JP2019101760A - Quality control information generation system, generation method and program - Google Patents

Abstract

To provide a generation system of quality control information that can be used to analyze an influence of a production process on product quality.SOLUTION: The present invention relates to a quality control information generation system comprising: feature quantity identifying means for identifying a feature amount characterizing a quality of a raw material obtained from time-series information obtained in a production process of a raw material subjected to lot management; lot information generating means for generating lot information of the raw material including the feature amount; and related information generation means for generating related information in which lot information is associated with identification information of individually managed products produced using the raw material. The quality control information generation system preferably further comprises analysis means for analyzing lot information of the raw material corresponding to the product on the basis of the related information. By utilizing the related information in which the product identification information and the lot information of the raw material are linked, it is possible to efficiently improve product quality and improve each production process.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a system and the like for generating quality control information that can be used to analyze the influence of the raw material production process on the quality of a product.

  Products are not only managed by part numbers indicating their types, but are often individually managed by identification information (serial numbers, numbers or symbols such as IDs) individually or in units of lots. However, even for individually managed products, up to the specific production information (such as data indicating the situation at the time of production) of the raw materials (raw materials or raw materials) used for the production of the products (or incorporated parts) There was no retrospective tracking, and no measures were proposed to make it possible. For this reason, for example, when a defect has occurred in a product, it has been difficult to efficiently determine where in the production process of the raw material the factor is caused. In particular, when the production process of the raw material used for the product is large (for example, when the number of processes is several hundred to several tens of thousands), it is very difficult to find the cause of such a defect.

JP, 2017-138929, A

  The present invention has been made in view of such circumstances, and enables access to production information of a raw material used for production of a product, and contributes to investigation of the cause of product failure and quality improvement. It relates to a generation system etc.

  Patent Document 1 describes a waveform analyzer and the like of time-series data that can extract feature quantities from time-series data. However, Patent Document 1 is not directly related to the object of the present invention described above.

  The inventor of the present invention diligently studied to solve this problem, and newly conceived to associate identification information of a product with a feature that indicates the situation at the time of production of the original material used for the production. The realization and development of this idea led to the completion of the invention described hereinafter.

Quality control information generation system
(1) The present invention is a feature quantity specifying means for specifying a feature quantity characterizing the quality of the raw material obtained from time-series information obtained in the production process of the raw material subject to lot management, and the original containing the feature quantity The system comprises: lot information generating means for generating lot information of the material; and related information generating means for generating related information in which the lot information is associated with identification information of an individually managed product produced using the original material. It is a quality control information generation system.

(2) According to the present invention, first, the feature quantity corresponding to each lot of the raw material based on the time-series information generated for each production process of the raw material used for the product by the feature quantity specifying unit Is identified. Next, the lot information generation means generates lot information including the feature amount for the raw material of each lot. Then, the related information generation means generates related information in which lot information of the original material used for manufacturing the product is associated with the identification information of the product.

  According to the present invention, for example, it becomes possible to grasp the feature quantities of the entire production process of the raw material involved in the production of a specific product as one data table (related information). By using such a data table, the production control conditions of the raw material far from the product which could not be considered up to now can be subjected to data analysis as to the influence on the final quality of the product. Through this data analysis, it is possible to predict the quality of the final product in the middle of the production process, and to estimate factors that significantly affect the quality of the final product, thereby reducing the defective rate and producing high-quality products. It is possible to improve the quality etc.

(3) The quality control information generation system (also referred to simply as “system”) of the present invention further includes a lot of the raw material corresponding to the product based on the related information in order to perform the data analysis described above. It is preferable to provide an analysis means for analyzing information (especially, feature quantities).

  Naturally, the system of the present invention is realized by a computer and a program to be executed by the computer. Each means mentioned above may be considered as a component of the program.

<< Method of generating quality control information or its program >>
(1) The present invention can also be understood as a method of quality control information generation or a program thereof. That is, according to the present invention, there is provided a feature amount specifying step for specifying a feature amount characterizing the quality of the raw material obtained from time-series information obtained in the production process of the raw material subjected to lot management; Quality control comprising a lot information generation step of generating lot information, and a related information generation step of generating related information in which the lot information is associated with identification information of individually managed products manufactured using the raw material It may be an information generation method.

