Universal production line production process control method

Abstract

This invention relates to the field of production control technology and provides a general production line process control method, comprising the following steps: assigning a globally unique identifier to each piece of equipment, binding the identifier with relevant equipment information, and storing it in a production database; dynamically combining multiple test sub-items according to test logic and mapping them to corresponding test stations based on product model; wherein the combination method of test sub-items, the number of stations, and the test order are dynamically adjusted according to product model; after each test station completes the test, the test result status is reported to the database in real time and recorded; the test result status includes untested, successful, failed, and locked status; and performing flow-type test control based on status determination. This invention achieves unified management and tracking of different equipment. Furthermore, by dynamically combining test sub-items and mapping them to corresponding test stations according to product model, this method can adapt to the production needs of different products, enhancing its versatility.

Description

Technical Field

[0001] This invention relates to the field of production control technology, specifically to a general production line process control method. Background Technology

[0002] In today's actual production environment, with the increasing diversification and personalization of market demands, equipment products are becoming increasingly diverse. This product diversity directly leads to a wide variety of production line processes. Different products often require different testing items, testing sequences, and testing station arrangements, making it difficult to achieve uniformity and universality in traditional production line process control methods.

[0003] Existing production line process control methods are mostly customized for specific products or production scenarios, lacking versatility and flexibility. When product types change or production demands adjust, large-scale modifications and redeployment of the entire process control method are often required, increasing production costs and time while reducing efficiency. Furthermore, traditional process control methods are often simplistic in their judgment and processing of test results, failing to meet the stringent quality requirements of modern production. Therefore, a universal production line process control method is needed to address these issues. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a general production line process control method to solve the problems existing in the above-mentioned background technology.

[0005] This invention is implemented as follows: a general production line process control method, the method comprising the following steps: Assign a globally unique identifier to each piece of equipment on the production line, and then bind the identifier with the relevant equipment information and store it in the production database; Based on the product model, multiple test sub-items are dynamically combined according to the test logic and mapped to the corresponding test stations; the combination method of test sub-items, the number of stations, and the test order are dynamically adjusted according to the product model. After each test station completes the test, the test result status is reported to the database in real time and recorded; the test result status includes untested, successful, failed, and locked status. A state-based flow-through test control system is implemented. Before testing equipment at the current workstation, a two-level state query and judgment process is performed: Level 1: The status of all preceding workstations is queried. Testing at the current workstation is only allowed if all preceding workstations are in a successful state; otherwise, the process is blocked and a warning is issued. Level 2: The existing status of the equipment at the current workstation is queried. Testing is only allowed if the status is "failed" or "not tested." If the status is "successful" or "locked," testing is prohibited. If the number of failed tests at the current workstation reaches a preset threshold, a failure lock is reported. If the equipment's dwell time in the production process exceeds the limit, a dwell lock is reported. Locked equipment must be repaired and unlocked before it can be retested.

[0006] As a further aspect of the present invention, the method further includes verifying the status of all workstations after the equipment completes all preset workstation tests; if all are successful, the process is determined to be completed; if any status is unsuccessful, the equipment is intercepted and the process is transferred to maintenance.

[0007] As a further aspect of the present invention, after entering the maintenance process, the unlocked equipment is directly repaired; for the locked equipment, an unlocking operation must be performed first. The unlocking methods include: unlocking only a specific workstation, unlocking the entire process and retesting from the first workstation, or unlocking the subsequent process from a designated workstation; when unlocking, the locked workstation, reason, result and number of times must be recorded; the equipment that has completed the process is randomly inspected according to preset rules, and if the random inspection fails, it is relocked and the maintenance unlocking process is entered.

[0008] As a further aspect of the present invention, the interactive interface between the test station and the test equipment is deployed on one or more control terminals on the production line; the control terminal is a physically independent PC or a logically independent software process; multiple test stations can be deployed on the same PC or distributed across multiple different PCs according to physical layout or functional modules.

[0009] As a further aspect of the present invention, each of the control terminals has the ability to connect to and control one or more test devices; during production testing, a single control terminal can be configured to connect to and sequentially test only one device, or it can be configured to connect to multiple devices simultaneously and use time-slice polling or parallel processing mechanisms to perform concurrent testing on these devices in order to improve the overall throughput of the production line.

