CN110794787A - SPC method suitable for mixed production of multiple varieties - Google Patents
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims description 22
- 238000005259 measurement Methods 0.000 claims description 13
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- 238000004364 calculation method Methods 0.000 claims description 4
- 238000004886 process control Methods 0.000 claims description 3
- 230000009466 transformation Effects 0.000 claims description 3
- 238000000844 transformation Methods 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 abstract description 6
- 238000013501 data transformation Methods 0.000 abstract description 4
- 238000010586 diagram Methods 0.000 abstract 4
- 238000003070 Statistical process control Methods 0.000 description 29
- 238000005098 hot rolling Methods 0.000 description 3
- 238000005096 rolling process Methods 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
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- G05B2219/32—Operator till task planning
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
Under the condition of multi-species mixed production, when the observed characteristics are continuous metering data, a control chart suitable for the metering data type is used, such as a mean-range diagram or a mean-standard-difference diagram, a single-value-moving-range diagram or a median-range diagram, and the like, and a uniform SPC control central line and upper and lower control limits are determined through data transformation, so that an SPC control chart can be generated in an off-line or real-time manner, and the monitoring of the production process is realized.
Description
Technical Field
The invention relates to the technical field of SPC (statistical process control), in particular to an SPC method suitable for multi-variety mixed production.
Background
The SPC control chart is an effective tool for helping a process to reach a statistical controlled state by mastering process variation by using a statistical process control theory, finding abnormality, improving in time and reducing fluctuation, and the process is produced in a statistical control state by monitoring and predicting the stability of the process in real time, so that the purposes of ensuring the stability of the process, ensuring the stability and reliability of the overall quality of products and reducing loss are achieved, but the SPC control chart has the following problems in practical application:
SPC control charts require that the control center line and the upper and lower limits of the measurement results for each lot in the sequential production process must be consistent, but when multiple products are produced in a mixed manner, the varieties and specifications of different products produced in sequence may be greatly different, and the process parameter control center and the upper and lower control limits for each lot are constantly changed, so that in this case, the SPC method cannot be applied to monitor the process.
Disclosure of Invention
The invention aims to provide an SPC method suitable for multi-variety mixed production, which determines a unified SPC control central line and upper and lower control limits through data transformation under the condition of multi-variety mixed production, thereby generating an SPC control chart in an off-line or real-time manner, realizing the monitoring of the production process and solving the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
an SPC process suitable for multi-species hybrid production, comprising the steps of:
s1: when the observed characteristics are all continuous metering type data, a control chart suitable for the metering type data type is used, and the control limit calculation formula is as follows:
statistics
R, s is divided into: the standard value is not given and the standard value is given for two conditions:
under the condition that the standard value is not given, the statistic is as follows: center line
UCL and LCL:or
Standard value given condition, statistic: center line X0Or μ, R0Or d2σ0，S0Or C4σ0(ii) a UCL and LCL: x0±Aσ0，D1σ0，D2σ0，B5σ0，B6σ0；
Wherein, X0、R0、S0Mu and sigma0Is a given standard value;
s2: according to the formula in S1, when creating the control chart, the characteristic values of the subgroups are calculated
Or mu0Then calculating the total average value of all observed values
And mean standard deviation
S3: for each batch of the production process, let the production sequence consist of n batches, where a certain control parameter x for the ith batchiSet value is Xi±ΔiWhere Δ is the upper and lower control limits and the average of the measurements is
Standard deviation of siMaximum value of ximaxMinimum value of ximinI.e. the measurement obeys a desired value of XiStandard deviation of siIs normally distributed, and ximax-Xi<Δi，Xi－ximin<ΔiFor parameter XiThe following transformations may be made: is provided with
Then y isiMathematical expectation value mu ofyi0, and-1. ltoreq. yi≤1；
S4: for the entire production sequence, use yiSPC control charts are generated, with X-axis for production completion time per lot and Y-axis for corresponding YiAnd the control center line is y which is 0, the upper limit and the lower limit of the control are +1 and-1, and the control chart which is continuous along with the time can be generated in real time or off line according to the actual production result of each batch.
Further, the control chart of the metering-type data type in S1 includes: a mean-range or mean-standard deviation plot, a single-value-moving range plot, or a median-range plot.
