CN115169876A - Closed-loop management method for magnetic component production line, computer equipment and storage medium - Google Patents
Closed-loop management method for magnetic component production line, computer equipment and storage medium Download PDFInfo
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Abstract
The invention discloses a high-quality closed-loop management method for a magnetic component production line, computer equipment and a storage medium, wherein the method comprises the following steps: step 1, reading a production plan; step 2, obtaining production information; step 3, detecting the completeness of feeding, and starting production line equipment production; step 4, monitoring the production information of the equipment in real time, and processing problems in the production process in real time; and 5, off-line production of finished products, automatically scanning finished product codes, and associating quality data, material data and equipment information of the products to a single component. Forming a traceable information platform of quality. The invention relates to a closed-loop management method, computer equipment and a storage medium for a magnetic component production line, which can manage feeding information, yield information, electrical property detection quality information and the like.
Description
Technical Field
The invention relates to the technical field of automatic production of magnetic components, in particular to a closed-loop management method for a magnetic component production line, computer equipment and a storage medium.
Background
The yield and quality influencing factors of the magnetic components exist in the teaching of production equipment, such as process setting of the production equipment, maintenance and repair of various components and the like, the quality condition of production raw materials, production process control, the temperature and humidity of soldering and baking environments and the like. When the product is formed into a finished product, a series of electrical property tests are carried out, and only a single product passing all the index measurements is qualified and off-line.
Therefore, a closed-loop management method for a magnetic component production line, which can manage loading information, yield information, electrical property detection quality information, and the like, is needed.
Disclosure of Invention
The invention aims to provide a closed-loop management method, computer equipment and a storage medium for a magnetic component production line, which can manage loading information, yield information, electrical property detection quality information and the like.
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
in a first aspect, the present invention provides a closed-loop management method for a magnetic component production line, including:
and 5, off-line production of finished products, automatically scanning finished product codes, and associating quality data, material data and equipment information of the products to a single component. Forming a traceable information platform of quality. In step 2, the acquiring material information includes: and checking the materials of the production line equipment, and scanning the material numbers during feeding.
In step 2, the obtaining production information includes: and acquiring material inspection of equipment on the production line, and scanning material number information during material loading.
In the step 4: the method comprises the step of monitoring the production information of the equipment in real time, including monitoring the real-time yield and quality of products.
And 4, monitoring the real-time yield and quality of the product, and if the product testing quality does not meet the requirements, performing 4.1, stopping the machine, modifying, adjusting the parameters on line, testing to reach the standard, recovering the production, and performing 3 again.
In step 2, the obtaining of the production information includes: and acquiring the production cost budget, and determining the unit yield target and the target quality control range.
In a second aspect, the present invention provides a computer device, where the computer device includes a storage medium and a processor connected to the storage medium, the storage medium is used to store a computer program, and when the processor runs the computer program, the processor executes the closed-loop management method for a magnetic component production line.
In a third aspect, the present invention provides a storage medium, where the storage medium is a readable storage medium and is used to store a computer program, and when the computer program is executed by a processor, the computer program executes the method for closed-loop management of a magnetic component production line.
The invention has the beneficial effects that:
1. the operation state of the production line is effectively optimized;
2. and carrying out closed-loop control on the product quality.
The invention will become more apparent from the following description when taken in conjunction with the accompanying drawings, which illustrate embodiments of the invention.
Drawings
Fig. 1 is a flow chart of a closed-loop management method for a magnetic component production line according to the present invention.
Fig. 2 is a schematic view illustrating an embodiment of a closed-loop management method for a magnetic component production line according to the present invention.
Fig. 3 is a schematic view illustrating another embodiment of the closed-loop management method for a magnetic component production line according to the present invention.
FIG. 4 is a flow chart of the product quality monitoring step.
FIG. 5 is a schematic diagram showing normal product quality measurement.
FIG. 6 is a schematic diagram showing that the product quality measurement is abnormal.
Fig. 7 is a schematic flow chart of product quality tracing.
Fig. 8 is a schematic diagram of a test station.
FIG. 9 is a schematic diagram of the computer apparatus of 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.
The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
Hereinafter, if the terms "including", "having", and their derivatives are used in various embodiments of the present invention, they are intended to indicate only specific features, numbers, steps, operations, elements, components, or combinations of the foregoing, and should not be understood as first excluding the existence of or adding to one or more other features, numbers, steps, operations, elements, components, or combinations of the foregoing.
