JP2837045B2 - Quality control equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a quality control apparatus for analyzing effective measures for restoring quality abnormalities occurring in a workpiece or the like.

[0002]

2. Description of the Related Art Generally, quality control of a product is performed by inspecting whether or not a quality abnormality has occurred in each product by an inspection machine or manually, and when the quality abnormality is found, the quality is restored. This is done by searching for and implementing effective countermeasures. Here, the measures against the quality abnormality are tried in order from the one generally recognized as the most effective for the content of the quality abnormality.

[0003]

The conventional quality management system as described above has the following problems to be solved.

[0004] A) Effective measures for restoring quality abnormalities vary depending on various conditions such as the contents of the processing steps of a product. Therefore, even though measures are generally considered effective, they are not always appropriate. In such a case, it takes a long time and a great deal of trouble to find a truly appropriate measure and execute it. In particular, when there are a wide variety of inspection items, it is very difficult to quickly find the most effective countermeasures for the quality abnormality items that have occurred, and improvement thereof is a major issue.

[0005] B) Conventionally, countermeasures are taken only when an unacceptable quality abnormality actually occurs in a quality inspection object such as the above-mentioned product, and the product having the quality abnormality is removed from the product object. Has been excluded. Therefore, if such unacceptable quality abnormalities can be predicted before they occur, and measures can be taken to prevent them before they occur, the production efficiency will be dramatically improved.

The present invention has been made in view of the above circumstances, and provides a quality control apparatus that enables a user to quickly find a measure effective in recovering from a quality anomaly when it occurs. It is an object of the present invention to provide a quality management device that predicts an unacceptable quality abnormality before it occurs and makes it possible to appropriately take measures to prevent the occurrence.

[0007]

The present invention is effective for information analysis means, quality abnormality input means for inputting an item of an actually occurring quality abnormality to the information analysis means, and restoration of the quality abnormality. A countermeasure input unit for inputting a countermeasure to the information analysis unit; and a countermeasure display unit for displaying the analysis result of the information analysis unit. Each time a corresponding measure is input, a measure storage means for learning and calculating a value relating to the recovery probability due to the execution of each measure and storing the value, and a quality abnormality item when a quality abnormality item is input from the quality abnormality input means. A display control means is provided for displaying on the countermeasure display means a value for each countermeasure name and its recovery probability stored corresponding to the abnormal item (claim 1).

Here, the inspection means may be singular or plural.

The quality error input means includes an inspection means for collecting information necessary for determining the quality abnormality of the quality inspection object, and whether the quality abnormality has occurred based on the information collected by the inspection means. It is more preferable that the apparatus further comprises a quality abnormality determining means for determining whether or not a quality abnormality has occurred and inputting the quality abnormality item to the information analyzing means when it is determined that a quality abnormality has occurred (claim 2).

Further, the apparatus further comprises an information storage means for sequentially storing information collected by the inspection means, and the quality abnormality judging means judges abnormality of the quality itself of the quality inspection object inspected by the inspection means. When it is determined that a quality abnormality has occurred, individual quality abnormality determination means for inputting this as the quality abnormality item to the information analysis means,
Analyzing the tendency of the quality change based on the information of the past plural times stored in the information storage means, and when the quality tendency is determined to be abnormal, the quality tendency to be input to the information analysis means as the quality abnormal item. By providing the abnormality determination means, more excellent effects as described below can be obtained (claim 3).

When a plurality of inspection means are provided, it is particularly effective to provide the individual quality abnormality determination means for each inspection means.

[0012]

According to the first aspect of the present invention, the item of the quality abnormality that has actually occurred is input to the information analysis means, and a measure that is actually effective in recovering the quality abnormality is input. Each time such an input is performed, a value relating to the probability of recovery due to the implementation of each measure corresponding to the abnormal quality item is learned and calculated based on the information. Then, when a quality abnormality similar to the above-mentioned item occurs, the item is input from the quality abnormality input unit to the information analysis unit, so that each of the countermeasure contents and each of the measures stored corresponding to this quality abnormality item are stored. The value related to the recovery probability due to the implementation of the countermeasure is displayed on the countermeasure display means. Therefore, by referring to the display contents, the user can easily find a measure suitable for the currently targeted quality abnormality item based on the past information.

