JP4758128B2 - Quality control system in product manufacturing and storage process - Google Patents

Description

  The present invention relates to a quality management system in a product manufacturing and storage process, and in particular, a process composed of a plurality of unit operation steps is constructed as a virtual process on a computer, and quality information of a semi-finished product or product is sent to the virtual process It relates to a quality management system that automatically manages the above. The present invention also relates to a quality control system that can automatically sample any semi-finished product or product based on the information.

  Various processes for manufacturing products are known through a continuous manufacturing process, and various films, paper, glass, steel plates, gypsum boards and the like can be exemplified.

  Such a continuous manufacturing process is usually composed of a plurality of unit operation steps, and the characteristics of the product, in other words, the quality is changed by passing through each step. Manufacturing a product with a predetermined quality is the purpose of product manufacture, so it is necessary to accurately grasp the quality in each process and to reliably manage the lot of the final product.

  However, in the continuous manufacturing process as described above, semi-finished products exist as a continuous body, so it is very difficult to grasp where the quality information is currently measured, and lot management. Has increased the trouble.

  Process speeds have increased dramatically due to technological innovations in various devices and control devices. The quality information includes not only information that can be visually confirmed such as width and thickness, but also information that is difficult to visually confirm such as density and cross-sectional shape, and information that cannot be visually confirmed such as product information. . Once these quality information is discharged as a final product, it is extremely difficult to check and manage the quality information later, and it is labor intensive.

  The present invention has been made in view of these problems. The quality data of a semi-finished product or product is checked on a continuous production line, and the quality data is constantly monitored in correspondence with the actual semi-finished product moving on the production line. An object is to provide a quality management system that enables lot management of quality information of final products.

The present invention
In the actual process related to product manufacture and storage including multiple unit operation steps,
Semi-finished product or product quality information measuring means installed in at least one of the unit operation steps,
Passage detecting means of each unit operation process of the semi-finished product or product,
And an arithmetic means for processing and storing the measurement information,
In correspondence with the actual process, a virtual process including a data storage area divided into at least the same number of blocks as the number of the plurality of unit operation steps in the computer is formed,
In accordance with the production and storage status of semi-finished products or products in the unit operation process, quality information is sequentially measured,
Storing the measurement information in a corresponding block of the data storage area on the virtual process;
By moving the quality information to the predetermined block corresponding to the data storage area in accordance with the passage of the unit operation process of the semi-finished product or product,
A quality control system characterized in that quality information of semi-finished products or products can be automatically managed on the calculation means.

The present invention further includes
A quality control system, wherein the product is a gypsum board.

The present invention also provides:
The unit control process includes a raw material weighing process, a raw material kneading process, a molding process, a semi-finished product rough cutting process, a drying process, a finishing process, and a product storage process.

  The quality of the semi-finished products and / or products produced in the continuous production process can be monitored, the factory personnel can refer to the information as necessary, and any semi-finished products and / or products can be It enables sampling automatically.

  Hereinafter, the best mode of the present invention will be described.

  The simplest configuration of the present invention includes a quality measuring unit corresponding to each unit operation step in a continuous manufacturing process, and includes an arithmetic unit that processes the information and a unit that stores the information.

  Means for storing quality information can be provided corresponding to each unit operation process, but it is more desirable to perform unified management considering the ease of handling the information.

  The quality information storage means has an information storage area corresponding to each unit operation process, and the arithmetic unit commands data transfer on the virtual process using a transfer signal between each unit operation process. Examples of the transition signal include operation information of a device used for movement between the unit operation processes, stop information of the previous unit operation process, start information of the next unit operation process, and the like.

  Next, an example of a configuration in which the system further includes quality information display means will be described. The display means can display any semi-finished product and / or product information, estimated automatic discharge expected time of defective products, and the like to the factory staff. Further, if necessary, it is possible to provide means for instructing discharge of any semi-finished product and / or product.

  Further, in the system, any semi-finished product and / or product is provided by means for sampling any semi-finished product and / or product, and by preparing a means capable of outputting a discharge command to the quality information display means. Can also be sampled.

Hereinafter, a gypsum board will be described as an example in more detail. In addition, this invention is not limited to gypsum board manufacture, It is possible to apply to the similar continuous production process.
The gypsum board is usually manufactured by the following unit operation process.

Raw material weighing process for weighing calcined gypsum and various additives,
A raw material kneading step in which a gypsum raw material in which calcined gypsum and additives are mixed is sent to a mixing stirrer with water and stirred to obtain a gypsum slurry
A molding process in which the gypsum slurry is poured between upper and lower gypsum board papers and passed through a molding machine that adjusts the thickness and width,
A semi-finished product rough cutting process in which a rough board is obtained by roughly cutting a semi-finished product into a length corresponding to several sheets of the final product after the gypsum slurry is cured.
A drying process of drying the coarse board with a dryer;
Finishing process to cut dry rough board into product size,
Product storage process for storing products by size and product type,
The gypsum board manufactured as described above is required to maintain predetermined quality such as size and cross-sectional shape such as thickness and width, surface smoothness, board density and board strength.

