CN113115978B - Technological method for reducing single gram weight deviation of cigarettes - Google Patents

Abstract

The technical method for reducing single gram weight deviation of cigarettes belongs to the technical field of tobacco manufacture, and comprises the following steps: the method comprises the steps of scoring and evaluating potential influence degree, occurrence frequency and control method and control degree of each influence factor on the gram weight deviation of a single cigarette in a selected cigarette type manufacturing process by adopting an FMEA fault mode influence analysis method, screening out items to be improved, verifying the screened out items one by adopting a statistical analysis method, and finally confirming that factors with the greatest influence on the gram weight deviation of the single cigarette are cut stem thickness, 20 cigarette weights and single box stem label rejection; step two: searching reasonable parameter collocations aiming at each influence factor: step three: and (3) making a control plan for each influence factor, and requiring the staff to execute the control plan strictly. The invention can reduce the single gram weight deviation of the cigarette from 19.91mg to 18mg and improve the stability of the cigarette.

Description

Technological method for reducing single gram weight deviation of cigarettes

Technical Field

The invention belongs to the technical field of cigarette manufacturing, and particularly relates to a process method for reducing single gram weight deviation of cigarettes.

Background

The single gram weight deviation of the cigarettes is used as a key index for process quality monitoring to carry out long-term daily monitoring. The deviation of the single gram weight of the cigarettes is the absolute value of the weight difference between the actual gram weight of the sample cigarettes and the single gram weight of the design standard cigarettes in the production process. The weight measuring device is used for measuring the degree that the weight value of a single cigarette is close to the design center value. The smaller the deviation of the single gram weight of the cigarette, the closer the weight of the cigarette is to the design center value. By counting the single gram weight deviation of good cat (monkey King) cigarettes in the year 2020 of 1 to 7, as shown in the following table,

single gram weight deviation statistics of 1-7 months of 2020 cigarettes

The method can be used for solving the problem that the control of the cigarette weight is unstable, the maximum value of the single gram weight deviation is 20.95mg, the average value of the single gram weight deviation is 19.91mg, and a certain distance is reserved between the single gram weight deviation and standard alignment indexes required by companies, so that the single gram weight deviation of the cigarettes is imperative to be reduced.

Disclosure of Invention

The invention solves the technical problems that: the invention provides a process method for reducing the single-branch gram weight deviation of cigarettes, which researches out relevant factors of the weight stability of cigarettes through measuring, analyzing, improving, controlling and other stages, and carries out parameter configuration and improved control, thereby reducing the single-branch gram weight deviation of cigarettes from 19.91mg to 18mg and improving the stability of the single-branch gram weight deviation of cigarettes.

The invention adopts the technical scheme that: the technological method for reducing the single gram weight deviation of the cigarettes comprises the following steps:

step one: the method comprises the steps of scoring and evaluating potential influence degree, occurrence frequency and control method and control degree of each influence factor on the gram weight deviation of a single cigarette in a selected cigarette type manufacturing process by adopting an FMEA fault mode influence analysis method, screening out items to be improved, verifying the screened out items one by adopting a statistical analysis method, and finally confirming that factors with the greatest influence on the gram weight deviation of the single cigarette are cut stem thickness, 20 cigarette weights and single box stem label rejection;

step two: searching reasonable parameter collocations aiming at each influence factor:

(1) Cut stalk thickness: under the condition that other conditions are unchanged, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thicknesses is detected, and the optimal stem pressing thickness is determined; verifying the optimal stem pressing thickness through the tobacco shred structure and the physical index of the finished product;

(2) 20 cigarettes by weight: carrying out full factor experiment on the wind pressure of the left and right chambers by using DOE test, and verifying and standardizing parameters obtained by the experiment;

(3) Single box stem label reject amount: regression analysis is used for verifying the relation between wind pressure of wind division and silk content in stems, and optimal parameters are found and standardized;

step three: a control plan is established for each influence factor, and workers are required to execute the control plan strictly;

(1) Cut stalk thickness: counting the thickness of cut stems in the working process, and drawing a process operation control chart;

(2) 20 cigarettes by weight: arranging inspection personnel for inspection according to the requirements of related process technical standards, and taking the inspection personnel into evaluation and examination according to the inspection results;

(3) Single box stem label reject amount: the quality control chart is used for controlling the reject quantity of the single box stalks; and (5) reinforcing inspection, wherein the single box stem label removing amount is not in a specified range and is subjected to evaluation and check.