In the apparatus according to the second aspect, information necessary for judging the quality abnormality of the quality inspection object is collected by the inspection means, and based on this information, the quality abnormality judgment means determines whether or not the quality abnormality has occurred. Determined automatically. If an abnormality has occurred, the quality abnormality item is automatically input to the information analysis means.

Further, in the apparatus according to the third aspect, regarding the determination of the quality abnormality, not only the abnormality of the quality itself of the quality inspection object inspected by the inspection means but also the information stored in the information storage means is determined. The tendency of the quality change is analyzed based on the information obtained a plurality of times in the past, and when the quality tendency is determined to be abnormal, the content is input to the information analysis means as the above-mentioned abnormal quality item. Therefore, by taking appropriate measures against the quality abnormality related to the quality tendency abnormality, it is possible to prevent the occurrence of an unacceptable quality abnormality in each quality inspection object.

In the quality control device according to the present invention, when a plurality of inspection means are provided, the individual quality abnormality determination means is provided for each inspection means. The possible abnormality determination items unique to each inspection means are determined by each inspection means, and the determination results are input to the information analysis means.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described with reference to FIGS.

The quality control device shown in FIG. 1 includes a quality abnormality input unit 10, a countermeasure input unit 20, an information analysis unit 30, and a countermeasure display unit 40.

The quality abnormality input means 10 includes n inspection machines 111, 112,..., 11n, information collection means 14, information storage means 16, quality tendency abnormality judgment means 18A, and individual quality abnormality judgment means 18B. ing.

Each of the inspection machines 111, 112,...
It measures information (for example, various dimensions, weights, etc.) necessary for quality determination of products (objects for quality inspection) which are sequentially carried in, and outputs measurement data output units 121, 122, and 122 for outputting the measurement data. .. 12n. The information collecting means 14 is provided for each of the inspection machines 111, 112,
, 11n, and the information storage means 16 sequentially takes in the collected data, classifies the data into each of the inspection machines 111, 112,..., 11n, and accumulates the data into past data. It is something to memorize.

The quality trend abnormality judging means 18A analyzes the current tendency of the change of the data based on the measurement data stored in the information storage means 16, and the analyzed quality tendency is If it indicates that there is a possibility that an unacceptable quality abnormality may occur in the product in the near future, the quality tendency is determined to be abnormal, and the content of the quality trend abnormality is determined by the information analysis means 3.
0 is input as an abnormal quality item. Specifically, the quality tendency abnormality determining means 18A is configured to determine that there is an abnormality in the quality tendency when the analyzed quality tendency corresponds to any of the items shown in Table 1 below.

[0021]

[Table 1]

In this table, for example, "the latest nine values" means an average value calculated nine times in the past from the present, and similarly, "the latest region width nine" means the current value. This means the area width calculated nine times in the past from the start.

The individual quality abnormality judging means 18B determines whether or not an unacceptable quality abnormality has occurred in the product based on the currently collected data, regardless of the past data (for example, the measured dimensions are set in advance). Is determined to be out of the permissible dimensional range, and if it is determined that a quality abnormality has occurred, the content is input to the information analysis means 30 as a quality abnormality item.

The countermeasure input means 20 is composed of a keyboard or the like. As described later, when a quality abnormality occurs, a manager or the like determines a countermeasure that has been effective in eliminating (ie, restoring) the quality abnormality. Information analysis means 30 by operation
It is for input to.

The information analysis means 30, as shown in FIG.
It includes a quality trend abnormality countermeasure storage unit 32A, an individual quality abnormality countermeasure storage unit 32B, and a display control unit.

The quality trend abnormality countermeasure storage means (countermeasure storage means) 32A includes a quality abnormality item (ie, an item relating to quality trend abnormality) input from the quality trend abnormality determination means 18A through the display control means 34, and As an appropriate countermeasure, a countermeasure input from the countermeasure input means 20 after the occurrence of the quality abnormality described above is taken, and the effective countermeasure for each quality abnormality item is stored. The probability that the quality tendency abnormality can be eliminated (that is, the restoration probability) is newly calculated and updated and stored. The recovery probability P due to the implementation of each countermeasure is represented by N, the total number of valid countermeasures for the above-mentioned abnormal quality items, and the number of times that the target countermeasure is input (actually, the countermeasure item corresponding to the above countermeasures) When the number of times a number is input) is m, the equation is given by P = m / N.