[0010] As a further aspect of the present invention, before determining all preceding workstations, a workstation process sequence table is dynamically configured for each product model; the process sequence table defines the logical sequential dependencies between each test workstation.

[0011] As a further aspect of the present invention, the preset threshold for triggering the failure lock is the maximum number of test failures, and the preset threshold for triggering the retention lock is the maximum retention time; both the maximum number of test failures and the maximum retention time are configurable system parameters.

[0012] As a further aspect of the present invention, the method also includes generating and saving an operation log for each unlocking operation. The log content includes at least the operation time, operator, target device, unlocking method, unlocking station, and maintenance remarks.

[0013] Compared with the prior art, the beneficial effects of the present invention are: By assigning a globally unique identifier to each piece of equipment on the production line, unified management and tracking of different devices are achieved. Simultaneously, by dynamically combining test sub-items based on product model and mapping them to corresponding test stations, this method can adapt to the production needs of different products, enhancing its versatility.

[0014] By dynamically combining test items and flexibly arranging test stations, the specificity of process control methods is reduced, allowing the same process control method to be applied to various different production scenarios. In this invention, the combination of test items, the number of test stations, and the test sequence are all dynamically adjusted according to the product model, providing great flexibility in the layout of the production process. Production personnel can flexibly adjust the combination of test items and the arrangement of test stations according to actual production needs, thereby optimizing the production process and improving production efficiency.

[0015] Through state-based flow-through test control, the test results of equipment at each test station are rigorously evaluated. Only when all previous station statuses are successful is the equipment allowed to proceed to the current station for testing. Simultaneously, the existing status of the equipment at the current station is also assessed to ensure the accuracy and effectiveness of the test. Furthermore, when the number of equipment test failures reaches a preset threshold or the dwell time exceeds the limit, a failure lock or dwell lock is reported to ensure that problematic equipment is handled promptly. These measures collectively improve the quality of equipment throughout the production process. Attached Figure Description

[0016] Figure 1 This is a flowchart of a general production line process control method.

[0017] Figure 2 This is an application scenario diagram of a general production line process control method. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0019] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0020] like Figure 1 and Figure 2 As shown, this embodiment of the invention provides a general production line process control method, the method comprising the following steps: The first step is to assign a globally unique identifier to each piece of equipment on the production line, and then bind this identifier with the relevant information of the equipment and store it in the production database. The second step is to dynamically combine multiple test sub-items according to the product model and map them to the corresponding test stations; the combination method of test sub-items, the number of stations and the test order are dynamically adjusted according to the product model. The third step is to report and record the test results status to the database in real time after each test station completes the test; the test results status includes untested, successful, failed, and locked status. The fourth step involves implementing state-based flow-through test control. Before testing the equipment at the current workstation, a two-level state query and judgment process is performed: First, the status of all preceding workstations is queried. Testing at the current workstation is only permitted if all preceding workstations are in a successful state; otherwise, the process is blocked and a warning is issued. Second, the existing status of the equipment at the current workstation is queried. Testing is only permitted if the status is "failed" or "not tested." If the status is "successful" or "locked," testing is prohibited. If the number of failed tests at the current workstation reaches a preset threshold, a failure lock is reported. If the equipment's dwell time in the production process exceeds the limit, a dwell lock is reported. Locked equipment must be repaired and unlocked before it can be retested.

[0021] In this embodiment of the invention, each device has a unique code (UNIQUEID). After the device completes all preset workstation tests, the status of all workstations is verified. If all are successful, the process is considered complete. If any status is unsuccessful, the device is intercepted and transferred to the maintenance process. After entering the maintenance process, unlocked devices are directly repaired. For locked devices, an unlocking operation must be performed first. Unlocking methods include: unlocking only a specific workstation, unlocking the entire process and retesting from the first workstation, or unlocking subsequent processes starting from a specified workstation. During unlocking, the locked workstation, reason, result, and number of times must be recorded. Devices that have completed the process are randomly inspected according to preset rules. If the inspection fails, the device is relocked and transferred to the maintenance unlocking process.

