and accurately controls the quality of the silk making production process, and scientifically and reasonably performs quality assessment and quality evaluation.
Description
Technical Field
The invention belongs to the technical field of cigarette production quality management, and particularly relates to a quality evaluation method in a tobacco shred production process.
Background
The quality of the tobacco shred production product is an integrated output result of processing process on-line detection equipment, process processing quality, production equipment, process quality early warning and quality management, in order to better identify the processing quality of different processes in the tobacco shred manufacturing process, a judgment standard of the processing line on-line detection equipment based on a statistical process control concept is established, the quality of the processing process of key processes is effectively monitored, the quality of the tobacco shred manufacturing process is more scientifically, reasonably and objectively evaluated, a set of processing process quality evaluation system suitable for the tobacco plant processing line is formed, the process detection and the production equipment are effectively monitored, the identification and the early warning of key processing processes are achieved, the scientific evaluation and management of the quality of the processing process are realized, the quality contribution weights of different processes are calculated and analyzed, the analysis and the improvement of weak processes and indexes are guided, the continuous improvement of the process capability is realized, and the accurate control, the quality of the tobacco shred manufacturing process is formed, Lean management and scientific judgment mode.
Disclosure of Invention
The invention aims to provide a quality evaluation method in a silk production process, so as to solve the problems.
In order to achieve the purpose, the application is realized by the following technical scheme:
a quality evaluation method for a silk making production process comprises a systematic orthogonal experiment of a silk making line, sensory quality evaluation and characteristic value calculation, inherent processing quality level evaluation and process control of an online monitoring device of the silk making line; the method specifically comprises the following steps:
(1) systematic orthogonal experiment for wire making line
The method is realized by equidistant orthogonal test of the processing strength of the leaf section and the leaf thread section of the silk making line, and a strength test interval with the same gradient is established according to the technological processing parameters of the leaf section and the leaf thread section;
(2) sensory quality evaluation and feature value calculation
According to the orthogonal test scheme of the tobacco shred making system, the test tobacco shreds of the whole production line, the leaf segment or the leaf and shred segment of the cigarette are respectively rolled, the sensory quality characteristic of the rolled cigarette is evaluated, and the sensory quality characteristic value of the tobacco shreds is calculated;
carrying out single-factor multivariate variance analysis on the sensory quality characteristic values and the test variables of the tobacco shreds by utilizing Minitab data analysis software to obtain the weights of the leaf segments and the leaf shred segments participating in the processing procedure of the strength test on the sensory quality characteristic values and the comfort index characteristic values of the tobacco shreds;
(3) evaluation of inherent processing quality level
On the premise of ensuring the product quality, using the original data with set time length, effectively cleaning the original data according to the Lauda abnormal data elimination rule, eliminating the influence of systematic error data, counting the current processing process capacity, and performing measurement and calculation of the inherent quality control level of the production equipment;
(4) process control of on-line monitoring equipment for manufacturing silk thread
And managing and controlling by utilizing an MES system according to an online moisture meter process judgment criterion for representing the moisture of the tobacco material.
Further, the processing intensity in the step (1) is to set high, medium and high treatment intensities for each process, and the current process standard of normal production is to be the medium treatment intensity.
Further, the sensory evaluation in the step (2) is based on a silk processing strength gradient test and comprises four parts of aroma characteristics, miscellaneous gases, smoke forms and comfort characteristics, wherein the evaluation of the aroma characteristics comprises three parts of aroma, namely fresh sweet, roasted sweet and burnt sweet, and the miscellaneous gases comprise green miscellaneous gases and scorched miscellaneous gases;
further, in the step (2), the procedures of the blade section participating in the strength test are respectively a loosening and moisture regaining procedure, a secondary moisture regaining procedure and a leaf moistening and feeding procedure; the indexes of the leaf silk section participating in the strength test are an HT discharging temperature index and a drying dehydration amount index.