However, the restoration probability P is not limited to the one given by the above equation. For example, the probability may be calculated by increasing the weight for newer data.

The individual quality abnormality countermeasure storage unit (countermeasure storage unit) 32B stores quality abnormality items (that is, items relating to abnormality in the quality of each product itself) input from the individual quality abnormality determination unit 18B through the display control unit 34. ,
As an appropriate countermeasure against the quality abnormality, a countermeasure input from the countermeasure input means 20 after the occurrence of the quality error is taken in, and, similarly to the quality trend abnormality countermeasure storage means 32A, the countermeasure effective for each quality error item is taken. Each time this measure is taken, the same recovery probability as above is newly calculated and updated and stored.

The display control means 34 responds to the quality abnormal item when a quality abnormal item is input from the quality tendency abnormality judging means 18A or the individual quality abnormality judging means 18B (that is, when a quality abnormality occurs). The measure data and the recovery probability data stored in the quality trend abnormality measure storage means 32A or the individual quality abnormality measure storage means 32B are called and output to the measure display means 40. The countermeasure display means 40 is constituted by a CRT, a printer, or the like, receives a command signal from the display control means 34, and externally displays data relating to the quality abnormality item, the countermeasure, the recovery probability, and the like.

Next, the operation of this device will be described.

In FIG. 1, a product to be quality inspected is transported from the first inspection machine 111 to each of the inspection machines 112,..., 11n in order, and each of the inspection machines 111, 112,. Done. These inspection machines 11
The measurement data output from 1, 112,.
The information is collected by the information collecting means 14 and sequentially stored in the information storage means 16.

The quality trend abnormality judging means 18A statistically analyzes the quality trend based on the present data and the past data stored in the information storage means 16, and checks whether there is any abnormality. Is done. At the same time, the individual quality abnormality judging means 18B checks, based on the currently collected data, whether there is any abnormality in the quality of the product from which the data is collected.

Here, when the quality tendency abnormality judging means 18A or the individual quality abnormality judging means 18B judges that there is an abnormality, the quality abnormal item is inputted to the display control means 34 of the information analyzing means 30. You. In principle, the information analysis means 30 calls up the data corresponding to the input quality abnormality item and the recovery probability thereof from the quality trend abnormality countermeasure storage means 32A or the individual quality abnormality countermeasure storage means 32B. Initially,
Since there is no data stored for learning, in this case, the countermeasure display means 40 exceptionally displays the quality abnormal item and a message indicating that there is no accumulated data corresponding to the quality abnormal item. At this time, the user refers to the above-mentioned abnormal quality item, finds a measure suitable for the quality item by himself, and tries this. If the quality abnormality is eliminated by taking this measure, the user inputs the measure
By operating, the above countermeasure is input to the information analyzing means 30 as an appropriate countermeasure.

In this way, quality abnormalities occur many times,
When appropriate measures are taken and input to the information analysis means 30, the quality trend abnormality measure storage means 32A and the individual quality abnormality measure storage means 32B store the measure data corresponding to each quality abnormality item. At the same time, the recovery probability due to the implementation of each countermeasure is updated to a more reliable value. In addition, the required amount of quality abnormal item data may be input in advance to the quality tendency abnormality countermeasure storage unit 32A and the individual quality abnormality countermeasure storage unit 32B to start using.

As described above, when a sufficient amount of data is accumulated and a quality abnormality occurs, and a quality abnormality item is input to the display control means 34 from the quality tendency abnormality determination means 18A or the individual quality abnormality determination means 18B. Unlike the earlier case where there is almost no data as described above, the screen of the countermeasure display means 40 displays useful data for finding an appropriate countermeasure, for example, as shown in FIG.

The screen display example shown in FIG. 3 is displayed on the countermeasure display means 40 when an abnormality occurs in the quality trend analyzed based on the data output from the after gauge device which is one of the inspection machines. It shows the contents.
This display shows a case in which effective measures against the quality trend abnormality have been input in the past ten times in total, of which six times a countermeasure of changing a grinding wheel is input, and two times, adjustment of the spindle cutting speed, and 1 time. The display is for the case where countermeasures such as coolant impurity removal and the remaining one are for gauge correction are input. The user can see this display,
It is possible to instantly grasp that the most probable cause to eliminate the quality trend abnormality that is currently occurring is to replace the grinding wheel. In addition, it is possible to quickly find a measure suitable for the current quality trend abnormality with a high probability, and to quickly deal with the quality abnormality.