In the second step, when the pressed stem thickness in the cut stem thickness is 0.8mm and the cut stem thickness is 0.12mm, the weight of the cigarette is closest to the set value, the standard deviation is 0.006, and the weight of the cigarette is the most stable.

In the second step, the left and right room wind pressures of the weight of the 20 cigarettes within the standard requirement range of 17.6+/-0.3 g/20 are as follows: in the case of removing the interaction, the left pressure was 7100Pa, and the right pressure was 8000Pa.

In the second step, the wind pressure of the wind in the single box stem label removing amount is 4.5mm. .

Compared with the prior art, the invention has the advantages that:

1. according to the scheme, relevant factors of the weight stability of the cigarettes are researched through measuring, analyzing, improving, controlling and other stages, and parameter configuration and improvement are carried out, so that the gram weight deviation of single cigarettes is reduced from 19.91mg to 18mg, and the stability of the single cigarettes is improved;

2. according to the scheme, the FMEA fault mode influence analysis is utilized, potential fault modes in the process can be accurately and rapidly found, risk quantification assessment is carried out on the found fault modes according to a corresponding evaluation system, fault causes are listed, preventive and improved measures are found, the method is more systematic in analysis of problems, and good promotion effect on quality analysis control is achieved.

Drawings

FIG. 1 is a chart of a C3 gauge report in the present invention;

FIG. 2 is a graph showing the efficacy of a single sample t-test according to the present invention;

FIG. 3 is a box plot of moisture content and cigarette weight in the present invention;

FIG. 4 is a probability graph of water cut in the present invention;

FIG. 5 is a probability graph of the weight of a cigarette in the present invention;

FIG. 6 is a graph showing an isovaria test of water content and cigarette weight in the present invention;

FIG. 7 is a graph showing the efficacy of a two sample t-test according to the present invention;

FIG. 8 is a graph of efficacy of a single sample t-test of the present invention;

FIG. 9 is a box plot of cut stem thickness cigarette weight in the present invention;

FIG. 10 is a box diagram of cut stem thickness-1 and cigarette weight-1 according to the present invention;

FIG. 11 is a probability graph of the weight of a cigarette in the present invention;

FIG. 12 is a graph of the equal variance test of the weight of the cigarettes, the weight of the cigarettes-1 and the weight of the cigarettes-2 in the invention;

FIG. 13 is an equivalent test chart of the weight average of a cigarette in the present invention;

FIG. 14 is a graph of a two sample T test data in accordance with the present invention;

FIG. 15 is a box diagram of the first, second, and third shifts of the present invention;

FIG. 16 is a probability graph of A, B, and C shifts in the present invention;

FIG. 17 is a graph showing the weight of 20 cigarettes and the like in the variance test;

FIG. 18 is a residual plot of 20 cigarette weights in the present invention;

FIG. 19 is a box plot of the weight of 20 cigarettes in the invention;

FIG. 20 is a single value plot of shift versus weight for 20 cigarettes according to the invention;

FIG. 21 is a probability diagram of machine 1,3, 6,7 according to the present invention;

FIG. 22 is a variance test chart of a single box stem label removing machine in the invention;

FIG. 23 is a graph showing the quantity of removed single box stalks and the machine station;

FIG. 24 is a single value chart of the single box stem culling amount in the present invention;

FIG. 25 is a residual diagram of machines 1,3, 6 and 7 with single-box stem label removal amount;

FIG. 26 is a box plot of the single box stem culling amount in the present invention;

FIG. 27 is a normal view of the effect of centralisation in the present invention;

FIG. 28 is a residual plot of 20 cigarette weights in the present invention;

FIG. 29 is a graph showing the main effect of the weight of 20 cigarettes in the invention;

FIG. 30 is a graph showing the interaction of the weights of 20 cigarettes in the invention;

FIG. 31 is a graph showing the weight of 20 cigarettes and the left and right wind pressure in the invention;

FIG. 32 is a contour plot of 20 cigarette weight versus left and right wind pressure in the present invention;

FIG. 33 is a graph showing the contour line comparison of the weight of 20 cigarettes and the left and right wind pressures in the invention;

FIG. 34 is a plot of a fit of the single box stem culling amount in the present invention;

FIG. 35 is a residual plot of the single box stem culling amount in the present invention;

FIG. 36 is a graph showing the comparison of the gram weight deviation of individual cigarettes before and after improvement in the present invention;

FIG. 37 is a probability map of the weight of a cigarette in the present invention;

FIG. 38 is a graph of I-MR control of the weight of a cigarette in accordance with the present invention;

FIG. 39 is a chart showing a summary report of the weight of cigarettes in the invention;

FIG. 40 is a graph of an equal variance test of the weight of a C14 cigarette in accordance with the present invention.