  Moreover, as a kind of gypsum board product manufactured with the same production line, in addition to a normal gypsum board, a waterproof gypsum board, a reinforced gypsum board, a hard gypsum board, a formaldehyde absorption decomposition gypsum board, etc. are mentioned.

  As described above, the quality of gypsum board manufactured in a continuous process must be constantly monitored during the manufacturing process. Conventionally, monitoring personnel are assigned to the important points of the process. In addition, marking is performed at the separation position in quality control, and the discharge time in the final process of the product is predicted and managed.

  Hereinafter, a detailed description will be given along the actual manufacturing process.

  First, gypsum board raw materials made of calcined gypsum and various additives are each weighed and kneaded with a mixer together with water and foaming agent to form a gypsum slurry that forms the core of the gypsum board. The gypsum slurry is supplied from the board surface base paper supply device, supplied from the mixer onto the surface base paper moving on the conveying belt, and is formed by the molding machine into a predetermined thickness and width and simultaneously supplied from the board back surface base paper supply device. The back base paper is covered. Next, the gypsum slurry is cured in the process of moving on the conveyor belt, and is roughly cut into a rough board having a length of several products by a rough cutting machine. The coarse board is guided to the dryer by the transporter, and excess moisture is removed for a predetermined time.

  After drying, the rough board is transported to a finish cutting machine, where it is cut to the final product board size, finally discharged as a gypsum board product, and stored in the warehouse by product type and size. Thus, the gypsum board is manufactured by a continuous production line from the supply of raw materials to the final product.

  As processing of measurement information, firstly, weighed data of calcined gypsum and various additives are stored as raw material data. Further, the board surface base paper data relating to the joints and properties is stored in the storage means when the base paper is guided to the transport belt. The storage unit of continuous data storage areas can be set according to time, base paper length, and the like.

  Next, information such as raw materials and water charged into the mixer is stored as kneading data. At this time, the raw material data is associated. Thereafter, molding conditions and measured shape data are stored.

  Furthermore, after passing through the rough cutting machine, the stored data is collected in units of rough boards which are semi-finished products. Rough board unit data can be obtained by managing the average of the data that passed the rough cutting machine after the previous rough cutting as the representative value of the original data, or the method of managing all data as they are. Also good.

  Thereafter, the rough board that has passed through the drying process is cut into a predetermined number of products by a finish cutting machine and stored in a warehouse. Sampling can be performed at an arbitrary place after the rough cutting step, but examples are after rough cutting and after finishing cutting.

  Examples of the movement information between the processes include stop of the conveyance device in the previous process, activation of the conveyance apparatus in the next process, and a switch for detecting the position of the semi-finished product and / or product.

  As described above, according to the gypsum board production line monitoring system according to the present embodiment, quality information is allocated to each block in synchronization with the movement between the semi-finished product and / or the product block transferred on the production line. Therefore, the quality information can be constantly monitored, and any semi-finished product and / or product can be sampled using the quality information. In addition, it is possible to manage lots of quality information of final products.

Claims (6)

A raw material kneading step of sending a gypsum raw material together with water into a mixing stirrer and stirring to obtain a gypsum slurry
A molding process in which the gypsum slurry obtained by the raw material kneading process is poured between the upper and lower gypsum board base paper and passed through a molding machine that adjusts the thickness and width,
After the gypsum slurry is cured, a rough cutting step of roughly cutting a continuous semi-finished product into a length of several sheets of the final product to obtain a rough board;
A drying step of drying the coarse board with a dryer;
Finishing process to cut dry rough board into product size,
Product storage process for storing products by size and product type,
In the actual process of manufacturing and storing gypsum board products including multiple unit operation steps,
Semi-finished product or product quality information measuring means installed in at least one of the unit operation steps,
Passage detecting means of each unit operation process of the semi-finished product or product,
And an arithmetic means for processing and storing the measurement information,
The storage unit of the storage area after the molding step of the data of the calculation means corresponds to the base paper length for the gypsum board, and the storage unit corresponding to the base paper length for the gypsum board after the rough cutting step. By collectively setting the data storage unit per coarse board ,
In correspondence with the actual process, a virtual process including a data storage area divided into at least the same number of blocks as the number of the plurality of unit operation steps in the computer is formed,
In accordance with the production and storage status of semi-finished products or products in the unit operation process, quality information is sequentially measured,
The measurement information is stored in a corresponding block of the data storage area on a virtual process, and the quality information of the semi-finished product or product corresponding to the passage of the unit operation process is stored in the data storage area. By moving to the block of
A quality control system for manufacturing a gypsum board, wherein quality information of semi-finished products or products can be automatically managed on the calculation means.   The quality management system according to claim 1, wherein the quality information measuring unit is a unit that measures a physical property of a semi-finished product or a product.   The quality according to claim 1 or 2, wherein the passage detection means of the unit operation step is an input / output signal accompanying an operation of a contact type or non-contact type switching sensor or an apparatus constituting the next step. Management system.   4. The quality management system according to claim 1, further comprising a display unit for displaying quality information stored in the data storage area in an arbitrary process.   5. The quality management system according to claim 1, further comprising means capable of automatically sampling an arbitrary semi-finished product or product from an actual process based on the quality information. . 6. The quality management system according to claim 1, further comprising means capable of automatically managing lots of a predetermined product based on the quality information.