After finding an appropriate countermeasure, the user selects an actually effective countermeasure according to the display on the screen and inputs it to the quality trend abnormality countermeasure storage unit 32A by operating the countermeasure input unit 20. Good. As a result, the input count of each measure and the recovery probability thereof stored in the quality trend abnormality measure storage means 32A are calculated again, and the new data is updated and stored. For example, in the state where the screen shown in FIG. 3 is displayed, if the quality abnormality is solved by actually performing the replacement of the grinding wheel, and “1” is input as an appropriate measure, the “1. The restoration probability is {(6 + 1) / (10 + 1)} × 100 = 6 from the current 60.0%.
Updated to 3.6 (%).

As described above, in this apparatus, the quality abnormality items determined by the quality tendency abnormality determining means 18A and the individual quality abnormality determining means 18B and the measures which were actually effective in eliminating the quality abnormalities are described. Is input to the information analysis means 30, and based on the input data, the information analysis means 30 learns and stores the content of the countermeasure corresponding to each quality abnormality item and the recovery probability due to the implementation of the countermeasure. Since the information is displayed every time an abnormality occurs, it is possible to quickly find the most effective measure against the currently occurring quality abnormality based on the past data only by referring to this display.

In addition, the apparatus of this embodiment not only determines the abnormality of the quality of each product itself as a quality abnormality item, but also analyzes the tendency of the quality change of the product on the basis of a plurality of past data. Since abnormalities in the quality trend are also determined and countermeasures and the like suitable for the abnormalities are displayed, the abnormalities in the quality trend are eliminated, that is, the cause of the abnormality in the quality of the product itself is removed in advance. By doing so, it is possible to prevent the occurrence of the abnormality in the quality itself, and there is an advantage that the production efficiency can be further improved.

Next, a second embodiment will be described with reference to FIG.

As shown in the first embodiment, when a large number of inspection machines 111, 112,..., 11n are used, as the number thereof increases, each of the inspection machines 111, 112,.
The items for which individual quality abnormalities need to be determined for the measurement data from a wide variety of items, and the structure of the determination means is complicated.

Therefore, in the second embodiment, instead of providing the common individual quality abnormality judging means 18B as in the first embodiment, the individual quality abnormality judging section 131 is provided for each of the inspection machines 111, 112,. , 132,..., 13n,
.., 11n, the individual quality abnormality is determined, and each of the determination units 131, 132,.
The individual quality abnormality judgment signal output from 3n is arranged by the information arrangement means 15 and input to the information analysis means 30. According to such a configuration, even in the case where the number of inspection machines is large and the determination content is diversified, it is possible to determine each abnormal quality item with a simple configuration as in the first embodiment. Also, when the number of inspection machines is increased or decreased, or when some of the inspection machines are replaced, there is almost no need to change the configuration other than the inspection machines, so that the versatility of the entire apparatus is improved.

In the above embodiment, the recovery probability of each measure is directly displayed on the measure display means. However, the present invention is not limited to this. May be displayed, for example, the absolute number of times each measure is input as an effective measure, or only the order of the recovery probability due to the implementation of each measure may be displayed.

In each of the above embodiments, the inspection and abnormality determination of each product are automatically performed, and the determination signal is input to the information analysis means 30. However, the inspection and abnormality determination are performed. May be performed by a device independent of the information analyzing means 30 or manually, and the user may directly input the abnormal quality item to the information analyzing means 30 by operating a keyboard or the like. In this case, the keyboard or the like serves as the quality abnormality input means in the present invention.

[0045]

As described above, according to the present invention, the following effects can be obtained.

According to the first aspect of the present invention, there is provided an apparatus having an abnormal quality item,
The countermeasures that were actually effective in resolving this quality anomaly should be input to the information analysis means, and based on this input data, the information analysis means would take countermeasures corresponding to each quality anomaly item and implement them. The value related to the recovery probability due to learning is calculated, stored, and displayed each time a quality abnormality occurs. By simply referencing this display, the most effective countermeasures for the currently occurring quality abnormality are stored in past data. There is an effect that the search can be quickly and easily performed based on the information.

