Automatic quality control method for production line and apparatus therefor as well as automatic quality control program
First Claim
1. An automatic quality control method for a production line, comprising:
- monitoring a plurality of production condition data for manufacturing products from a production line and product quality data indicating quality of manufactured products;
storing the production condition data and product quality data thus monitored in a database;
checking the production condition data to detect whether or not there is an event which deteriorates the quality of products;
extracting, if a quality deteriorating event is detected, a quality deteriorating factor which causes the quality deteriorating event and improvement contents of production conditions against the quality deteriorating factor on the basis of the quality deteriorating event and the production condition data;
collating the quality deteriorating factor and improvement contents thus extracted with improvement examples pre-stored for possible quality deteriorating factors and confirming the validity of the quality deteriorating factor and improvement contents;
executing a simulation of manufacture of a product in the production line based on the quality deteriorating factor and improvement contents thus extracted, and verifying the correctness of the quality deteriorating factor and the validity of the improvement contents, extracted from the result of the simulation; and
if the correctness of the quality deteriorating factor and the validity of the improvement contents are verified, the production conditions for the production line in accordance with the improvement contents.
1 Assignment
0 Petitions
Accused Products
Abstract
Production condition data and product quality data in a production line are monitored and stored in a production history database. When a quality deterioration event in the production line is detected while checking the product quality data, the improvement contents of the quality deterioration factor and production conditions are extracted. The extracted results and pre-stored quality improvement history data are collated with each other in order to confirm the validity thereof, and a simulation of the phenomenon of the production line is executed in order to verify the correctness. When the validity and correctness are verified, the production condition for the production line are revised to improve the quality deterioration factor.
18 Citations
19 Claims
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1. An automatic quality control method for a production line, comprising:
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monitoring a plurality of production condition data for manufacturing products from a production line and product quality data indicating quality of manufactured products;
storing the production condition data and product quality data thus monitored in a database;
checking the production condition data to detect whether or not there is an event which deteriorates the quality of products;
extracting, if a quality deteriorating event is detected, a quality deteriorating factor which causes the quality deteriorating event and improvement contents of production conditions against the quality deteriorating factor on the basis of the quality deteriorating event and the production condition data;
collating the quality deteriorating factor and improvement contents thus extracted with improvement examples pre-stored for possible quality deteriorating factors and confirming the validity of the quality deteriorating factor and improvement contents;
executing a simulation of manufacture of a product in the production line based on the quality deteriorating factor and improvement contents thus extracted, and verifying the correctness of the quality deteriorating factor and the validity of the improvement contents, extracted from the result of the simulation; and
if the correctness of the quality deteriorating factor and the validity of the improvement contents are verified, the production conditions for the production line in accordance with the improvement contents. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An automatic quality control apparatus for a production line, comprising:
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a production line configured to produce products;
a first database configured to store a plurality of production condition data for producing the products and product quality data indicating quality of the products;
a monitoring section configured to monitor a plurality of production condition data for product the products from the production line and further monitor the product quality data indicating the quality of the products, to store them in the first database;
an extraction section configured to check the production condition data to detect whether or not there is an event which deteriorate the quality of products, and to extract a quality deteriorating factor which causes the quality deteriorating event and improvement contents of production conditions regarding the quality deteriorating factor on the basis of the quality deteriorating event and the production condition data;
a second database configured to store, in advance, improvement examples for the quality deterioration factor;
a validity confirming section configured to confirm the validity of the quality deteriorating factor and improvement contents by collating the quality deteriorating factor and improvement contents extracted by the extracting section with the improvement examples pre-stored in the second database;
a verifying section configured to execute a simulation of production of the products in the production line under current production conditions, and to verify the correctness of the quality deteriorating factor and the validity of the improvement contents from a result of the simulation; and
a feedback control section configured to revise the production conditions for the production line in accordance with the improvement contents when the correctness of the quality deteriorating factor and the validity of the improvement contents are verified. - View Dependent Claims (11, 12, 13, 14, 15, 17, 18, 19)
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16. An automatic quality control program for a production line, comprising:
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monitoring a plurality of production condition data for manufacturing color cathode ray tubes from a production line and product quality data indicating quality of manufactured products;
storing the production condition data and product quality data thus monitored in a database;
checking the production condition data to detect whether or not there is an event which deteriorate the quality of products;
extracting, if a quality deteriorating event is detected, a quality deteriorating factor which causes the quality deteriorating event and improvement contents of production conditions against the quality deteriorating factor on the basis of the quality deteriorating event and the production condition data;
collating the quality deteriorating factor and improvement contents thus extracted with improvement examples pre-stored for possible quality deteriorating factors and confirming the validity of the quality deteriorating factor and improvement contents;
executing a simulation of manufacture of a product in the production line based on the quality deteriorating factor and improvement contents thus extracted, and verifying the correctness of the quality deteriorating factor and the validity of the improvement contents, extracted from the result of the simulation; and
if the correctness of the quality deteriorating factor and the validity of the improvement contents are verified, the production conditions for the production line in accordance with the improvement contents.
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Specification