(2) The present invention can also be grasped as a quality control information generation program which causes a computer to execute the steps relating to the quality control information generation method.

<< Others >>
(1) The terms "means" and "step" in the present specification can be interchanged depending on the subject of the present invention (the invention of a substance or the invention of a method). In addition, "means" can be put in another way as "part".

(2) Raw material "The raw material" as used in this specification means a raw material or a raw material. Those materials and forms are selected in accordance with the specifications of the product and the conditions of each process. The raw materials are not individually controlled by identification numbers, etc. like products, but are continuals or aggregates controlled in lots as things produced under the same conditions or provided for production. is there. Unless otherwise specified, in the present specification, the unit of the raw material managed as such is referred to as “lot”, and managing by the unit of lot is referred to as “lot management”. In addition, lot information (in particular, a number, a symbol, etc.) of the raw material to be lot-managed is also referred to simply as "raw material lot".

(3) Product The “product” in the present specification may be a final product or an intermediate product, but in any case, each is individually managed by identification information (number, symbol, etc.). However, the unit of individual management and the way of assigning identification information may differ depending on the type of product. For example, if there is a case where identification information such as a number or a symbol is given to each product and individual management is performed, the number or the symbol for each group (group) of a plurality of (individual) products Etc., and may be individually managed as a group of a predetermined quantity (so-called lot unit).

(4) Time-series information "Time-series information" as referred to in this specification consists of measured values obtained during the production process of the raw material along with the passage of time, and is continuous or discrete (intermittently at fixed intervals) Serial information (series of data).

It is a schematic diagram of an assumption case to which the present invention is applied. 3 is a flowchart according to an embodiment of the present invention. It is a data table which illustrated the management data (time series data) obtained by a production process. It is a data table which illustrated specification of the feature-value based on management data. It is a data table which illustrated the tying between material lots. It is a data table which illustrated the tying of the feature-value of each raw material lot, and product ID.

  One or more components arbitrarily selected from the present specification may be added to the above-described components of the present invention. The contents described in this specification appropriately apply not only to a quality control information generation system but also to a generation method, a generation program, and the like.

<< Feature quantity identification means (step) >>
The feature amount specifying means calculates a feature amount that characterizes the quality of the raw material that may affect the quality of the product, based on the time-series information (time-series data) obtained in each production process of the raw material. When there are many types of time-series information (data) obtained in each production process, time-series information that may affect each quality of the product or the raw material is extracted or selected, and at least one or more feature quantities are specified. Be done.

  The feature amount is specified by calculation or the like for each variable based on a predetermined method in consideration of the physical meaning of manufacturing conditions (variables) managed in each production process. For example, when the manufacturing conditions managed in the production process are load, temperature, and the like, an average value, an upper limit value, a lower limit value, and the like calculated based on time-series data thereof are used as feature amounts. The feature amount is usually calculated or the like for each lot of the original material, and is made part of the lot information of the original material.

<< lot information generation means (step) >>
The lot information generation means generates lot information including at least the above-described feature quantity. This lot information usually includes lot identification information (lot number etc.) of the lot given to the raw material obtained in each production process in time series, and a feature amount specified corresponding to the identification information.

<< Related information generation means (step) >>
The related information generation means generates related information in which the lot information of the original material described above and identification information (such as an identification number) of a product produced using the original material are associated (linked). Since the lot information includes the above-described feature quantity, if the related information is used, not only the lot number of the original material used for the production but also the production time of the original material based on the identification information of the product Situations (such as indicators that affect quality) can also be tracked efficiently.

<< Analytical means (step) >>
The analysis means analyzes lot information (especially, a feature amount) of the raw material used for producing the product based on the related information described above. For example, when a defect occurs in a certain product, the characteristic number indicating the situation at the time of production as well as the lot number of the original material used for the production of the product is retroactively extracted from the identification number. Can track Further, by comparing the lot information relating to the non-defective product and the non-defective product, the cause of the non-defective product can be accurately estimated by extracting the part (feature amount) in which the lot information is different. Note that general statistical analysis or machine learning may be used for data analysis.

  The present invention will be more specifically described by showing a supposed case to which the quality control information generation system of the present invention can be applied.