Further, in S3, in the actual production process, each lot is produced according to a set of PDI parameters consisting of a target value and upper and lower limits thereof, the PDI parameters being a set value of the production process and a target value of process control, for each lot, if the production process is in a statistically controlled state, the mathematical expected value of a measurement of a certain parameter is equal to the set value thereof, and the maximum and minimum values of the measurement of each lot should not exceed the upper and lower limits of the parameter.
Compared with the prior art, the invention has the beneficial effects that:
the SPC method suitable for the multi-variety mixed production determines the uniform SPC control center line and the upper and lower control limits through the data transformation under the condition of the multi-variety mixed production, thereby generating an SPC control chart in an off-line or real-time manner and realizing the monitoring of the production process.
Drawings
FIG. 1 is a hot rolling thickness SPC control chart of the present invention;
FIG. 2 is a SPC control chart of the hot finishing temperature of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the embodiment of the invention: for multi-species hybrid production, there is provided an SPC method suitable for multi-species hybrid production, comprising the steps of:
the first step is as follows: when the observed characteristics are all continuous metering type data, a control chart suitable for the metering type data type is used, and the control limit calculation formula is as follows:
statistics
R, s is divided into: the standard value is not given and the standard value is given for two conditions:
under the condition that the standard value is not given, the statistic is as follows: center line
UCL and LCL:or
Standard value given condition, statistic: center line X0Or μ, R0Or d2σ0，S0Or C4σ0(ii) a UCL and LCL: x0±Aσ0，D1σ0，D2σ0，B5σ0，B6σ0；
Wherein, X0、R0、S0Mu and sigma0Is a given standard value; see table 1 below:
TABLE 1 control limit calculation formula
The second step is that: calculating the characteristic values of the subgroups according to the formula in the first step when establishing the control chart
Or mu0Then calculating the total average value of all observed values
And mean standard deviation
However, for the mixed production of many varieties, each lot can be used as a subgroup to calculate its characteristic value
(or μ)0) However, since the different products produced in sequence have great differences in their varieties and specifications, the characteristic value of each batch is very different
(or R, s) are very different and the production status of different batches is very different, so the overall characteristic value cannot be calculated simply from the characteristic values of all batches
(or
) Therefore, the upper and lower limits of the control chart cannot be calculated according to the above formula, and therefore, the characteristic value of each batch needs to be further processed;
the third step: for each batch of the production process, let the production sequence consist of n batches, where a certain control parameter x for the ith batchiSet value is Xi±ΔiWhere Δ is the upper and lower control limits and the average of the measurements is
Standard deviation of siMaximum value of ximaxMinimum value of ximinI.e. the measurement obeys a desired value of XiStandard deviation of siIs normally distributed, and ximax-Xi<Δi，Xi－ximin<ΔiFor parameter XiThe following transformations may be made: is provided withThen y isiMathematical expectation value mu ofyi0, and-1. ltoreq. yi≤1；
The fourth step: for the entire production sequence, use yiSPC control charts are generated, with X-axis for production completion time per lot and Y-axis for corresponding YiAnd the control center line is y which is 0, the upper limit and the lower limit of the control are +1 and-1, and the control chart which is continuous along with the time can be generated in real time or off line according to the actual production result of each batch.
In the above embodiment, the control chart of the metering-type data type in the first step includes: a mean-range or mean-standard deviation plot, a single-value-moving range plot, or a median-range plot.
In the above embodiment, in the actual production process in the third step, each batch is produced according to a set of PDI parameters consisting of a target value and upper and lower limits thereof, where the PDI parameters are a set value of the production process and a target value of process control, and for each batch, if the production process is in a statistically controlled state, the mathematical expected value of a measurement result of a certain parameter is equal to the set value thereof, and the maximum and minimum values in the measurement result of each batch should not exceed the upper and lower limits of the parameter.
In the above embodiments, generally speaking, where quality control is required, a control chart may be used, and specifically, which control chart is used is determined according to the analysis of the process and the data type of the process characteristics, and the control limit is a limit on the control chart for deciding whether a signal for taking a measure needs to be sent or whether the process is in a "statistical control state".
According to standard SPC theory, conventional control charts are mainly of two types, metrology control charts and count control charts, each of which has two different scenarios: a standard value is not given and a standard value is given; the purpose of standard values not giving control charts is to find the dotted features (e.g.
