TW201437779A - Automatic alerting method for exceedance of defective product threshold - Google Patents

Abstract

An automatic alerting method for exceedance of a defective product threshold is applicable to a statistical process control (SPC) system which includes at least one detector, a server, and at least one monitoring terminal. The method includes the steps, to be performed by the server, of: receiving plural entries of detection data sent from the at least one detector; generating a statistical value according to the detection data; generating an alert message when the statistical value reaches a threshold value stored in the server; and sending the alert message to the corresponding monitoring terminal. Should any of the at least one production line respectively detected by the at least one detector have a problem that causes the products of the production line to have a fraction defective exceeding the threshold value, the server will automatically notify the monitoring terminal corresponding to the production line, so as for the monitoring terminal to provide the condition of the production line to the department or individual in charge in a timely, accurate, complete, and comprehensive manner, with as little delay and as few errors in message transmission as possible, thereby increasing the efficiency with which the problem can be solved and effectively improving production efficiency and yield rate.

Description

Automatic warning method for defective products exceeding the standard

The invention relates to an automatic alarm method for exceeding the standard of defective products, in particular to a method for applying to a statistical process control system, which can enable one of the servers to statistically detect the detection data transmitted by the device, and when the server judges When the defective product exceeds a predetermined threshold, the server can automatically send an alarm message to one of the monitoring terminal devices of the system.

According to the statistical process control (SPC), the data is collected and statistically analyzed in the process, so that the abnormal state of the process can be detected by the analysis, and the cause of the abnormal state can be found through the problem analysis. According to the improvement measures to make the process back to normal, through the analysis and standardization of these process capabilities, the process capability can be continuously improved. Obviously, the establishment of an efficient SPC system and the proper use of the system can not only effectively improve production efficiency, but also help maintain the stability of product quality. Therefore, the establishment of a complete SPC system is almost a modern factory. One of the essential conditions necessary.

It is found that the SPC system currently used in major factories mainly detects a plurality of products in a production system through at least one detecting device, and the detecting device can judge each product product according to a predetermined criterion. Defective product, the system will record the detection data obtained by the detection device (that is, the data of each product is good or defective), for example, record the detection data in the detection device, or perform the detection The data is recorded on a server. At this time, if the number of defective products in the products continues to accumulate, the detection data recorded by the system can be immediately detected that the process is different, and the problems occurring in the process can be eliminated as soon as possible.

Although the conventional SPC system detects, records, and analyzes the product, it can quickly and effectively find the abnormal state of the process. However, after detecting the abnormal state of the process, most of the operators will pass through the site. The abnormal situation occurred in the process is reported to the person in charge of the relevant production line. After the relevant responsible person receives the report, the number of tests recorded by the system is recorded. Analyze and try to find ways to eliminate the problem. In the above-mentioned way, since it is necessary to carry out the layer-by-layer reporting after the on-site operator gathers the information, the person in charge of the relevant production line can gradually grasp the abnormal situation occurring in the process, so that the overall reaction time of the system is obviously affected. It is difficult to effectively reduce the time required to eliminate the problem; in addition, because the person in charge of the relevant production line is not in contact with the first-hand information, the transmission of information is difficult to complete and comprehensive, and it is inevitable in information transmission. There are errors in the process, and the person in charge of the relevant production line cannot find the problem quickly and accurately.

In summary, although the operation mode of the SPC system is known, it is possible to immediately discover the abnormal situation occurring in the process. However, since the conventional SPC system reports the relevant information to the relevant responsible layer through manual reporting. People, so that at the stage of problem elimination, it is really a pity that they cannot perform good functions quickly and effectively. Therefore, how to design an automatic warning method for the defective product exceeding the standard, so that the SPC system can quickly and comprehensively transmit the relevant information to the relevant responsible person when the abnormal situation occurs in the detection process, so that the relevant responsible person can Quickly and fully grasping the first-hand information, and thus greatly improving the efficiency of problem elimination, is a subject that the relevant industry is eager to solve.

In view of the above-mentioned problems in the conventional SPC system, the operational efficiency of the overall system cannot be effectively improved. Therefore, the inventors have carefully observed the current lack of SPC systems based on their long-term experience in serving related industries, and have considered various After the advantages and disadvantages of the improved method, the automatic warning method of the defective product exceeding the standard of the present invention was finally developed, and the overall efficiency of the SPC system can be greatly improved by the method of the present invention, thereby enabling the production efficiency of the product to be remarkably Improve and maintain the stability of product quality.