Detailed Description

The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

Referring to fig. 1-40, embodiments of the present invention are described in detail.

The technological method for reducing the single gram weight deviation of the cigarettes comprises the following steps:

step one: and (3) scoring and evaluating potential influence degree, occurrence frequency and control degree of each influence factor on the gram weight deviation of the single cigarette in the selected cigarette type manufacturing process by adopting an FMEA fault mode influence analysis method in each link of a measuring system and a process flow related to the gram weight deviation of the single cigarette, and screening out items to be improved.

The specific screening process is as follows:

1. screening of measurement systems associated with cigarette individual grammage deviations

Taking good cat (monkey King) cigarette single gram weight deviation as an example, sampling, measuring and analyzing plan,

measurement system analysis

Analytical data sheet for measuring system

simple	opera	Zhongliang	simple	opera	Zhongliang
							1	1	878	1	2	879
2	1	906	2	2	905
						3	1	871	3	2	871
4	1	877	4	2	870
						5	1	861	5	2	863
6	1	913	6	2	916
						7	1	900	7	2	900
8	1	879	8	2	878
						9	1	890	9	2	891
10	1	918	10	2	926
						1	1	878	1	2	879
2	1	905	2	2	907
						3	1	872	3	2	870
4	1	877	4	2	870
						5	1	862	5	2	862
6	1	913	6	2	916
						7	1	900	7	2	900
8	1	879	8	2	878
						9	1	890	9	2	891
10	1	916	10	2	926

By studying the gauge R & R-analysis of variance, as shown in figure 1,

two-factor analysis of variance table containing interactions

Alpha=0.05 for deleting interaction item

Measuring tool R & R

Variance component

Measuring tool evaluation

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Distinguishable category number=9

From the analysis results of the measurement system, the main difference of the measurement system is derived from a sample (the component variance component is 103.432), and the variance contribution rate of the measuring tool is 2.83% < 10%; measuring 13.69% < 30% of the system fluctuation; the accuracy of the measurement system accounts for 2.83 percent of the tolerance of less than 30 percent; the distinguishable category number is 9 & gt 4, namely the instrument resolution meets the requirement, which indicates that the measuring system is effective.

2. Taking good cat (monkey King) as an example for carrying out process flow analysis

The technological process of good cat (monkey King) is carded, the details are known, the flow chart is drawn, and the research scope of the invention is mainly focused on the yarn making and winding part.

According to a good cat (monkey King) process flow chart, deep thinking is carried out from aspects of people, machines, materials, methods, rings, tests and the like, potential reasons are found, and FMEA analysis is carried out as follows:

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scoring and evaluating according to the potential influence degree of important factors on the weight deviation of the single item cigarette, the occurrence frequency, the current control method, the control degree and the like, and finally confirming an improvement flow and the important potential factors, wherein the specific table is as follows:

process flow	Important potential factors	Score value
			Wire drying process	Water content	216
Stalk pressing procedure	Thickness of pressed stem	216
			Winding process	Single box stem label removing quantity	192
Winding process	Unstable weight of cigarettes	224

The process uses FMEA fault mode influence analysis, the method can find potential fault modes of the process, the risk of the found fault modes is quantitatively evaluated according to a corresponding evaluation system, fault causes are listed, and preventive and improved measures are found.

3. In order to prove whether the determined reasons are correct, the screened improvement items are verified one by adopting a statistical analysis method.

(1) Verification of silk drying procedure

The stability of the moisture content of the cut tobacco in the cut tobacco drying process is directly related to the stability of the moisture content of the cut tobacco finished product.

The moisture content of the cut tobacco drier is not in accordance with the requirement, and is larger or smaller, and is classified as that the moisture content is not up to the standard, and whether the moisture content of the cut tobacco drier is a main reason for influencing the single gram weight deviation of cigarettes is researched.