[0022] The overall implementation process of this invention is as follows: S110. Import device unique code and attribute binding relationship into the database. The device unique code is used as a unique identifier for the device and will be bound together with other non-identifier codes, and imported into the database for production use.

[0023] S111. Test sub-items are incorporated into production workstations, and production workstations and processes are assigned. Since there are many test sub-items in the production process, these sub-items are merged into corresponding different test workstations according to their testing functions and convenience. Different test workstations are arranged on the production line according to a certain process sequence. Depending on the production testing needs, different test workstations can be deployed to different PCs individually, or they can all be deployed to the same PC.

[0024] S112. The production line begins testing on the equipment. Depending on the production testing needs, a single PC can be connected to only one device, or multiple devices can be connected simultaneously for testing.

[0025] S113. Obtain the test status of the previous station of the current equipment.

[0026] S114. Determine the test status. If successful, proceed to the next step; otherwise, proceed to S125 for repair or unlocking.

[0027] S115. Obtain the test status of the current station of the current device.

[0028] S116. Determine the test status. If it fails or is not tested, proceed to the next step; otherwise, proceed to S125 for repair or unlocking.

[0029] S117. The equipment performs functional testing and reports the test results status. The test results status of the current workstation of the current equipment is reported, serving as the basis for judgment at each workstation in the testing process.

[0030] S118. Test whether the entire process is complete. If not, proceed to S113; if complete, proceed to the next step.

[0031] S119. Check the test status of all workstations on the equipment. This is the final step in the testing process; perform a final check of the test status of all workstations.

[0032] S120: Are all workstation statuses successful? If all are successful, proceed to the next step; if not all are successful, proceed to S125 for repair or unlocking.

[0033] S121. Has the equipment been selected for random inspection? If selected, proceed to S122 for random inspection; otherwise, continue to the next step.

[0034] S123, Test complete.

[0035] S124. Random inspection test to see if the test was successful. If the test is successful, proceed to S123; if it fails, proceed to S125 for repair or unlocking.

[0036] S125. Repair or unlock. Repair or unlock devices that have failed tests or are locked.

[0037] S126. Determine if the repair or unlocking was successful. If successful, proceed to S112 to continue testing; if unsuccessful, proceed to S127.

[0038] S127, Exiting after failure.

[0039] In this embodiment of the invention, the interaction interface between the test station and the test equipment is deployed on one or more control terminals on the production line. The control terminal is a physically independent PC or a logically independent software process. Multiple test stations can be deployed on the same PC or distributed across multiple different PCs according to the physical layout or functional modules. This deployment method supports dynamic adjustment without affecting the defined test logic and data flow.

[0040] In this embodiment of the invention, each control terminal has the ability to connect to and control one or more test devices. During production testing, a single control terminal can be configured to connect to and sequentially test only one device, or it can be configured to connect to multiple devices simultaneously and perform concurrent testing on these devices using time-slice polling or parallel processing mechanisms to improve the overall throughput of the production line. Before determining all preceding workstations, a workstation process sequence table is dynamically configured for each product model; the process sequence table defines the logical dependencies between each test workstation; when performing a preceding status query, the system dynamically determines the set of all direct and indirect preceding workstations for the current workstation based on this table.

[0041] In this embodiment of the invention, the preset threshold for triggering the failure lock is the maximum number of test failures, and the preset threshold for triggering the dwell lock is the maximum dwell time; the maximum number of test failures and the maximum dwell time are both configurable system parameters, and the configuration system supports setting independent thresholds for different product models, different test stations, or the entire production line.

[0042] In this embodiment of the invention, the method further includes generating and saving an operation log for each unlocking operation. The log content includes at least the operation time, operator, target device, unlocking method, unlocking station, and maintenance remarks.

[0043] In this embodiment of the invention, the sampling inspection rule is either based on a production input ratio or based on production testing time. After all processes are completed, the corresponding globally unique identifier, all workstation status records in the complete testing process, test timestamps, and final conclusions are packaged and persistently stored in the historical database. This archived data is used for subsequent product quality traceability, production report statistics, and process analysis.

