Quality control apparatus and control method of the same, and recording medium recorded with quality control program

• US 20050246045A1
• Filed: 04/28/2005
• Published: 11/03/2005
• Est. Priority Date: 04/30/2004
• Status: Active Grant

• Current Assignee: Omron Corporation
• Original Assignee: Omron Corporation
• Inventors: Fujii, Toru, Sono, Mineo, Sugihara, Shiro
• Granted Patent: US 7,324,862 B2
• Time in Patent Office: Days
• US Class Current: 700/109
• CPC Class Codes: G05B 2219/32196 Store audit, history of inspection, control and workpiece data into database
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G07C 3/00 Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
• CPC Class Codes: G07C 3/14 Quality control systems
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Various items of data collected at different process steps are associated on production sites where traceability is hard to conduct. A quality control apparatus controls a manufacturing process in order to manufacture products of predetermined quality, including a data storing part which collects measurement data measured by multiple devices disposed in a manufacturing process and stores the collected measurement data along with measured time or collected time; and a scheduler which associates the measurement data of the devices with each other in consideration of dead time generated between the devices at measured time or collected time.

Claims

1. A quality control apparatus which controls a manufacturing process in order to manufacture products of predetermined quality, the apparatus comprising:

a storing module which collects measurement data measured by multiple measuring devices disposed in a manufacturing process and stores the collected measurement data along with measured time or collected time; and

an associating module which associates the measurement data of the multiple measuring devices with each other in consideration of dead time generated between the measuring devices at measured time or collected time.

2. The quality control apparatus according to claim 1, wherein the associating module associates given numbers of items of measurement data of the multiple measuring devices with each other.

3. The quality control apparatus according to claim 1, wherein when improper measurement data is included in the measurement data to be associated with each other, the associating module stops association of the improper measurement data with the measurement data that is the measurement data measured by the other measuring device and corresponds to the improper measurement data.

4. The quality control apparatus according to claim 3, wherein when an intermediate product is put back at a certain process step in a manufacturing process, the associating module stops association of measurement data relating to the intermediate product of the measuring device on an upstream side of the process step with measurement data relating to the intermediate product of the measuring device at the process step and on a downstream side thereof.

5. The quality control apparatus according to claim 3, wherein when an intermediate product removed at a certain process step in a manufacturing process, the associating module stops association of measurement data of the measuring device on a downstream side of the process step with measurement data relating to the intermediate product of the measuring device at the process step and on an upstream side thereof.

22. A computer readable recording medium on which a quality control program which operates the quality control apparatus according to claim 1, and functions a computer as the individual modules is recorded.

6. A quality control apparatus which controls a manufacturing process in order to manufacture products of predetermined quality, the apparatus comprising:

a storing module which collects and stores intermediate characteristic data of an intermediate product measured by an intermediate characteristic measuring device and final characteristic data of a completed product measured by a final characteristic measuring device;

a specification limit generating module which generates an intermediate characteristic specification limit set to the intermediate characteristic measuring device based on a data distribution of the final characteristic data stored in the storing module and a final characteristic specification limit set to the final characteristic measuring device; and

a specification limit setting control module which controls the intermediate characteristic measuring device so as to set the generated specification limit generated by the specification limit generating module.

7. The quality control apparatus according to claim 6, wherein the specification limit generating module generates the intermediate characteristic specification limit based on a differential between a mean value of the data distribution of the final characteristic data and the final characteristic specification limit.

8. The quality control apparatus according to claim 7, wherein the specification limit generating module generates the intermediate characteristic specification limit so that a ratio of a differential between a mean value of a data distribution of the intermediate characteristic data stored in the storing module and the intermediate characteristic specification limit with respect to the differential between the mean value of the data distribution of the final characteristic data and the final characteristic specification limit is a ratio of a variation value of the data distribution of the intermediate characteristic data with respect to a variation value of the data distribution of the final characteristic data.

9. The quality control apparatus according to claim 6, wherein the specification limit generating module further generates the intermediate characteristic specification limit based on a safety factor.

10. The quality control apparatus according to claim 9, wherein the safety factor is calculated based on discard cost when the completed product is removed based on the final characteristic specification limit and discard cost when the intermediate product is removed based on the intermediate characteristic specification limit.

11. The quality control apparatus according to claim 6, wherein the storing module stores the intermediate characteristic data and the final characteristic data along with measured time or collected time, the apparatus further comprising:

an associating module which associates the intermediate characteristic data with the final characteristic data in consideration of dead time generated between the intermediate characteristic measuring device and the final characteristic measuring device at measured time or collected time.

12. The quality control apparatus according to claim 6, wherein the specification limit generating module generates a subsequent specification limit by using the intermediate characteristic data and the final characteristic data collected by the storing module after a given time period has elapsed from when the specification limit setting control module controlled the intermediate characteristic measuring device.