First, a null hypothesis and an alternative hypothesis are established according to the analyzed data:

h0: μ1=μ2=μ3h1: mu 1, mu 2, mu 3 are not all equal

1) The number of samples is determined as shown in figure 2,

efficacy and sample number

Single sample t-test

Mean value = zero being examined (and +.zero)

Mean = zero + difference of calculated efficacy

α=0.05 assume standard deviation=0.14

Results

Sample of

From the above, as long as the number of samples is greater than 28, the target efficacy can be more than 0.95, so the number of samples is determined to be 30.

2) The box diagram is drawn as shown in fig. 3, and the difference of the moisture content of the cut tobacco has no influence on the gram weight of a single cigarette under the 95% confidence interval.

3) The normalization test is shown in fig. 4 and 5, and the P value is greater than 0.05, which indicates that the data distribution accords with the normalization distribution.

4) Equal variance testing, as shown in FIG. 6

95% Bonferroni standard deviation confidence interval

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Single group confidence level = 99.1667%

P=0.278 >0.05, so the sample is equally variance.

5) The T-test is shown in figure 7,

efficacy and sample number

Double sample t-test

Mean 1=mean 2 being tested (and +.

Efficacy of calculating mean 1 = mean 2+ difference

α=0.05 assume standard deviation=0.05

Results

Sample of

The number of samples refers to each group.

Inspection conclusion: p value=0.005, so the original assumption cannot be rejected, indicating that the moisture content of the baked shreds is not the main cause.

(2) Verification of cut stem thickness

1) The number of samples is determined and, as shown in figure 8,

efficacy and sample number

Single sample t-test

Mean value = zero being examined (and +.zero)

Mean = zero + difference of calculated efficacy

α=0.05 assume standard deviation=0.01

Results

Sample of

From the above, as long as the number of samples is greater than 16, the target efficacy can be more than 0.95, so the number of samples is determined to be 20.

2) Drawing box line diagrams, as shown in figures 9 and 10,

the difference of the cut stem thickness has an effect on the gram weight of a single cigarette.

3) The normalization test, as shown in figure 11,

p=0.483 >0.05, indicating that the data fit the normal distribution.

4) The equal variance test, as shown in figure 12,

equal variance test, cut stem thickness, cut stem thickness_1, cut stem thickness_2, cigarette weight,..

Method

The original assumption is that all variances are equal

The alternative hypothesis has at least one variance different

Significance level α=0.05

The Bartlett method has been used. This method is only applicable to normal data.

95% Bonferroni standard deviation confidence interval

Single group confidence level = 98.3333%

Inspection of

Inspection system

P=0 is less than 0.05, so rejecting the original hypothesis suggests that at least one variance is different at different cut stem thicknesses.

5) Equivalence check, as shown in figure 13,

efficacy and sample number

Double sample t-test

Mean 1=mean 2 being tested (and +.

Efficacy of calculating mean 1 = mean 2+ difference

α=0.05 assume standard deviation=0.021

Results

Sample of

The number of samples refers to each group.

Efficacy curve of double sample t test

The results show that the weights of cigarettes are different under different cut stem thicknesses, and the cut stem thicknesses are the reasons for influencing the gram weights of single cigarettes. The obvious difference of different cut stem thicknesses on the gram weights of single cigarettes is shown.

(3) Weight verification of 20 cigarettes

The weight of the cigarettes does not meet the requirement, the cigarettes are overweight and ultralight, and the weight of the cigarettes does not reach the standard, and we study whether the weight of 20 cigarettes is the main reason for influencing the gram weight deviation of a single cigarette.

First, a null hypothesis and an alternative hypothesis are established according to the analyzed data:

h0: μ1=μ2=μ3h1: mu 1, mu 2, mu 3 are not all equal

1) The number of samples is determined and, as shown in figure 14,

from the above, as long as the number of samples is greater than 27, the target efficacy can be more than 0.95, so the number of samples is determined to be 30.

2) Drawing a box line graph, as shown in figure 15,

indicating that the weight of 20 cigarettes has an effect on the deviation of the gram weights of the individual cigarettes.

3) If the data is not normal, the data is converted normally, as shown in figure 16,

from the above graph, the p value is greater than 0.05, and thus, the normal distribution is satisfied.