[0044] The above description only details the preferred embodiments of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0045] It should be understood that although the steps in the flowcharts of the various embodiments of the present invention are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the various embodiments may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these sub-steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least a portion of the sub-steps or stages of other steps.

[0046] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The program can be stored in a non-volatile computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), Rambus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0047] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the disclosure in the specification and embodiments. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the claims.

Claims

1. A general production line process control method, characterized in that, The method includes the following steps: Assign a globally unique identifier to each piece of equipment on the production line, and then bind the identifier with the relevant equipment information and store it in the production database; Based on the product model, multiple test sub-items are dynamically combined according to the test logic and mapped to the corresponding test stations; the combination method of test sub-items, the number of stations, and the test order are dynamically adjusted according to the product model. After each test station completes the test, the test result status is reported to the database in real time and recorded; the test result status includes untested, successful, failed, and locked status. A state-based flow-through test control system is implemented. Before testing equipment at the current workstation, a two-level state query and judgment process is performed: Level 1: The status of all preceding workstations is queried. Testing at the current workstation is only allowed if all preceding workstations are in a successful state; otherwise, the process is blocked and a warning is issued. Level 2: The existing status of the equipment at the current workstation is queried. Testing is only allowed if the status is "failed" or "not tested." If the status is "successful" or "locked," testing is prohibited. If the number of failed tests at the current workstation reaches a preset threshold, a failure lock is reported. If the equipment's dwell time in the production process exceeds the limit, a dwell lock is reported. Locked equipment must be repaired and unlocked before it can be retested.

2. The general production line process control method according to claim 1, characterized in that, The method also includes verifying the status of all workstations after the equipment completes all preset workstation tests; if all are successful, the process is considered complete; if any status is unsuccessful, the equipment is intercepted and the process is transferred to maintenance.

3. The general production line process control method according to claim 2, characterized in that, After entering the maintenance process, repairs are carried out directly on the unlocked equipment; for locked equipment, an unlocking operation must be performed first. Unlocking methods include: unlocking only a specific workstation, unlocking the entire process and retesting from the first workstation, or unlocking the subsequent processes starting from a designated workstation; when unlocking, the locked workstation, reason, result, and number of times must be recorded; for equipment that has completed the process, random checks are performed according to preset rules. If the random check fails, the equipment is relocked and the maintenance unlocking process is initiated.

4. The general production line process control method according to claim 1, characterized in that, The interface between the test station and the test equipment is deployed on one or more control terminals on the production line. The control terminal is a physically independent PC or a logically independent software process. Multiple test stations can be deployed on the same PC or distributed across multiple different PCs, depending on the physical layout or functional modules.

5. The general production line process control method according to claim 4, characterized in that, Each of the control terminals has the ability to connect to and control one or more test devices. During production testing, a single control terminal can be configured to connect to and sequentially test only one device, or it can be configured to connect to multiple devices simultaneously and use time-slice polling or parallel processing mechanisms to perform concurrent testing on these devices in order to improve the overall throughput of the production line.

6. The general production line process control method according to claim 1, characterized in that, Before determining all the preceding workstations, a workstation process sequence table will be dynamically configured for each product model; the process sequence table defines the logical dependencies between each test workstation.

7. The general production line process control method according to claim 1, characterized in that, The preset threshold for triggering the failure lock is the maximum number of test failures, and the preset threshold for triggering the retention lock is the maximum retention time; both the maximum number of test failures and the maximum retention time are configurable system parameters.

8. The general production line process control method according to claim 3, characterized in that, The method also includes generating and saving an operation log for each unlocking operation. The log content includes at least the operation time, operator, target equipment, unlocking method, unlocking station, and maintenance remarks.

9. The general production line process control method according to claim 3, characterized in that, The sampling inspection rules are based on either the production input ratio or the production testing time.

10. The general production line process control method according to claim 3, characterized in that, Once the process is complete, the corresponding globally unique identifier, all workstation status records in the complete test process, test timestamps, and final conclusions will be packaged and persistently stored in the historical database.

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