Furthermore, to the extent that the present disclosure is directed to the terms "first," "second," "third," etc., this is used merely to distinguish one element from another, and is not intended to indicate or imply relative importance.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments of the present invention belong. The terms (such as those defined in commonly used dictionaries) should be interpreted as having a meaning that is consistent with their contextual meaning in the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein in various embodiments of the present invention.
The invention adopts automatic equipment to collect material feeding information, yield information, electrical property detection quality information and appearance detection information of each work station, scans and associates finished product components, traces back 3 main bodies of equipment utilization rate monitoring and intervention, quality control and intervention and product quality, intensively completes the monitoring and intervention, the quality control and intervention and the product quality in a system, and can realize the streamlined closed-loop management by contrasting the production cost budget in a production plan.
The electrical property test mainly comprises the following steps: turns, inductance, DC resistance, leakage inductance, pin shorts, balance values, and common mode parameters.
The appearance detection information mainly includes: the adhesive tape packaging is irregular, the stitches are inclined, the outer surface is polluted and the like.
Referring to fig. 1, the present invention provides a closed-loop management method for a production line of magnetic components, including:
s01, reading a production plan;
s02, acquiring production information;
s03, detecting the completeness of feeding, and starting production line equipment for production;
s04, monitoring the production information of the equipment in real time, and processing problems in the production process in real time;
and S05, finished product offline, automatic scanning of finished product codes, and association of quality data, material data and equipment information of the products to a single component. Forming a traceable information platform of quality.
It should be noted that, in the step S03, the detecting completeness of feeding includes: copper wire, adhesive tape, skeleton, glue, soldering tin, etc.
In step S05, finished product codes are automatically scanned, and the quality data of the associated product refers to that each finished product component needs to be subjected to an electrical performance test, the test is divided into a plurality of work stations, data of the electrical performance test is output, and if the finished product component needs to be paired with each component, the codes of the components and the test data of the components at each test station need to be associated in some way. So that later in the system, according to the coding of the element, the corresponding test data index generated in the production process can be traced and inquired.
Note that the "operating ratio" is explained: the "utilization rate" refers to the percentage of time that the equipment takes to create value in the time available.
The utilization rate is divided into a time utilization rate and a performance utilization rate.
The time utilization rate refers to the time of the effective working state of the equipment compared with the power-on time of the upper equipment.
The performance utilization rate is the time utilization rate and the yield.
The specific reasons for the low utilization rate may be:
mainly, various faults of stopping production occur in the process, or the time of material shortage and material supplement exceeds the preset time. Failure to resume production in time can result in the utilization rate being below the preset target.
In an embodiment, referring to fig. 1 and 2, a closed-loop management method for a magnetic component production line provided in an embodiment of the present invention includes:
s001, reading a production plan;
in step S002, the acquiring of the production information includes: and acquiring material inspection of equipment on the production line, and scanning material number information during material loading.
In the step S003, the completeness of feeding is detected, and production line equipment production is started;
and step S004, namely monitoring the production information of the equipment in real time, including monitoring the real-time yield and quality of the product.
It should be noted that quality monitoring mainly monitors whether the indexes of each link of the electrical performance indexes of the product are within the standard range. In addition, appearance monitoring is not an electrical property indicator, but is also part of the quality detection.
If the product test quality does not meet the requirements in the step S004, the method goes to the step S0041, which is to stop the machine for modification, adjust the parameters on line, resume the production after the test reaches the standard, and go to the step S003 again.
If the equipment utilization rate is low and the equipment downtime exceeds the response time in step S004, the process proceeds to step S0042: responding to the equipment alarm, maintaining the equipment, replacing the consumable, recovering the production of the sample, and re-entering the step S002.
Referring to fig. 1 and 3, a closed-loop management method for a magnetic component production line according to an embodiment of the present invention includes:
s001, reading a production plan;
s002, in the step S002, the acquiring the production information includes: and acquiring the production cost budget, and determining the unit yield target and the target quality control range.
S003, detecting the completeness of the feeding, and starting production line equipment for production;
s004: the method comprises the steps of judging the running state of production line equipment in real time, and if the yield is low, entering a step S0041: the production line equipment is automatically stopped, and the process and the materials are detected. Removing the problems, and after the sample passes through the production line, recovering the production and re-entering the step 3; if the utilization rate is low, the process proceeds to step S0042: the alarms are pushed to machine maintenance personnel, production line and workshop responsible persons in real time, and are solved within a specified time or the production plan is informed to be adjusted; step 4.3: and analyzing the root cause with low utilization rate and pushing the analysis result to a manager.