4) Equal variance testing, as shown in FIG. 17

From the above graph, bartlett test p values are greater than 0.05, and therefore, conform to the equal variance assumption.

5) Single factor analysis of variance

Single factor analysis of variance C12 and C13

S= 0.2308R-sq=29.77% R-Sq (adjustment) = 28.15%

Merge standard deviation=0.231

Grouping information using Tukey method

There is a significant difference between the means of not sharing letters.

Tukey 95% overall confidence interval

All pairwise comparisons between C13 levels

Single group confidence level = 98.06%

C13 =1 subtracted from:

c13 =2 subtracted from:

as shown in particular in fig. 18-20

Conclusion: the residual error is normally distributed, the mean value is 0, the variance is constant, the P value is less than 0.05, the original assumption is refused, and the weight of at least one horizontal 20 cigarettes is stable. From the single-factor analysis of variance, there was no significant difference between the two levels of cigarette weights of the first shift and the third shift, and there was a significant difference from the second shift.

(4) The removal amount of the single box stem sticks is verified,

1) Determining the number of samples

The different machine stations are regarded as a factor, and the factors are respectively as follows: 1#, 3#, 5#, 6#, 7#, determining α=0.05, β=0.1, and determining the number of samples according to the single-branch gram weight deviation counted in the defining stage:

efficacy and sample number

Single factor analysis of variance

The number of samples refers to each level.

And 6 data are acquired at each level according to the difficulty level of data collection.

2) The normalization test is shown in figure 21,

from the p value, the data p of six levels of 5 machines is larger than 0.05, and the normal distribution is obeyed.

3) Equal variance test

Equal variance test 1,3,5,6,7

Method

The original assumption is that all variances are equal

The alternative hypothesis has at least one variance different

Significance level α=0.05

95% Bonferroni standard deviation confidence interval

Single group confidence level = 99%

Inspection of

Inspection system

As shown in FIG. 22, the level test p-value is greater than 0.05, illustrating the isovaria.

4) Single factor analysis of variance

Single-factor analysis of variance 1,3,5,6,7

Method

The original assumption is that all mean values are equal

Alternative assumptions are not all averages equal

Significance level α=0.05

Equal variances have been assumed for this analysis.

Factor information

Analysis of variance

Model summarization

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Mean value of

Merge standard deviation= 0.145285

As shown in figures 23-26 of the drawings,

conclusion: the residual is a normal distribution with a mean of 0 and a constant variance, so there is not enough reason to reject the model. The P value is larger than 0.05, the original assumption is refused, and at least one horizontal single box stem label is stable in rejection. The method shows that the single box stem label removing quantity levels among different machine stations have significant differences.

4. Results of cause verification

Through the verification of the screening reasons, the main reasons are reconfirmed:

sequence number	Name of the name	Status of	Whether or not to improve
				1	Moisture content of silk drying process	Is not remarkable	Whether or not
2	Cut stem thickness	Is remarkable in	Is that
				3	Weight of 20 cigarettes	Is remarkable in	Is that
4	Single box stem label removing quantity	Is remarkable in	Is that

Finally, factors which have the greatest influence on the single-branch gram weight deviation of the cigarettes are determined to be cut stem thickness, 20-branch weight and single-box stem rejection;

step two: searching reasonable parameter collocations aiming at each influence factor:

(1) Cut stalk thickness: under the condition that other conditions are unchanged, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thicknesses is detected, and the optimal stem pressing thickness is determined; and verifying the optimal stem pressing thickness through the tobacco shred structure and the physical index of the finished product.

The stem cutting thickness is a target value, and excessive or insufficient thickness can generate unqualified cigarettes to influence the single gram weight deviation of cigarettes. The thickness of the cut stems is limited by the thickness of the pressed stems, so the thickness of the pressed stems is tested.

1) The tobacco rod weight is detected by respectively setting the pressing stem thickness to be 0.7mm, 0.8mm and 0.9mm and the cutting stem thickness to be 0.12mm, and the results are shown in the following table:

from the results, it was found that, assuming that the other conditions were not changed, the tobacco rod weight was closest to the set value, the standard deviation was 0.006, and the tobacco rod weight was most stable when the stem pressing thickness was 0.8mm and the stem cutting thickness was 0.12 mm.