More specifically, in the device according to the second aspect,
Inspection means collects information necessary to determine the quality abnormality of the quality inspection target, and based on this information, the quality abnormality determination means automatically determines whether or not a quality abnormality has occurred. In such a case, the abnormal quality item is automatically inputted to the information analysis means, so that the burden on the quality control operator can be further reduced.

Further, in the apparatus according to the third aspect, regarding the determination of the quality abnormality, not only the abnormality of the quality itself of the quality inspection object inspected by the inspection means but also the abnormality is judged.
Analyzing the tendency of the quality change by the quality trend abnormality judging means based on the past plural times of information stored in the information storage means,
When this quality tendency is determined to be abnormal, this is also input to the information analysis means as the above-mentioned quality abnormality item. Therefore, by taking appropriate measures against this quality tendency abnormality, each quality inspection is actually performed. An unacceptable quality abnormality can be prevented from occurring in the target object, and the production efficiency can be further improved.

Further, in the apparatus according to the fourth aspect, an individual quality abnormality judging means is provided for each inspection means so that the inspection machine can judge a quality abnormality item peculiar to each inspection machine. Even when the quality abnormality judgment items are diverse, such as when the total number of inspection means is large, it is possible to appropriately judge the individual quality abnormality with a simple configuration. Also, when the number of inspection means is increased or decreased, or the type of inspection means is changed, only the quality abnormality determination means suitable for the additional or replacement inspection means is provided, and other configurations are almost changed. Since there is no need, there is an effect that the versatility of the entire apparatus can be further improved.

[Brief description of the drawings]

FIG. 1 is a functional block diagram of a quality management device according to a first embodiment of the present invention.

FIG. 2 is a functional block diagram of information analysis means provided in the quality control device.

FIG. 3 is a diagram showing an example of a display screen by a measure display unit of the quality management device.

FIG. 4 is a functional block diagram of a quality management device according to a second embodiment of the present invention.

[Explanation of symbols]

 , 11n Inspection machine (inspection means) 131, 132,..., 13n Individual quality abnormality determination section 16 Information storage means 18A Quality trend abnormality determination means 18B Individual quality abnormality determination means 20 Countermeasure input means Reference Signs List 30 information analysis means 32A quality trend abnormality countermeasure storage means (countermeasure storage means) 32B individual quality abnormality countermeasure storage means (countermeasure storage means) 34 display control means 40 countermeasure display means

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Hajime Oba 5-3-38 Ujinahigashi, Minami-ku, Hiroshima Toyo-A-Tech Co., Ltd. (56) References JP-A-5-258143 (JP, A) (58 ) Field surveyed (Int. Cl. ⁶ , DB name) G07C 3/14 G06F 17/00

Claims (4)

(57) [Claims] 1. An information analysis means, a quality abnormality input means for inputting an item of a quality abnormality that has actually occurred to the information analysis means, and a measure effective for recovery of the quality abnormality is input to the information analysis means. A countermeasure input unit; and a countermeasure display unit that displays an analysis result of the information analysis unit. The information analysis unit receives a quality abnormality item and a corresponding measure from the quality abnormality input unit and the measure input unit. Means for learning and calculating a value related to the recovery probability by the implementation of each measure and storing the same, and when a quality abnormal item is input from the quality abnormal input means, the value is stored corresponding to the quality abnormal item. And a display control means for displaying the value of each measure content and its recovery probability on the measure display means. 2. A quality abnormality input means for inspecting information necessary for determining a quality abnormality of a quality inspection object, and a quality abnormality occurring based on the information collected by the inspection means. 2. A quality abnormality judging means for judging whether or not a quality abnormality has occurred, and inputting the quality abnormality item to the information analyzing means when it is determined that a quality abnormality has occurred. Quality control equipment. 3. An information storage means for sequentially storing information collected by the inspection means, and as the quality abnormality determination means, an abnormality of the quality itself of the quality inspection object inspected by the inspection means is determined. When it is determined that a quality abnormality has occurred, an individual quality abnormality determination unit that inputs this as the quality abnormality item to the information analysis unit, and a quality change based on a plurality of past information stored in the information storage unit. 3. A quality tendency abnormality judging means for analyzing the tendency of the quality, and when the quality tendency is judged to be abnormal, is input to the information analysis means as the quality abnormality item. Management device. 4. The quality control device according to claim 3,
A quality management device comprising: a plurality of inspection means; and the individual quality abnormality determination means provided for each inspection means.