Further, the method also comprises quality management and quality evaluation of the silk making batch process
The quality of the tobacco shred manufacturing batch process is that the tobacco shreds meeting the quality requirement of the product are finally formed through physical change and chemical change under the combined action of three factors of time, temperature and moisture; the quality management comprises five parts of feeding formula integrity, material accumulation amount of each processing procedure, material flow fluctuation of each procedure, material processing process storage time and batch shutdown and material breakage; the quality evaluation comprises heat source parameter stability, processing process water stability, feeding integrity and uniformity, perfuming integrity and uniformity, blending integrity and uniformity, and the quality management of the whole silk making process is formed through the reasonable setting of the weight of each process of the quality evaluation.
Further, the quality score H of the cut tobacco in batches is as follows:
H＝A 0.03 ×B 0.17 ×C 0.24 ×D 0.09 ×E 0.2 ×F 0.1 ×G 0.17 wherein, A is the quality score of the process of the loosening and dampening procedure, B is the quality score of the process of the secondary dampening procedure, C is the quality score of the process of the leaf moistening and feeding procedure, D is the quality score of the process of the moisture procedure after cutting, E is the quality score of the process of the HT steam pressure procedure, F is the quality score of the process of the moisture procedure after drying, and G is the quality score of the process of the blending and adding fragrance.
Further, the method for evaluating and calculating the weight of each process in the silk making process according to the contribution rate comprises the following steps:
Y＝Y1 Q1 ×Y2 Q2 ×Y3 Q3 …×Yn Qn wherein Y is the quality qualified rate of the silk making process, Y1, Y2 and Y3. cndot. Yn are items, and Q1, Q2 and Q3. cndot. Qn are item weights.
The invention has the beneficial effects that:
according to the technical scheme, through systematic orthogonal test scheme design of the tobacco shred manufacturing line and establishment of a tobacco shred quality evaluation method, the quality contribution weight of a processing strength process in the tobacco shred manufacturing link is calculated scientifically, and a core tobacco shred manufacturing production process link is effectively identified; the establishment of the sensory comfort evaluation method provides important theoretical support for technologists to scientifically and reasonably adjust parameter indexes in the test process according to the requirements of product formulas.
The establishment of the process control method of the online monitoring equipment in the silk making process realizes scientific representation of moisture indexes of all procedures in the silk making link, ensures effective control of the operation process of the online moisture meter of the silk making line through the application of a statistical process control technology, improves the reality and the effectiveness of MES data collected moisture data, and lays a foundation for subsequent quality management and quality evaluation.
The establishment of the inherent processing level evaluation method carries out scientific calculation according to the prior processing data, standardizes the reference quality level of quality assessment, effectively avoids manually setting the grade of the fraction gradient, and has more reasonable quality management work. Meanwhile, scientific reference is provided for process quality early warning and process quality improvement in the machining process.
The establishment of the weight evaluation system of the weight division of the silk production strengthens the consciousness transition of workshop production and management personnel from emphasizing the result to emphasizing the process quality, and also provides data support for the quantification of production quality responsibility. The establishment of the evaluation system in the tobacco shred production process meets the actual production reality of a tobacco factory, realizes three major changes from 'control index to control parameter', 'control result to control process', 'artificial experience decision to scientific decision' in the tobacco shred production process, continuously meets the requirements of a rolling and packing workshop and a consumer on the quality of high-quality tobacco shreds, and promotes the high-quality development of the factory.
Drawings
FIG. 1 is a flow chart of the quality evaluation in the production process of the invention.
Detailed Description
The following embodiments are merely exemplary, and are not to be construed as limiting the technical aspects of the present invention.
According to the technical scheme, through four aspects of systematic orthogonal test of the production line, sensory quality evaluation and characteristic value calculation, inherent processing quality level and process control of the production line online monitoring equipment, quality identification of core procedures and quality weight calculation of the processing procedures are carried out, the running process of the production line online monitoring equipment is effectively controlled, validity of data acquisition data participating in quality management and quality evaluation is ensured, and therefore a new batch quality management mode and a new production line processing level evaluation mode for checking according to procedure weights are established.