According to the production plan and the production process, within unit hour on each production line, a rated output target, various material consumption indexes and a real-time monitoring result of the product quality exist. According to the statistics of unit time, whether the output and consumption of each machine on the production line are matched with the production cost budget of the product of the model or not and whether the expected qualified output is achieved or not under the rated cost consumption can be estimated.
The production plan is explained as follows: a production plan can be given by combining actual generation, and according to a product order, a production task is transferred to each production line, the planned yield and the completion time period of each production line are made, and the required total amount of materials and the required personnel configuration number are determined. The key contents are as follows: product model, production line number, production quantity, planned start time and end time.
It should be noted that the operation states of the equipment include normal, shutdown and maintenance.
For example, in a production plan:
the order of a certain type of a certain client can be decomposed into a production planning list on certain production lines and certain workshops of a factory, wherein the production planning list comprises order numbers, material numbers, planned output, planned time and the like.
Specifically, the method comprises the following steps: 500 ten thousand of production orders of the needed transformers in the mobile phone charger of the mobile phone manufacturer A are transferred to the manufacturer B, delivery and quality acceptance are required to be completed within 4 months, and the quality requirement of acceptance is that the number of unqualified products with defects detected per million is less than 20.
And the manufacturer B builds a production line, allocates production personnel, purchases corresponding materials and makes a production plan according to the delivery date and the quality requirement of the product.
According to the capacity planning of the existing production line of the manufacturer B, for example, 2 ten thousand transformers are produced by one standard transformer production line every day. Then 500 ten thousand pieces need one production line to be produced for 250 days, if 3 production lines are simultaneously produced, 83.3 days are needed, and the period is close to 3 months, so that the delivery requirement of a mobile phone manufacturer A in 4 months can be met.
Therefore, the production plan needs to start 3 production lines simultaneously to carry out production. The production time period is 3 months. The production quantity per day of each production line is required to be 2 ten thousand pieces. And quality control needs to be carried out on-site SPC control, defective products are removed from the source, and the control target is less than or equal to 20 defective products per million.
And the material purchasing corresponding to the production plan needs to be dynamically supplemented according to the inventory of the material warehouse and the production progress. The quality of the materials is required to meet the requirements, and the raw materials are also on the safety stock level line, for example: keeping the stock available throughout can last for 2 weeks of production, below which standards rapid replenishment of stock is required.
And the personnel configuration of the production line binds workers and the production line through team organization, and also binds the workers and the orders within a certain time.
Referring to fig. 4, in step S004, the real-time monitoring of the product yield specifically includes:
s00410, starting production line equipment or a data acquisition machine;
s00420, periodically reading a plc or a controller on a test machine by a data acquisition industrial personal computer; or reading an electrical property test meter; in the step, the data acquisition industrial personal computer is used for acquiring information such as the working state, the yield, the test index and various alarms of the machine;
s00430a, reading information such as yield count, operation status, and alarm status in the tool plc or the controller via a dedicated protocol; or
S00430b, reading information such as yield count, operation status, and alarm status in the tool plc or the controller via a dedicated protocol;
and S00440, sending the collected data to a factory server for data summarization and statistical analysis, providing the system for alarming, stopping or triggering the data update of a signboard, and providing the retrieval and analysis of yield information.
Referring to fig. 5, for example, normal measurement values are a small number outside the control values, and the mean value is near the centerline.
Referring to fig. 6, the following distribution should also be alerted if it occurs: it falls within the range of actual mean distribution deviating from the median. An intervention analysis is required, and if it is due to a problem of a material or a process, a defective product is likely to occur on a large scale at the next stage.
If a large number of samples fall outside the control line, the machine must be stopped for problem resolution before production can continue.
It should be noted that, in the closed-loop control of the product quality, in the quality control chart, if the quality control chart of a batch of products is close to the control down-line or on-line, the batch of products is essentially statistically lower than the factory quality requirement. Normal quality control should fluctuate at the midline.
This test, in the past, was by sampling quality. This is done after a batch is sent for inspection. But when discovered, large batches of product may be included as secondary product. In order to reduce the possibility of mass loss, a real-time analysis function is added into a production data acquisition quality analysis system, and in the production process of batch products, on-line quality full inspection is carried out, and monitoring and comparison of production quality models are carried out. Once a problem is found, intervention is performed in advance.