2) Post-adjustment result analysis

Cut tobacco structure

The whole thread rate of the cut tobacco after the primary test is 78.3 percent, the cut tobacco after the secondary test is 78.3 percent, the cut tobacco after the tertiary test is 78.2 percent, and the whole thread rate is basically unchanged; the broken silk rate and the filling value are stable and basically have no change.

Physical index of finished cigarette

The stem pressing thickness test is used for detecting and analyzing the end content, the end cut-off amount and the cigarette suction resistance of the finished cigarette. The final content after the first test is 1.32, the final content after the second test is 1.22, and the final content after the second test is 1.3; the fiber falling amount of the end part after the primary test is 4.2, the fiber falling amount of the end part after the secondary test is 3.8, and the fiber falling amount after the tertiary test is 4.1; the standard deviation of the cigarette after one test is 40, the standard deviation of the cigarette after two tests is 32, and the standard deviation of the cigarette after three tests is 46; the end content, the end cut-off amount and the suction resistance deviation of the cigarettes are obviously reduced after the second test, which indicates that the parameters of the second test can best meet the requirements of finished products of cigarettes.

(2) 20 cigarettes by weight: carrying out full factor experiment on the wind pressure of the left and right chambers by using DOE test, and verifying and standardizing parameters obtained by the experiment;

1) Design of DOE experiments

The project group discusses how to stabilize the parameters of the equipment related to the weight of the cigarettes, searches the relation through experimental design, and then finds the optimal value of each parameter, so that the weight of 20 cigarettes is stabilized within the standard requirement range (17.6 plus or minus 0.3), the wind pressure of the left wind chamber and the wind pressure of the right wind chamber are set, and the left wind chamber: 7 x 100pa,9 x 100pa; right air chamber: 7 x 100pa,9 x 100pa. The full factor test was selected and 4 center point tests were arranged, and a 2-factor 2-level 4 center point full factor design of experiments was generated using MINITAB software and the experimental sequence was randomized such that the center points were approximately at the beginning, middle and end of the test, and tested according to the test protocol.

Standard sequence	Run sequence	Center point	Granule group	Left side	Right side
						3	1	1	1	7	9
6	2	0	1	8	8
						8	3	0	1	8	8
1	4	1	1	7	7
						5	5	0	1	8	8
2	6	1	1	9	7
						7	7	0	1	8	8
4	8	1	1	9	9

a. Analysis of influence of right wind pressure on weight of 20 cigarettes under interaction

Fitting factor of weight and positive and negative pressure

Estimation effects and coefficients of weight (encoded units)

Term effect coefficient standard error T P

Constant 0.908000 0.001555 584.09 0.000

Positive pressure-0.010000-0.005000 0.001555-3.22.049

Negative pressure 0.025000 0.012500 0.001555 8.04 0.004

Positive pressure negative pressure 0.001000 0.000500 0.001555 0.32 0.769

Ct Pt-0.002500 0.002198 -1.14 0.338

S＝0.00310913PRESS＝*

R-sq=96.22% R-Sq (prediction) =% R-Sq (adjustment) =91.18%

Analysis of variance of weight (coded units)

Degree of freedom of origin Seq SS Adj SS Adj MS F P

Main effect 2 0.00072500 0.00072500 0.00036250 37.50 0.008

Positive pressure 1 0.00010000 0.00010000 0.00010000 10.34 0.049

Negative pressure 1 0.00062500 0.00062500 0.00062500 64.66 0.004

Factor interaction 1 0.00000100 0.00000100 0.00000100 0.10 0.769

Positive pressure negative pressure 1 0.00000100 0.00000100 0.00000100 0.10 0.769

Bending 1 0.00001250 0.00001250 0.00001250 1.29 0.338

Residual error 3 0.00002900 0.00002900 0.00000967

Pure error 3 0.00002900 0.00002900 0.00000967

Totaling 7.00076750

Analysis of variance was performed on the weight data under left and right wind pressure, and the results showed that: under no interaction, P < 0.008, 0.049, 0.004] < alpha, which shows that the main effect, positive pressure and negative pressure difference have obvious influence on the weight of the cigarettes; under interaction, P [0.769, 0.769] > alpha, the probability of each test mean value is very high, and the weight difference of cigarettes under different positive pressure and negative pressure is not obvious, and the interaction is not obvious. Therefore, the main effect is obvious, the interaction effect is not obvious, and the interaction items can be removed.