As shown in fig. 1, the present application provides a method for evaluating the quality of a silk production process, comprising the following steps:
(1) systematic orthogonal experiment of silk thread making:
in order to evaluate the influence of the processing strength of each procedure of the tobacco shred manufacturing line on the quality characteristic value of the tobacco shred, the weight coefficient of each procedure is calculated scientifically, basic data and theoretical support are provided for a quality evaluation system in the tobacco shred manufacturing process, and equidistant orthogonal tests of the processing strength of leaf segments and leaf shred segments of the tobacco shred manufacturing line are carried out. The equidistant orthogonal test establishes the strength test interval with the same gradient according to the processing parameters of the process, and provides a test scheme for the quantitative calculation of the influence of the processing strength of different procedures on the quality of the cut tobacco.
In the present application, the cloud smoke (purple) is taken as an example for explanation, in the present application, the index of the processing strength of the leaf section for representing the process design is the outlet material temperature, and the index of the processing strength of the leaf shred section for representing the process design is the drying and dewatering amount and the material temperature after passing through the HT. The orthogonal test setting needs to be combined with the actual equipment condition, each procedure is respectively provided with high, medium and low processing strengths, the process standard of the current normal production is the medium processing strength by default, the actual performance of the equipment needs to be considered in the equidistant design of the discharging temperature of each procedure of the blade section, and the equidistant test design is reasonably carried out within the range of meeting the adjustable parameter interval of the equipment. The isometric orthogonal test of the processing strength of the cut tobacco sections is reasonably set within the range required by the process processing standard.
(2) Method for calculating tobacco shred sensory quality characteristic value
The tobacco shred quality characteristic evaluation method comprises two parts of sensory quality evaluation and physical quality characteristic evaluation. According to the project orthogonal test scheme, the whole line, the leaf segment and the cut tobacco test cut tobacco are respectively rolled, and the rolling standard is executed according to normal production.
And (4) evaluating the sensory quality characteristics of the rolled cigarettes, and measuring the tobacco shred structure and filling value of the tobacco shreds by using different gradient tests. As the gradient adjustment of the orthogonal test of the leaf silk section is in the process processing standard range, the test under different gradient strengths has no significant influence on the whole silk rate and the filling value. The sensory evaluation comprises four parts of aroma characteristics, miscellaneous gas, smoke forms and comfort characteristics. Meanwhile, the cigarette aroma characteristic evaluation based on the processing strength gradient test of the tobacco processing line meets the practical requirements of simple evaluation, easy scoring, objectivity and accuracy and conforms to the aroma characteristic style of the product of the cloud cigarette brand 'fresh and sweet aroma'. Therefore, the evaluation of the cigarette aroma characteristics in the project is composed of three parts of fresh and sweet, roasted and sweet aroma, so that the evaluation not only meets the aroma style characteristics of the brand, but also considers the evaluation reality of the cigarette aroma characteristics of the project and covers the main aroma characteristic requirements of cigarette smoking. The miscellaneous gases comprise green impurities, wood, scorch, earthy smell and the like, and according to the actual project research, the sensory evaluation of the processing strength only needs to evaluate the change of the green impurities and the scorch smell by a strength gradient test, so that only the green impurities and the scorch miscellaneous gases need to be evaluated.
The aroma characteristics in the smoke part are divided by the offensive odor, the aroma characteristics are the aroma part which brings comfortable and pleasant smoking of the cigarette, the offensive odor is the smoke part which brings disgustability, the ratio of the aroma characteristic to the offensive odor can reflect the influence of different processing process strengths on the quality of the cut tobacco, meanwhile, the process processing strength evaluation can be better carried out, and the larger the score is, the better the sensory quality of the cut tobacco is represented.
The method for calculating the process quality contribution rate comprises the following steps:
in the application, the procedures of the blade section participating in the strength test are loosening and moisture regaining, secondary moisture regaining and blade moistening feeding procedures respectively; in order to ensure the stability of moisture at the cut tobacco drying outlet, the hot air temperature does not participate in the strength test adjustment, so the indexes participating in the strength test are HT discharging temperature (HT steam pressure) and drying dehydration amount respectively.