The production data acquisition quality analysis system aims at the production line equipment to acquire the statistical data of the yield and the quality of products in each section and specific indexes of a plurality of electrical property tests.
According to the corresponding relation between normal yield and quality. And establishing a normal operation quality data model. In contrast monitoring, deviations in quality data were encountered and the number of consecutive deviations, if not eliminated as outlier anomalies, was considered likely to be significant anomalies in the equipment tuning and raw material batches.
Different from the traditional sampling quality inspection method, the method is to carry out statistical analysis on the quality inspection indexes of each product. The method is not only used for tracing the quality of products one by one, but also has more precise discovery and intervention on the deviation trend of the quality in the production process.
After the deviation of the quality problem is found, the key machine of the control procedure stops the production of the next batch of products through an online system program, and more finished product flow production lines deviating from the normal quality level are avoided. And batch products on the production line can be continuously output to finished product output.
In a factory range, the system collects data of a plurality of production lines and a plurality of workshops at the same time. If multiple lines of the same batch of raw materials are used, quality deviations only occur on individual lines, which can be considered a problem for line equipment tuning. If multiple production lines occur simultaneously, a greater probability is considered a raw material batch problem.
The system classifies and comprehensively analyzes the reasons of the quality problems according to the coverage rate of the production line, the raw material batches and the quality problems, and gives the possible reasons of the quality problems. And the quality fault is corrected by production management personnel.
After the equipment and the raw materials are adjusted and rechecked and the quality standard requirement is met through the generation of the sample, the normal flow production of the production line is started and recovered in the production management system.
Referring to fig. 7, in product quality traceability:
the collected production data, namely raw material batch data, electrical property test data, appearance detection data, environment temperature and humidity data and the like, are associated and correspond to the components. For the component, if the component has the capability of laser code burning, the read test data result can be related to a single component in a two-dimensional code scanning mode. If the element does not have the condition of burning the two-dimensional code, the test data of the boxed elements can be related to the two-dimensional code of the box body in batch when the elements are boxed.
S0071, starting production line equipment or a data acquisition machine;
s0072, scanning the material codes during feeding, and associating and reporting the material codes with a production line machine;
s0073, transferring the components to an electrical performance testing site, reading electrical performance data tested by each component, numbering the components, and corresponding the test data to the serial numbers of the products one by one;
and S0074, corresponding the electrical performance data of the batched components to each loaded box. A box element for generating a code and corresponding the code to each element in the box;
s0075, the system can be used for quality tracing according to the coding of a single element or according to the coding of one box.
Referring to fig. 8, fig. 8 is a schematic diagram of a test station. The testing station receives the components transmitted by the feeding equipment.
The numbers are 1 to 8 in the test station 1 in chronological order.
And (4) the test station finds abnormality on the 3 rd element and the 7 th element, and sends the elements to a failure area after judging failure.
While the other components are sent to the test station 2 in the order in which they are still entered. The components entering the test station 2 are numbered by the system in sequence 1, 2, 4, 5, 6, 8. Fail nos. 3 and 7, and do not inform test site 2.
And the test station receives the components sent in sequence and tests the components.
And finding out that the component with the global number of 5 is abnormal, and sending the component into a non-qualified area after judging that the component is not qualified.
And the other components are still sent into the balance in the entering sequence, and the components entering the balance are numbered as 1, 2, 4, 6 and 8 in sequence by the system. And number 5, which is unqualified, does not inform the balance placing station.
Thus, the last station of the production line has the global serial number for the components coming in sequence. And the final product can be stored in a finished product data quality library by combining the test data-global serial number data pairs of each test station, so that the subsequent quality tracing is facilitated.
If the codes (two-dimensional codes or bar codes and the like) can be burnt on each component, the components can be scanned at the feeding position of a production line or the swinging position. Because the system knows the global component numbers at these two locations, the scanned code can be mapped to the global code. This eliminates the need for a code reading device at each test site. And the position for placing the code reading equipment can be arranged according to the layout of a production line and is not limited to be arranged on a certain machine table.
Referring to fig. 9, the present invention provides a computer apparatus 100, where the computer apparatus 100 includes a storage medium 10 and a processor 20 connected to the storage medium 10, the storage medium 10 is used to store a computer program 30, and the processor 20 executes the magnetic component production line closed-loop management method when running the computer program 30. In addition, the computer apparatus 100 further includes an internal memory 40 and a network interface 50, and the internal memory 40 and the network interface 50 are respectively connected to the processor 20.