(2) Analysis of the influence of positive and negative pressure on the weight of cigarettes without interaction

Fitting factor of weight and positive and negative pressure

Estimation effects and coefficients of weight (encoded units)

Term effect coefficient standard error T P

Constant 0.908000 0.001369 663.11 0.000

Positive pressure-0.010000-0.005000 0.001369-3.65.022

Negative pressure 0.025000 0.012500 0.001369 9.13 0.001

Ct Pt-0.002500 0.001936 -1.29 0.266

S＝0.00273861PRESS＝0.000112

R-sq=96.09% R-Sq (prediction) = 85.41% R-Sq (adjustment) = 93.16%

Analysis of variance of weight (coded units)

Degree of freedom of origin Seq SS Adj SS Adj MS F P

Main effect 2 0.00072500 0.00072500 0.00036250 48.33 0.002

Positive pressure 1 0.00010000 0.00010000 0.00010000 13.33 0.022

Negative pressure 1 0.00062500 0.00062500 0.00062500 83.33 0.001

Bending 1 0.00001250 0.00001250 0.00001250 1.67 0.266

Residual error 4 0.00003000 0.00003000 0.00000750

Failure to mimic 1 0.00000100 0.00000100 0.00000100 0.10 0.769

Pure error 3 0.00002900 0.00002900 0.00000967

Totaling 7.00076750

Analysis shows that under the condition of removing interaction, the main effect, positive pressure and negative pressure P [0.002, 0.022 and 0.001] < alpha are obvious, and the obvious influence of the difference of the main effect, the positive pressure and the negative pressure on the weight of the cigarettes is shown; bending, mismatch P [0.266, 0.769] >0.05, indicates that the data is free of bending and mismatch.

As shown in figures 27-33 of the drawings,

fitting value

Independent variable value of new observed value

New-style viewing

Measured value C5C 6

1 8.01 7.4

The predicted value is obtained by demodulating the optimal value into analysis prediction, the predicted response to the weight at the new design point is 95% of the predicted interval, and the weight value is between (17.431, 17.808), so that the weight of the cigarette is stable and controlled to be in the expected target.

And setting the left pressure of the cigarette machine set to 7100Pa and the right pressure to 8000Pa, extracting 3 groups of data, and verifying the difference of the weights of cigarettes. It can be seen that the weight values all fall into the prediction interval, and the selected model is proved to be effective, so that the weight of the cigarettes is stabilized.

Therefore, the left and right room wind pressures, in which the weight of 20 cigarettes is stabilized within the standard requirement range of 17.6+/-0.3 g/20, are determined as follows: in the case of removing the interaction, the left pressure was 7100Pa, and the right pressure was 8000Pa.

(3) Single box stem label reject amount: regression analysis is used for verifying the relation between wind pressure of wind division and silk content in stems, and optimal parameters are found and standardized;

the size of the primary air pressure can directly influence the cut tobacco content in the stems, the size of the stem mark removing amount is recorded through measuring an air pressure meter on 5 cigarette making machines, and whether the change of the air pressure value can influence the cut tobacco content in the stems is determined through a regression analysis tool. Because the data of the data field Y of X belongs to continuous data, regression analysis is selected to determine the relationship between two variables. The wind pressure values on 5 rolling units are collected, and regression analysis is carried out by using MINITAB. As shown in figures 34 and 35 of the drawings,

regression analysis 3 and C10

Regression equation is

3＝-0.5047+1.558C10

Model summarization

Analysis of variance

It is considered that when the R-Sq value is 0.7 or more, the relationship between the output variable and the input variable is large, R-sq=80.78%, R-Sq (adjustment) = 75.98%,

the S value is 0.06, which means that the residual error is very small, R-sq=79.6%, R-Sq

(adjustment) =78.6%, the two values are very close and the residual plot is normal, so the whole model is valid. Meanwhile, the independent variable P-value=0.005 is smaller than 0.05, so that the wind pressure Value can be considered to have a significant influence on the stem note removing amount. Through the above confirmation, the wind pressure of the wind in the single box stem label removing amount is 4.5mm.

(4) Verification improvement

As can be seen from the improvement effect fig. 36, the improvement effect is remarkable, reaching the target value.