"system"
The generation system according to the present embodiment is configured of a general-purpose or dedicated computer and a program executed on the computer. The computer includes an arithmetic unit (CPU, etc.), a storage unit (ROM, RAM, HDD, SSD, etc.) for temporarily or long-term storage of data and programs, a display unit (display, etc.), an input / output unit (keyboard, mouse, Communication interface etc. etc. are provided. The computer may be a dedicated machine or a general-purpose machine (such as a personal computer (PC)). The program is temporarily or long-term installed in a computer to execute each step of the method of generating quality control information described later. The program may be dedicated software or may be general purpose software (spreadsheet software etc.). In addition, the program part which performs each step becomes each means based on this invention.

"Production process"
In this embodiment, as shown in FIG. 1, continuous raw materials or raw materials (both are simply referred to as “raw materials” which are not individually managed but are managed (simply referred to as “lot management”) in units according to the production process. ), Each step of producing a product individually managed by an identification number (ID, part number) or the like is assumed.

  Specifically, the product according to the present embodiment is formed by assembling parts obtained by cutting continuous bonding rolls subjected to lot management into a predetermined length on a base, and individually managing them one by one with an identification number (ID). Ru. Details of each process from raw material to production of product are as follows.

(1) First Step The first step consists of a first step (A) and a first step (B). The first step (A) is a step of obtaining a paste (A) obtained by kneading the powder (A) and the liquid (A). The first step (B) is a step of obtaining a paste (B) obtained by kneading the powder (B) and the liquid (B). The paste (A) and the paste (B) are continuous raw materials, and are lot-managed for each production unit along the time series. 1, No. 2, No. A number such as 3 is assigned.

(2) Second Step The second step comprises a second step (A) and a second step (B). The second step (A) is a step of applying the paste (A) to the roll (A) to obtain a roll (A) after application. The second step (B) is a step of applying the paste (B) to the roll (B) to obtain the post-application roll (B). The post-application roll (A) and the post-application roll (B) are also continuous raw materials, and as in the case of the first step, lot management is performed for each production unit along the time series. 1, No. 2, No. A number such as 3 is assigned (see FIG. 3).

(3) Third Step The third step is a step of obtaining a post-lamination roll in which the post-application roll (A) and the post-application roll (B) are laminated. Rolls after lamination are also continuous raw materials, and as in the case of the first step and the second step, lot management is performed for each production unit along the time series, and No. 1 1, No. 2, No. A number such as 3 is assigned (see FIG. 3).

(4) 4th process A 4th process is a process of obtaining the components which cut | disconnected the roll after bonding in predetermined size. The parts can be individually managed one by one, but may be managed per production unit as long as the product and the raw material can be linked.

(5) Fifth Step The fifth step is a step of obtaining a product in which the component is attached to the base. In the present embodiment, it is assumed that one component is assembled to one base for each product. The final products obtained in this way are individually managed with identification (ID) given one by one.

Quality control information generation
FIG. 2 shows a flowchart for generating a database (related information) in which lot information (feature amount) of raw materials and product identification information are linked in the above setting example.

(1) Acquisition of management data (time-series information acquisition step)
First, in step S1, data (simply referred to as "management data") managed when performing each step (particularly, the first to third steps) is acquired. The management data is mainly time-series data related to manufacturing conditions and the like that affect the quality of the product (raw material) obtained in each process or the quality of the final product. An example is shown in FIG. For example, in the case of the second step, the management data includes the coating thickness (measured value A) when applying the paste to the roll, the winding speed of the roll (measured value B), the ambient temperature at the time of application (measured value C), etc. The table is made up of a list acquired in chronological order (simply referred to as "table 1").

  The management data of the second step includes data on the previous step in addition to the data on the own step (this is the same for the other steps). In the case of the second step, for example, the data on the own step is lot information (lot No. etc.) on the pre-application roll and the post-application roll, and the data on the previous step is lot information on the paste to be applied to the roll (lot No. Etc.). Incidentally, as apparent from Table 1, lot No. of the dough obtained in the first step. And the lot No. of rolls used in the second step of applying the paste. Does not correspond with 1: 1.