The whole line test becomes a 2-factor 3-level orthogonal test, and a corresponding core value is calculated and analyzed to be a sensory quality characteristic value; the leaf segment test becomes a 3-factor 3-level orthogonal test, and a corresponding core value is calculated and analyzed to be a sensory quality characteristic value; the leaf silk section test becomes a 2-factor 3-level orthogonal test, and the core value corresponding to the calculation and analysis is the sensory quality characteristic value. The method is characterized in that single-factor multivariate variance analysis of the tobacco shred sensory quality characteristic values and test variables is respectively carried out on Minitab (data analysis software), theoretical support is provided for evaluation and parameter adjustment of each procedure in the cigarette processing process, and the tobacco shreds meeting high quality are produced better.
(3) Evaluation of inherent processing quality level
In the actual production process, because the equipment capacity has certain difference, under the same standard, the equipment process capacity cannot be objectively and effectively evaluated and the quality of the equipment process capacity cannot be improved, by an evaluation method of the inherent quality control level, on the premise of ensuring the product quality, the original data is used, the large batch of original data is effectively cleaned according to the Lauda (PauTa) abnormal data elimination rule, the influence of systematic error data is eliminated, the current processing process capacity is counted, the inherent quality control level of the production equipment is calculated, the early warning, calculation, analysis and improvement mechanism of the production process equipment is established, and the continuous improvement work is effectively carried out.
(4) Controlling the process of the online monitoring equipment of the production line:
in the online detection equipment of the tobacco processing line, an online moisture meter for representing the moisture of the tobacco material plays an important role in judging the process quality of the processed tobacco. In the technical scheme, the online moisture meter process judgment criterion representing the moisture of the tobacco material is used for management and control by utilizing an MES system.
(5) The quality management and quality evaluation method in the wire-making batch process comprises the following steps:
the quality of the tobacco shred manufacturing batch process is that the tobacco shreds meeting the quality requirements of products are finally formed through physical change and chemical change under the combined action of three factors of time, temperature and moisture. The quality management mainly comprises five parts of feeding formula integrity, material accumulation amount of each processing procedure, material flow fluctuation of each procedure, material processing process storage time and batch shutdown and material breakage. The quality evaluation mainly comprises heat source parameter stability, processing water stability, charging integrity and uniformity, perfuming integrity and uniformity, and blending integrity and uniformity. And forming quality management of the whole silk making process and a quality evaluation method based on contribution rate difference by reasonably setting the weight of each process in quality evaluation.
Batch process quality management:
the batch process quality management should set corresponding judgment standards according to different processing grades, as shown in table 1:
TABLE 1 quality management table for filament making process
Batch process quality evaluation:
after all links of batch quality management and assessment in the tobacco shred shredding process reach the specified requirements, batch process quality evaluation is carried out, and the quality evaluation is shown in table 2. The batch quality evaluation mainly comprises the process stability of hot air temperature, steam pressure, leaf and tobacco shred moisture, feeding, perfuming and blending links in the process of processing the leaves into the tobacco shreds, and the conformity evaluation to the process processing standard execution process. And combining the processing level of the prior silk making process, considering the evaluation result of the process quality contribution rate, and reasonably setting the weight coefficient of each process, wherein in the scheme, the subentry weight is uniformly set.
TABLE 2 evaluation chart of quality of the process of making the silk batch
The quality score H of the cut tobacco in batches is as follows:
H＝A 0.03 ×B 0.17 ×C 0.24 ×D 0.09 ×E 0.2 ×F 0.1 ×G 0.17 wherein, A is the quality score of the process of the loosening and dampening procedure, B is the quality score of the process of the secondary dampening procedure, C is the quality score of the process of the leaf moistening and feeding procedure, D is the quality score of the process of the moisture procedure after cutting, E is the quality score of the process of the HT steam pressure procedure, F is the quality score of the process of the moisture procedure after drying, and G is the quality score of the process of the blending and adding fragrance.