Referring to fig. 9, the present invention provides a storage medium 10, where the storage medium 10 is a readable storage medium and is used for storing a computer program 30, and when the computer program 30 is executed by a processor 20, the closed-loop management method for a magnetic component production line is performed. In addition, the computer apparatus 100 further includes an internal memory 40 and a network interface 50, and the internal memory 40 and the network interface 50 are respectively connected to the processor 20.
The above disclosure is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the scope of the present invention, therefore, the present invention is not limited by the appended claims.
Claims (10)
1. A closed-loop management method for a magnetic component production line is characterized by comprising the following steps:
step 1, reading a production plan;
step 2, acquiring production information;
step 3, detecting the completeness of the feeding, and starting production line equipment for production;
step 4, monitoring the production information of the equipment in real time, and processing problems in the production process in real time;
and 5, finished product offline, automatically scanning finished product codes, and associating quality data, material data and equipment information of the products to a single component. Forming a traceable information platform of quality.
2. The closed-loop management method for a magnetic component production line according to claim 1, wherein in the step 2, the obtaining material information includes: and checking the material of the production line equipment, and scanning the material number during feeding.
3. The closed-loop management method for a magnetic component production line according to claim 2, wherein in the step 2, the obtaining production information includes: and acquiring material inspection of equipment on the production line, and scanning material number information during material loading.
4. The closed-loop management method for the production line of the magnetic components as claimed in claim 2, wherein in the step 4: the method comprises the step of monitoring the production information of the equipment in real time, including monitoring the real-time yield and quality of products.
5. The closed-loop management method for the production line of the magnetic components as claimed in claim 2, wherein the step 4 comprises monitoring the real-time yield and quality of the product, and if the product quality does not meet the requirements, the step 4.1 comprises stopping the machine, adjusting parameters on line, recovering the production after the test reaches the standard, and then the step 3 is carried out again.
6. The closed-loop management method for the production line of the magnetic components as claimed in claim 2, wherein the step 4 includes monitoring the real-time yield and quality of the product, and if the utilization rate of the equipment is low and the downtime of the equipment exceeds the response time, the step 4.2 is executed: responding to equipment alarm, equipment maintenance, consumable replacement, sample production recovery and re-entering step 2.
7. The closed-loop management method for a production line of magnetic components as claimed in claim 1, wherein in the step 2, the obtaining production information includes: and acquiring the production cost budget, and determining the unit yield target and the target quality control range.
8. The closed-loop management method for the production line of the magnetic components as claimed in claim 1, wherein the step 4 includes real-time judgment of the operation state of the production line equipment, and if the yield is low, the step 4.1 is performed: the production line equipment is automatically stopped, the process and the materials are detected, the problems are eliminated, the production line resumes production after the sample passes through the production line, and the step 3 is carried out again; if the utilization rate is low, the method proceeds to step 4.2: the alarms are pushed to machine maintenance personnel, production line and workshop responsible persons in real time, and are solved within a specified time or the production plan is informed to be adjusted; step 4.3: and analyzing the root cause with low utilization rate and pushing the analysis result to a manager.
9. A computer device, comprising a storage medium and a processor connected to the storage medium, wherein the storage medium is configured to store a computer program, and the processor executes the method for closed-loop management of a magnetic component production line according to any one of claims 1 to 8 when running the computer program.
10. A storage medium, wherein the storage medium is readable and is used for storing a computer program, and when the computer program is executed by a processor, the method for managing a magnetic component production line in a closed loop manner according to any one of claims 1 to 8 is performed.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116165966A (en) * | 2023-04-21 | 2023-05-26 | 沈阳精锐数控机床有限公司 | Informationized self-adaptive material regulation and control method and system for numerical control machine tool |
| CN116362454A (en) * | 2023-06-03 | 2023-06-30 | 宁德时代新能源科技股份有限公司 | Yield analysis system and method, electronic equipment, storage medium and product |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116165966A (en) * | 2023-04-21 | 2023-05-26 | 沈阳精锐数控机床有限公司 | Informationized self-adaptive material regulation and control method and system for numerical control machine tool |
| CN116362454A (en) * | 2023-06-03 | 2023-06-30 | 宁德时代新能源科技股份有限公司 | Yield analysis system and method, electronic equipment, storage medium and product |
| CN116362454B (en) * | 2023-06-03 | 2023-10-20 | 宁德时代新能源科技股份有限公司 | Yield analysis system and method, electronic equipment, storage medium and product |
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