R or any other statistic) whether the observed values themselves are significantly more variable than those due to only incidental causes, such a control chart being based entirely on subgroup data for detecting those variations due to non-incidental causes(ii) a Standard values the purpose of a given control chart is to determine several subgroups
Observed value of equal characteristics and standard value X corresponding to observed value0(or μ)0) Whether the difference is significantly greater than the difference due to only the expected incidental cause; the difference between the control chart for the standard value given case and the control chart for the standard value not given case is that the additional requirements regarding the process center position and the variation are different, and the standard value may be determined based on experience obtained by using the control chart without prior information or random standard values, may be determined based on an economic value established by considering the need for service and the cost of production, or may be a nominal value specified by the product specifications.
In order to further explain the above invention better based on the above logic, the following cases are provided:
an online SPC chart is developed in an MES system of a certain hot-rolled plate factory, six indexes of the width and the thickness of a hot-rolled coil, the hot-rolled final rolling temperature, the coiling temperature and the convexity and the wedge of a reaction plate shape are extracted in real time, all data are processed according to the logic of the invention, an SPC control chart is generated for each index according to the upper limit and the lower limit of +/-1, the central line of 0 and the X axis of the finishing time of rolling, the refreshing is set to be carried out every 3 minutes according to the actual situation of hot-rolled production, and the selection frames are switched, so that the online monitoring is very convenient.
FIG. 1 shows a SPC control chart of hot rolling thickness;
referring to FIG. 2, a SPC control chart of the finishing temperature of hot rolling is shown, in which the middle point is the average value of the batches, the upper point is the maximum value of the batches, and the lower point is the minimum value of the batches.
In summary, the following steps: the SPC method suitable for the multi-variety mixed production determines the uniform SPC control center line and the upper and lower control limits through the data transformation under the condition of the multi-variety mixed production, thereby generating an SPC control chart in an off-line or real-time manner and realizing the monitoring of the production process.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be able to cover the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.
Claims (3)
1. An SPC method suitable for mixed production of multiple species, comprising the steps of:
s1: when the observed characteristics are all continuous metering type data, a control chart suitable for the metering type data type is used, and the control limit calculation formula is as follows:
statistics
R, s is divided into: the standard value is not given and the standard value is given for two conditions:
under the condition that the standard value is not given, the statistic is as follows: center line
UCL and LCL:
or
Standard value given condition, statistic: center line X0Or μ, R0Or d2σ0，S0Or C4σ0(ii) a UCL and LCL: x0±Aσ0，D1σ0，D2σ0，B5σ0，B6σ0；
Wherein, X0、R0、S0Mu and sigma0Is a given standard value;
s2: according to the formula in S1, when creating the control chart, the characteristic values of the subgroups are calculated
Or mu0Then calculating the total average value of all observed values
And mean standard deviation
S3: for each batch of the production process, let the production sequence consist of n batches, where a certain control parameter x for the ith batchiSet value is Xi±ΔiWhere Δ is the upper and lower control limits and the average of the measurements is
Standard deviation of siMaximum value of ximaxMinimum value of ximinI.e. the measurement obeys a desired value of XiStandard deviation of siIs normally distributed, and ximax-Xi<Δi，Xi－ximin<ΔiFor parameter XiThe following transformations may be made: is provided with
Then y isiMathematical expectation value mu ofyi0, and-1. ltoreq. yi≤1；
S4: for the entire production sequence, use yiSPC control charts are generated, with X-axis for production completion time per lot and Y-axis for corresponding YiAnd the control center line is y which is 0, the upper limit and the lower limit of the control are +1 and-1, and the control chart which is continuous along with the time can be generated in real time or off line according to the actual production result of each batch.
2. An SPC process suitable for multi-item hybrid manufacturing as defined in claim 1 wherein the control chart of metrology-type data types in S1 includes: a mean-range or mean-standard deviation plot, a single-value-moving range plot, or a median-range plot.
3. An SPC method suitable for multi-item hybrid production as recited in claim 1, wherein in S3, in the actual production process, each lot is produced according to a set of PDI parameters consisting of a target value and its upper and lower limits, the PDI parameters are a set value of the production process and a target value of process control, for each lot, if the production process is in a statistically controlled state, the mathematical desired value of a measurement result of a certain parameter is equal to its set value, and the maximum and minimum values of the measurement result of each lot should not exceed the upper and lower limits of the parameter.
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