The evaluation method of the processing level of the silk making thread comprises the following steps:
according to the technical scheme, the quality characteristics or parameters representing the processing intensity of the blade section and the leaf thread section are adopted; the uniformity and the integrity indexes of the processes of feeding, flavoring and blending are involved. The evaluation period is set as needed, and in this example, the evaluation period is in units of months, as shown in table 3:
TABLE 3 evaluation items of quality and processing level in the process of producing filaments and weight table
The weights of items in the moisture regain section, the drying section and the blending, feeding and perfuming section are obtained by conversion according to the evaluation and calculation results of the contribution rate; the weight setting of each procedure of the moisture regain section is calculated and obtained based on the sensory quality contribution rate of the processing procedure of the blade section; the weight of each procedure in the drying section is comprehensively discussed, analyzed and set by combining the calculation result of the quality contribution rate of the procedures and the actual situation of the silk making process in the Wulan tobacco plant; the weight of the process items of the blending, feeding and flavoring section is combined with the style characteristics and sensory quality requirements of the product, and the key arrangement is carried out.
The method for evaluating and calculating the weight of each procedure in the silk making process according to the contribution rate comprises the following steps:
Y＝Y1 Q1 ×Y2 Q2 ×Y3 Q3 …×Yn Qn wherein Y is the quality qualification rate of the silk thread making process, Y1, Y2,
Y13＝Y131 0.5 ×Y132 0.5
Y1＝Y11 Q11 ×Y12 Q12 ×Y13 Q13
Y2＝Y21 Q21 ×Y22 Q22 ×Y23 Q23
Y3＝Y31 Q31 ×Y32 Q32 ×Y33 Q33
Y＝Y1 Q1 ×Y2 Q2 ×Y3 Q3
Converting the wire manufacturing line Y into a SIGMA level according to the process quality qualified rate, and specifically directly realizing the conversion in EXCEL, wherein the EXCEL editing function is as follows: and (6) inputting a geometric algorithm qualification value Y in the EXCEL, and editing an IF function to obtain the corresponding SIGMA level. When the SIGMA level is more than 4.28, the silk making process is at a better process quality level; when the SIGMA level is more than 3.19 and is more than or equal to 4.28, the silk making process is in a controlled state and belongs to a normal control level; and when the SIGMA level is less than or equal to 3.19, the quality stability of the silk making process is in an out-of-control state, and corresponding measures are taken to enable the silk making process to return to a controlled state.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. A quality evaluation method for a silk making production process comprises a systematic orthogonal experiment of a silk making line, sensory quality evaluation and characteristic value calculation, inherent processing quality level evaluation and process control of an online monitoring device of the silk making line; the method is characterized by comprising the following steps:
(1) systematic orthogonal experiment for wire making line
The method is realized by equidistant orthogonal test of the processing strength of the leaf section and the leaf thread section of the silk making line, and a strength test interval with the same gradient is established according to the technological processing parameters of the leaf section and the leaf thread section;
(2) sensory quality evaluation and feature value calculation
According to the orthogonal test scheme of the tobacco shred making system, the test tobacco shreds of the whole production line, the leaf segment or the leaf and shred segment of the cigarette are respectively rolled, the sensory quality characteristic of the rolled cigarette is evaluated, and the sensory quality characteristic value of the tobacco shreds is calculated;
carrying out single-factor multivariate variance analysis on the sensory quality characteristic values and the test variables of the tobacco shreds by utilizing Minitab data analysis software to obtain the weights of the leaf segments and the leaf shred segments participating in the processing procedure of the strength test on the sensory quality characteristic values and the comfort index characteristic values of the tobacco shreds;
(3) evaluation of inherent processing quality level
On the premise of ensuring the product quality, using the original data with set time length, effectively cleaning the original data according to the Lauda abnormal data elimination rule, eliminating the influence of systematic error data, counting the current processing process capacity, and performing measurement and calculation of the inherent quality control level of the production equipment;
(4) process control of on-line monitoring equipment for manufacturing silk thread
And managing and controlling by utilizing an MES system according to an online moisture meter process judgment criterion for representing the moisture of the tobacco material.