13. A quality control apparatus which controls a control target device disposed in a manufacturing process in order to manufacture products of predetermined quality, the apparatus comprising:

a storing module which collects and stores a set value of a control value set as a target value to the control target device, control data that is a measurement value of the control value measured by the control target device with respect to the set value, and intermediate characteristic data of an intermediate product measured by an intermediate characteristic measuring device;

an intermediate characteristic estimating module which estimates a variation in a data distribution of the intermediate characteristic data when the set value of the control value stored in the storing module is switched;

a defective number estimating module which estimates a number of defectives based on a variation in the data distribution of the intermediate characteristic data estimated by the intermediate characteristic estimating module and an intermediate characteristic specification limit;

a switching amount deciding module which decides a switching amount for the set value of the control value so that the number of defectives estimated by the defective number estimating module is the minimum; and

a control switching module which switches the set value of the control value of the control target device based on the switching amount decided by the switching amount deciding module.

14. The quality control apparatus according to claim 13, further comprising an impact storing module which stores an impact that indicates a degree of a variation in the data distribution of the intermediate characteristic data with respect to a change in a mean value of the control data,

wherein the intermediate characteristic estimating module estimates the variation in the data distribution of the intermediate characteristic data based on the switching amount for the set value of the control value stored in the storing module and the impact stored in the impact storing module, and

the switching amount deciding module decides a switching amount for the set value of the control value so that the number of defectives estimated by the defective number estimating module is the minimum.

15. The quality control apparatus according to claim 14, further comprising an impact creating module which creates the impact and stores it in the impact storing module when a difference more than a given amount is generated between the data distribution of the intermediate characteristic data corresponding to a switching amount for the set value of the control value decided by the switching amount deciding module and the distribution of the intermediate characteristic data collected by the storing module after the control switching module switches control.

16. The quality control apparatus according to claim 13, wherein the storing module further collects and stores final characteristic data of a completed product measured by a final characteristic measuring device, the apparatus further comprising:

a specification limit generating module which generates an intermediate characteristic specification limit set to the intermediate characteristic measuring device based on a data distribution of the final characteristic data stored in the storing module and a final characteristic specification limit set to the final characteristic measuring device, and

the defective number estimating module uses the intermediate characteristic specification limit generated by the specification limit generating module.

17. The quality control apparatus according to claim 13, wherein the storing module stores the control data and the intermediate characteristic data along with measured time or collected time, the apparatus further comprising:

an associating module which associates the control data with the intermediate characteristic data in consideration of dead time generated between the control target device and the intermediate characteristic measuring device at measured time or collected time.

18. The quality control apparatus according to claim 13, wherein the intermediate characteristic estimating module estimates a subsequent data distribution of the intermediate characteristic data by using the intermediate characteristic data collected by the storing module after a given time period has elapsed from when the control switching module switched control.

19. A control method of a quality control apparatus which controls a manufacturing process in order to manufacture products of predetermined quality,

the apparatus comprising:

a storing module which collects measurement data measured by multiple measuring devices disposed in a manufacturing process and stores the collected measurement data along with measured time or collected time, and

the method comprising;

an association step of associating the measurement data of the measuring devices with each other in consideration of dead time generated between the measuring devices at measured time or collected time.

20. A control method of a quality control apparatus which controls a manufacturing process in order to manufacture products of predetermined quality,

the apparatus comprising:

a storing module which collects and stores intermediate characteristic data of an intermediate product measured by an intermediate characteristic measuring device and final characteristic data of a completed product measured by a final characteristic measuring device, and

the method comprising;

a specification limit generating step of generating an intermediate characteristic specification limit set to the intermediate characteristic measuring device based on a data distribution of the final characteristic data stored in the storing module and a final characteristic specification limit set in the final characteristic measuring device; and

a specification limit setting control step of controlling the intermediate characteristic measuring device so as to set the specification limit generated at the specification limit generating step.

21. A control method of a quality control apparatus which controls a control target deviced is posed in a manufacturing process in order to manufacture products of predetermined quality, the apparatus comprising:

a storing module which collects and stores a set value of a control value set as a target value to the control target device, control data that is a measurement value of a control value measured by the control target device with respect to the set value of the control value, and intermediate characteristic data of an intermediate product measured by an intermediate characteristic measuring device, and

the method comprising;

an intermediate characteristic estimating step of estimating a variation in a data distribution of the intermediate characteristic data when the set value of the control value stored in the storing module is switched;

a defective number estimating step of estimating a number of defectives based on the variation in the data distribution of the intermediate characteristic data estimated at the intermediate characteristic estimating step and an intermediate characteristic specification limit;

a switching amount deciding step of deciding a switching amount for the set value of the control value so that the number of defectives estimated at the defective number estimating step is the minimum; and

a control switching step of switching the set value of the control value of the control target device based on the switching amount decided at the switching amount deciding step.