(2) Hypothesis testing significance of improved single gram weight deviation of cigarette

Problems: whether the modified cigarette single-cigarette gram weight deviation reaches the target value 18

The object is: reaching a target value of 18

Assume that: h0: mu 1 is less than or equal to 18 mu 2 is more than 18

The statistical test method comprises the following steps: since σ is unknown, a single sample t-test is chosen.

Select α=0.05, β=0.1

Single sample T:

verification of mu=18 and >18

As shown in figure 37 of the drawings,

p=0.483 >0.05, and the data conforms to a normal distribution.

Process stability determination as shown in fig. 38-40

Conclusion: the p value is larger than 0.05, so that the original assumption is rejected, and the single-branch gram weight deviation of the improved cigarette is lower than 18mg.

Step three: a control plan is established for each influence factor, and workers are required to execute the control plan strictly;

(1) Cut stalk thickness: counting the thickness of cut stems in the working process, and drawing a process operation control chart;

(2) 20 cigarettes by weight: arranging inspection personnel for inspection according to the requirements of related process technical standards, and taking the inspection personnel into evaluation and examination according to the inspection results;

(3) Single box stem label reject amount: the quality control chart is used for controlling the reject quantity of the single box stalks; and (5) reinforcing inspection, wherein the single box stem label removing amount is not in a specified range and is subjected to evaluation and check.

In summary, the invention researches out the relevant factors of the weight stability of the cigarettes through measuring, analyzing, improving, controlling and other stages, and carries out parameter configuration and improved control, thereby reducing the gram weight deviation of single cigarettes from 19.91mg to 18mg and improving the stability of the single cigarettes.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present disclosure describes embodiments, not every embodiment is provided with a separate embodiment, and that this description is provided for clarity only, and that the disclosure is not limited to the embodiments described in detail below, and that the embodiments described in the examples may be combined as appropriate to form other embodiments that will be apparent to those skilled in the art.

Claims (1)

1. The technological method for reducing the single gram weight deviation of the cigarettes is characterized by comprising the following steps of: the method comprises the following steps:

step one: the method comprises the steps of scoring and evaluating potential influence degree, occurrence frequency and control method and control degree of each influence factor on the gram weight deviation of a single cigarette in a selected cigarette type manufacturing process by adopting an FMEA fault mode influence analysis method, screening out items to be improved, verifying the screened out items one by adopting a statistical analysis method, and finally confirming that factors with the greatest influence on the gram weight deviation of the single cigarette are cut stem thickness, 20 cigarette weights and single box stem label rejection;

step two: searching reasonable parameter collocations aiming at each influence factor:

(1) Cut stalk thickness: under the condition that other conditions are unchanged, different stem pressing thicknesses are set, the weight value of the cigarettes under the set stem pressing thicknesses is detected, and the optimal stem pressing thickness is determined; verifying the optimal stem pressing thickness through the tobacco shred structure and the physical index of the finished product;

when the pressed stem thickness in the cut stem thickness is 0.8mm and the cut stem thickness is 0.12mm, the weight of the cigarette is closest to a set value, the standard deviation is 0.006, and the weight of the cigarette is the most stable;

(2) 20 cigarettes by weight: carrying out full factor experiment on the wind pressure of the left and right chambers by using DOE test, and verifying and standardizing parameters obtained by the experiment; the air pressure of the left and right chambers, with the weight of the 20 cigarettes being stabilized within the standard requirement range of 17.6+/-0.3 g/20 cigarettes, is as follows: under the condition of removing interaction, the left pressure is 7100Pa, and the right pressure is 8000Pa;

(3) Single box stem label reject amount: regression analysis is used for verifying the relation between wind pressure of wind division and silk content in stems, and optimal parameters are found and standardized; the wind pressure of wind in the single box stem label removing amount is 4.5mm;

step three: a control plan is established for each influence factor, and workers are required to execute the control plan strictly;

(1) Cut stalk thickness: counting the thickness of cut stems in the working process, and drawing a process operation control chart;

(2) 20 cigarettes by weight: arranging inspection personnel for inspection according to the requirements of related process technical standards, and taking the inspection personnel into evaluation and examination according to the inspection results;

(3) Single box stem label reject amount: the quality control chart is used for controlling the reject quantity of the single box stalks; and (5) reinforcing inspection, wherein the single box stem label removing amount is not in a specified range and is subjected to evaluation and check.

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