  Further, the management data of the third step may be, for example, the pressure (measurement value A) at the time of bonding the roll after application (A) and the roll after application (B), the ambient temperature at that time (measurement value B), etc. It is obtained as a list acquired in series (simply called "table 2"). The management data also includes lot information (lot No., etc.) for the post-bonding roll, and lot information (lot No.) for the post-application roll (A) and post-application roll (B) for the preceding process. Etc.) are included. Further, as apparent from Table 2, each lot No. of the post-application roll (A) and the post-application roll (B) obtained in the second step is obtained. And lot No. of rolls after lamination obtained in the third step of laminating them. Also, 1: 1 does not correspond.

(2) Calculation of feature quantity (feature quantity identification step)
In step S2, based on the control data of each process, the lot No. of the raw material obtained in each process is obtained. Calculate the feature to be associated with The feature amount is, for example, lot No. obtained in each process. A representative value is selected to indicate the characteristics (quality) of each raw material. For example, in the case of the second step, as shown in FIG. 4, an average value of coating thickness (measurement value A) and winding of the roll are used as feature quantities that indicate the quality of the roll after application (quality affecting the product). The maximum value of the velocity (measured value B), the minimum value of the atmosphere temperature (measured value C) at the time of application, etc. are calculated. Each feature amount obtained in this manner is used as the lot No. of the raw material (roll after application). , The correspondence table (simply referred to as “table 3”) shown in FIG. 4 is obtained. Note that the feature amount is previously defined for each variable in consideration of the physical meaning of each variable (measurement value or the like), such as the above-described average value and maximum value.

(3) Raw material lot No. Connection (lot information generation step)
In step S3, lot No. of each raw material in the same process or between adjacent processes. Connect For example, as shown in FIG. 5, stringing is sequentially performed from the rear (downstream side) of each process related to the production of the raw material. Corresponding lot No. When there are a plurality of lot numbers, for example, lot No. 1 with the longest processing time (production time). (Or the largest lot number) is adopted.

  Raw material lot No. in the same process. For example, when specifically referring to the second step, lot No. The paste (A) to be applied to the roll (A) corresponding to No. 2 is lot No. 2, No. 3 and No. There are three of four. At this time, lot No. In the second roll (A), lot No. No. 3 paste is mainly used. The time (10:10 to 10:35) prepared using the three pastes is the other lot no. It is longer than the case of using the paste of Therefore, lot No. In the second roll (A), lot No. Attach 3 pastes.

  Also, specifically speaking about the third step, considering, for example, lot No. For the roll after lamination of No. 1, lot No. After application 2, the roll (A) (after application, roll (B) is lot No. 1) is tied.

  Furthermore, between the adjacent steps, lot no. The case of tying is also conceivable. For example, lot No. relating to control data of the third process. Lot No. 2 according to the control data of the second step on the post-application roll (A) of No. 2. Tie 2 rolls (A).

  Thus, as shown in FIG. A list (simply referred to as “table 4”) is obtained.

(4) Linking of feature amount and product ID (related information generation step)
In step S4, the lot No. of each raw material is selected. If the feature quantity calculated for each item is associated with the product ID, for example, a list (simply referred to as “table 5”) as shown in FIG. 6 is obtained. Table 5 shows lot No. of raw materials in each process until each product is produced. And their feature quantities become clear.

  Therefore, by utilizing the table 5 (related information), it is possible to efficiently estimate, for example, the feature amount common to defective products. As a result, it becomes possible to efficiently realize review of manufacturing conditions, improvement of product quality, reduction of defective product rate (improvement of yield), and the like.

Claims (5)

Feature quantity identifying means for identifying a feature quantity characterizing the quality of the raw material obtained from time-series information obtained in the production process of the raw material subjected to lot management;
Lot information generating means for generating lot information of the original material including the feature amount;
Related information generation means for generating related information in which the lot information is associated with identification information of individually managed products produced using the raw material;
Quality control information generation system comprising:   The quality control information generation system according to claim 1, further comprising: analysis means for analyzing lot information of the raw material corresponding to the product based on the related information. With a computer
A program to be executed by the computer,
The quality control information generation system according to claim 1 or 2, comprising: A feature amount identification step of identifying a feature amount characterizing the quality of the raw material obtained from time-series information obtained in the production process of the raw material subject to lot management;
A lot information generation step of generating lot information of the original material including the feature amount;
A related information generation step of generating related information in which the lot information is associated with identification information of individually managed products produced using the raw material;
A method of generating quality control information comprising:   The quality control information generation program which makes a computer perform each step of Claim 4.

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