An object of the present invention is to provide an automatic alarm method for defective products exceeding the standard, which is applied to a statistical process control system (SPC), the system comprising at least one detecting device, a server and at least one monitoring a terminal device capable of detecting a plurality of products in a production system according to a predetermined criterion, and generating a detection data according to a detection result corresponding to each product, the server storing at least a threshold value, the monitoring terminal device can receive and present information, the method enables the server to perform the following steps: receiving the detection data transmitted by the detecting device; The measured data generates a statistical value; when the statistical value reaches the threshold, an alarm message is generated; and the alarm message is sent to the monitoring terminal device. In this way, when the detection is performed for each of the production lines by using the detection device, if any production line has a problem, and the product defect rate of the production line is higher than the corresponding threshold value, the server will actively notify the corresponding production line. The monitoring terminal devices are such that the monitoring terminal devices can accurately and instantaneously provide the conditions occurring in each production line to the unit or individual responsible for the production line, thereby avoiding delays or errors in message transmission. This improves the efficiency of problem elimination, which in turn can effectively improve production efficiency and product yield.

For your convenience, the review committee can make a further understanding and understanding of the purpose, structure and efficacy of the present invention. The embodiments are described in conjunction with the drawings, which are described in detail as follows:

[study]

no

〔this invention〕

A1, A2, A3‧‧‧ detection devices

B‧‧‧Server

C1, C2, C3, C4‧‧‧ monitoring terminal devices

11, 12, 13 ‧ ‧ 槛 槛

2‧‧‧ comparison table

1 is a structural diagram of a statistical process control system to which the present invention is applied; and FIG. 2 is a flow chart showing the steps of a preferred embodiment of the present invention.

The present invention is an automatic alarm method for exceeding the standard of defective products. Referring to FIG. 1 , the method is applied to a statistical process control system (SPC). In a preferred embodiment, the system is used. Included in the plurality of detecting devices A1, A2, and A3, each of the detecting devices A1, A2, and A3 can respectively correspond to one of the production lines in the production system, and can respectively be determined according to one of the preset determination criteria, respectively, for the corresponding production line A plurality of products are tested, and according to the detection results of the corresponding products, respectively, a test data (good or defective, even good, tangible or defective) is generated.

In this preferred embodiment, the system further includes a server B and a plurality of monitoring terminal devices C1, C2, C3, and C4. The server B stores a plurality of threshold values 11, 12 and 13 and a comparison table 2. In actual application, only a single threshold value 11 may be set, or the threshold values 11, 12 and 13 are respectively set to The conditions of the specific conditions are appropriately adjusted according to actual needs; the comparison table 2 stores the correspondence between the detection devices A1, A2 and A3 and the monitoring terminal devices C1, C2, C3 and C4. The monitoring terminal devices C1, C2, C3 and C4 can receive and present information so that the person in charge of each production line can Through these monitoring terminal devices C1, C2, C3 and C4, information about the status of each production line is grasped.

Referring to Figures 1 and 2, in a preferred embodiment of the present invention, the method enables the server B to perform the following steps: (301) receiving the transmissions from the detection devices A1, A2, and A3. Waiting for the test data, 嗣, proceeds to step (302); (302) generating a statistical value based on the detected data, 嗣, proceeds to step (303); (303) determines whether the statistical value reaches the threshold value, and if so, proceeds Step (304), otherwise, returning to step (301); (304) generating an alert message, 嗣, proceeding to step (305); and (305) transmitting the alert message to the corresponding monitoring according to the lookup table 2 The terminal device C1, C2, C3 or C4 ends the flow.

A practical application example is given to illustrate the mode of operation of the present invention and its efficacy: if a product is produced through a first production line, a second production line and a third production line, the first production line is responsible for producing the product. The first part, the second production line is responsible for producing the second part of the product, and the third production line is responsible for forming the first part and the second part to form the product, at this time, each of the detecting devices A1, A2 and A3 corresponds to the first production line, the second production line, and the third production line, respectively, so that each of the detection devices A1, A2, and A3 can be respectively performed for each of the first part, each of the second parts, and each of the products. Detection. In order to determine whether the first part of the first production line is a good product or a defective product, the detecting device A1 is preset with a first criterion; in order to determine whether the second part of the second production line is good or not For the good product, the detecting device A2 is preset with a second criterion; in order to determine whether the product of the third line is good or defective, the detecting device A3 is preset with a third criterion. The detecting device A1 can determine each of the first parts to be good or defective according to the first determination criterion, and generate a first detection data corresponding to each of the first parts. Similarly, the detecting devices A2 and A3 can also generate a plurality of second detection data and third detection data, respectively.