2. The method for evaluating the quality of a silk making production process according to claim 1, wherein the processing intensity in the step (1) is set to three processing intensities of high, medium and medium generation for each process, and the process standard of the current normal production is assumed to be a medium processing intensity.
3. The method for evaluating the quality of the silk making production process according to claim 1, wherein the sensory evaluation in the step (2) is based on a silk making thread processing strength gradient test and comprises four parts of a fragrant characteristic, a miscellaneous gas, a smoke form and a comfort characteristic, the evaluation of the fragrant characteristic comprises three parts of fragrant, sweet and burnt, and the miscellaneous gas comprises green miscellaneous gas and burnt miscellaneous gas;
4. the method for evaluating the quality of the silk making production process according to claim 3, wherein in the step (2), the procedures of the blade section participating in the strength test are respectively a loosening and moisture regaining procedure, a secondary moisture regaining procedure and a leaf moistening and feeding procedure; the indexes of the leaf silk section participating in the strength test are an HT discharging temperature index and a drying dehydration amount index.
5. The method of claim 1, further comprising quality control and quality evaluation of the manufacturing lot process
The quality of the tobacco shred manufacturing batch process is that the tobacco shreds meeting the quality requirement of the product are finally formed through physical change and chemical change under the combined action of three factors of time, temperature and moisture; the quality management comprises five parts of feeding formula integrity, material accumulation amount of each processing procedure, material flow fluctuation of each procedure, material processing process storage time and batch shutdown and material breakage; the quality evaluation comprises heat source parameter stability, processing process water stability, feeding integrity and uniformity, perfuming integrity and uniformity, blending integrity and uniformity, and the quality management of the whole silk making process is formed through the reasonable setting of the weight of each process of the quality evaluation.
6. The method for evaluating the quality in the tobacco shred production process according to claim 5, wherein the quality score H of the batch of the tobacco shreds is as follows:
H＝A 0.03 ×B 0.17 ×C 0.24 ×D 0.09 ×E 0.2 ×F 0.1 ×G 0.17 wherein, A is the quality score of the process of the loosening and dampening procedure, B is the quality score of the process of the secondary dampening procedure, C is the quality score of the process of the leaf moistening and feeding procedure, D is the quality score of the process of the moisture procedure after cutting, E is the quality score of the process of the HT steam pressure procedure, F is the quality score of the process of the moisture procedure after drying, and G is the quality score of the process of the blending and adding fragrance.
7. The method for evaluating the quality of the silk making production process according to claim 6, wherein the method for evaluating and calculating the weight of each process in the silk making process according to the contribution ratio comprises the following steps:
Y＝Y1 Q1 ×Y2 Q2 ×Y3 Q3 …×Yn Qn wherein Y is the quality qualification rate of the silk thread making process, and Y1, Y2 and Y3 … Yn areEach item, Q1, Q2, Q3 … Qn is an item weight.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115437333A (en) * | 2022-11-07 | 2022-12-06 | 杭州安脉盛智能技术有限公司 | Sensory quality-based adjusting method, device, equipment and storage medium |
| CN117634993A (en) * | 2023-11-27 | 2024-03-01 | 红云红河烟草(集团)有限责任公司 | Tobacco shred quality evaluation method, system, electronic equipment and storage medium |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115437333A (en) * | 2022-11-07 | 2022-12-06 | 杭州安脉盛智能技术有限公司 | Sensory quality-based adjusting method, device, equipment and storage medium |
| CN115437333B (en) * | 2022-11-07 | 2023-02-28 | 杭州安脉盛智能技术有限公司 | Sensory quality-based adjusting method, device, equipment and storage medium |
| CN117634993A (en) * | 2023-11-27 | 2024-03-01 | 红云红河烟草(集团)有限责任公司 | Tobacco shred quality evaluation method, system, electronic equipment and storage medium |
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