Referring to FIGS. 1 and 2, in the foregoing step (301), the server B can receive and record the detection data transmitted by the detection devices A1, A2, and A3, and in step (302). The server B generates a first, second, and third statistical values according to the first, second, and third detection data, and the first, second, and third statistical values are respectively Minute It is not used to indicate the defect rate of these first parts, second parts and products. In the foregoing step (303), the server B determines whether each of the first, second, and third statistical values reaches each of the threshold values 11, 12, and 13, respectively, to determine whether to proceed to step (304), and generate Corresponding to one of the first, second or third alarm messages. In particular, as described above, the server B can also set only a single threshold value 11 and set the threshold value 11 to "the detection data of 1000 consecutive products to be inspected, and the proportion of defective products exceeds 2 %", so that the first, second and third statistical values can share a common judgment criterion. However, considering the difference between the individual production lines, it may be necessary to set different degrees of fault tolerance in actual operation. Each of the threshold values 11, 12, and 13 may be set to "in the detection data of 1000 consecutive products to be inspected, the proportion of defective products exceeds 2%", and "in the detection data of 1000 consecutive products to be inspected, The proportion of good products exceeds 5%" and the "test data of 1000 consecutive products under inspection, the proportion of defective products exceeds 3%"; in addition, even if the tolerances of the respective production lines are the same, Each of the threshold values 11, 12, and 13 is set to "in the detection data of 10 consecutive products to be inspected, the proportion of defective products exceeds 50%", and in the detection data of 100 consecutive products to be inspected, the defective product is Proportion of more than 10%" and "continuous In the test data of 1000 tested products, the proportion of defective products exceeds 2%, etc., which helps the SPC system to react quickly when there is a significant abnormality in the process.

In the foregoing step (303), if the server B determines that the first statistic value reaches the corresponding threshold value 11, in the foregoing step (304), the server B according to the detecting device A1 The first detection data is transmitted to generate a first alarm message. In this embodiment, each of the first, second, and third production lines is respectively provided with a production line leader, and each of the production line supervisors monitors the first and second portions through the respective monitoring terminal devices C1, C2, and C3. And the production status of the third production line, and the product still has a general manager who is in charge of the production status of the first, second and third production lines through the monitoring terminal device C4, so In the information stored in the comparison table 2 of the server B, it is recorded that the detecting device A1 corresponds to the monitoring terminal devices C1 and C4, and the detecting device A2 corresponds to the monitoring terminal devices C2 and C4, and the detecting device A3 It corresponds to the monitoring terminal devices C3 and C4. As described above, if in the foregoing step (305), the server B finds the monitoring terminal devices C1 and C4 corresponding to the detecting device A2 according to the comparison table 2, and sends the first alarm message. The monitoring terminal devices C1 and C4 are provided to enable the person in charge of the production line of the first production line and the product The heads of the department are able to grasp the complete and comprehensive information in the first time, without having to report through the on-site personnel, and then try to understand the situation by the contents of the report. Therefore, the method of the present invention enables the SPC system to accurately and instantaneously provide the conditions occurring in each production line to the unit or individual responsible for each production line, thereby avoiding delays or errors in message transmission, thereby improving the problem. Eliminate the efficiency, which in turn can effectively improve production efficiency and product yield. In addition, in a preferred embodiment of the present invention, the server B can drive each of the detecting devices A1, A2, and A3 to classify each product according to each of the detected data, for example, The products to be inspected are divided into two categories: good products and defective products, which are collected separately so that the good products can be concentrated for subsequent processing. The unified centralized defective products are beneficial to the field personnel or responsible persons in understanding and analyzing the process. The abnormal situation that occurred.

In summary, the method of the present invention can effectively improve the working efficiency of the SPC system in the problem elimination stage, thereby greatly improving the overall process production efficiency and improving the yield of the products produced, and in addition, due to problems In the process of elimination, it is usually necessary to suspend production until the problem is solved before the production can be restarted, and the SPC system applying the method of the present invention can quickly eliminate the problem after the problem is found, so that the abnormal situation can be effectively reduced. The downtime of the production line can effectively save the cost of the plant operation.

The above description is only a preferred embodiment of the present invention, but the technical features of the present invention are not limited thereto, and any one skilled in the art can easily change in the technical field of the present invention. Or, modifications are intended to be included in the scope of the claims of the invention below.

Claims (4)

An automatic alarm method for exceeding a standard of defective products, the method is applied to a statistical process control system, the system comprising at least one detecting device, a server and at least one monitoring terminal device, the detecting device capable of producing according to a judgment standard A plurality of products in the system are detected, and a detection data is generated according to the detection result corresponding to each product, the server stores at least one threshold value, and the monitoring terminal device can receive and present information, and the method is The server can perform the following steps: receiving the detection data transmitted by the detecting device; generating a statistical value according to the detection data; generating an alarm message when the statistical value reaches the threshold; and generating the alarm The message is sent to the monitoring terminal device and presented through the monitoring terminal device. The method of claim 1, wherein the server further stores a comparison table, wherein the comparison table stores a correspondence between the detection device and the monitoring terminal device, and the method further enables the server to perform the following steps Determining, by the source of the detection data, the detection device corresponding to the alarm message; and transmitting the alarm message to the monitoring terminal device corresponding to the detection device according to the comparison table. According to the method of claim 1 or 2, the server is further enabled to perform the following steps: driving the detecting device to classify each product according to each of the detected data. The method of claim 1, wherein the statistical value is used to indicate a defect rate of the products.