A digital system and its operation method for improving manufacturing quality in C2B manufacturing

Abstract

This invention patent provides a digital system and its operation method for improving manufacturing quality in C2B manufacturing. It uses a handheld terminal equipped with a quality inspection app to collect data, which is then analyzed and processed in real-time by a server. Quality issues are accurately categorized and alerted to responsible parties, and a closed-loop system for problem containment is completed based on WeChat and a large data dashboard. This system can effectively address quality issues occurring in the workshop, providing real-time and precise intervention and containment, thus significantly improving manufacturing quality.

Description

Technical Field

[0001] This invention relates to a digital system for automobile manufacturing and its operating method, and more particularly to a digital system for improving manufacturing quality in C2B manufacturing and its operating method, belonging to the technical field of vehicle automation control. Background Technology

[0002] In existing large-scale, multi-variety C2B automotive manufacturing, frontline inspectors lack practical quality inspection tools and rely solely on knowledge accumulated through offline training. This is insufficient to handle the quality inspection work of high-volume, high-paced, and complex product configurations on assembly lines, making it highly dependent on the individual inspectors' professional knowledge, skills, and judgment. Fluctuations in personnel can lead to fluctuations in manufacturing quality records (DRs). Furthermore, quality inspection results are recorded on paper, relying on human reading and writing abilities. Paper records are inefficient in both forward and backward feedback, resulting in delayed transmission and an inability to immediately identify responsible parties to curb escalation of problems. This can easily trigger a snowball effect, leading to ever-increasing remedial costs. Paper-based records also result in insufficient data transparency and analysis, poor data timeliness, and a lack of digital tools to support on-site manufacturing quality work. Summary of the Invention

[0003] This invention provides a digital system and its operation method for improving manufacturing quality in C2B manufacturing. It can solve quality problems that occur in the workshop in real time and accurately from exposure to pull and containment, effectively improving manufacturing quality.

[0004] To achieve the above objectives, the present invention provides a digital system for improving manufacturing quality in C2B manufacturing, characterized by comprising the following modules that are interconnected in communication:

[0005] Inspection terminal APP module: By scanning the vehicle's VIN code, the content and standards required for inspection at the current workstation are obtained, and the inspector is provided with these for comparison to generate a quality problem record;

[0006] Alarm module: Includes an alarm threshold setting submodule and an automatic frequency monitoring submodule, used to monitor the frequency of quality problems according to rule thresholds and generate alarm events.

[0007] The response module includes alarm delivery display and the responsible person's response, used to accurately send alarm events to the responsible person's WeChat and the administrator's large screen. The responsible person can directly respond and provide feedback on the WeChat mini program;

[0008] Automatic Quality Indicator Evaluation Module: Used to automatically calculate and evaluate process data in various dimensions on a daily, weekly, and monthly basis.

[0009] An operational method for a digital system to improve manufacturing quality in C2B manufacturing includes the following specific steps:

[0010] Step 1: The inspector uses a handheld terminal device equipped with the digital system app to scan the VIN barcode on the user's vehicle to directly retrieve the original configuration information of the user's vehicle. At different inspection stations, by scanning the VIN code on the chassis, the handheld terminal device automatically displays the process inspection items and standards corresponding to each configuration of the vehicle. The inspector visually compares the physical condition with the condition displayed on the handheld device and gives instructions to meet or comply with the requirements.

[0011] If it is determined to be non-compliant, a quality problem record is directly generated, which includes at least the current shift, workshop workstation, location, defect type, level, and responsible department information. The data is transmitted to the alarm server to generate an alarm. If it is determined to be compliant, the next item of the inspection will be displayed in the APP for comparison.

[0012] Step 2: Configure rules for alarm triggering. The rules define several alarm levels, each level including minimum and maximum thresholds and the corresponding alarm sender.

[0013] Step 3: Based on the quality problem data generated in Step 1 and the rule base set in Step 2, monitor independently through multiple threads on the server whether the frequency of occurrence reaches the rule threshold.

[0014] Step 4: Based on the alarm event generated in Step 3, the server asynchronously pushes it to the WeChat Official Account. The WeChat Official Account will obtain the openid of the responsible recipient in the Official Account based on the recipient's mobile phone number to achieve accurate template message push.

[0015] Step 5: Based on the mini-program ID and alarm event ID in the WeChat official account message received in Step 4, jump to the corresponding WeChat mini-program to view the alarm event; the responsible recipient directly fills in the handling measures and saves them to the server through the WeChat mini-program; the server traces back to the source of the quality problem and distributes the measures to the inspector's handheld terminal, the on-site large screen, and the corresponding manager's WeChat.

[0016] Step 6: Based on the collected data of the responsible person's response actions in Step 5, including response time and completion time, automatically calculate the response rate for alarm events, using this as a process control point; at the same time, based on the quality problem data generated in Step 1, automatically calculate the quality evaluation index DR according to the time dimensions of daily, weekly, and monthly.

[0017] Furthermore, in step 1, the original configuration information of the user vehicle comes from the enterprise order system, and the process inspection items matched by the configuration come from a preset process database.

[0018] The inspection stations include at least the body delivery station, painting delivery station, interior 1 station, interior 2 station, exterior lining station, chassis station, electronics and electrical station, final assembly delivery station, rain-drying drum station, four-wheel alignment station, and final delivery station.

[0019] Furthermore, in step 2, the rule has five levels, which correspond to engineer level, manager level, senior manager level, factory manager level, and general manager level in charge, from low to high.

[0020] Furthermore, the associated personnel are identified by their mobile phone numbers.

[0021] Furthermore, the specific process of step 3 is as follows: First, obtain all quality problem records in the current shift from step 1, and count them according to frequency, level, and responsibility; match them according to the rule base set in step 2, and generate an alarm event when the count is greater than or equal to the min threshold or less than or equal to the max threshold in the rule; if the current shift ends, the count is reset to zero and restarted for the next shift.

[0022] Furthermore, the shift schedule is a preset parameter, with a maximum of three shifts per day: morning, noon, and evening, and each shift is counted independently.

[0023] Furthermore, the responsible recipient needs to register a WeChat official account in advance using the mobile phone number set in step 2.

[0024] Compared with the prior art, the beneficial effects of this invention patent are:

[0025] 1. In contrast to tools that lack quality inspection capabilities, this system not only provides mobile handheld terminals as inspection tools for inspectors, but also offers advantages over fixed equipment, such as greater flexibility, lack of site restrictions, and more convenient human-computer interaction.

[0026] 2. This system achieves automatic, multi-level, and precise alarm triggering by clearly defining the dimensions of the problem, such as frequency, level, and responder, and by leveraging the computing power of the server.

[0027] 3. Through the standardization of the entire process, this system realizes the digitization of quality issues and the automatic calculation of quality indicators (DR), thereby achieving the goal of digital and automated evaluation of manufacturing quality. Attached Figure Description

[0028] Figure 1 This is a flowchart of the present invention.

[0029] Figure 2 This is a flowchart of step 1 of the present invention.

[0030] Figure 3 This is a flowchart of step 3 of the present invention.

[0031] Figure 4 This is a flowchart of step 4 of the present invention.

[0032] Figure 5 This is a flowchart of step 5 of the present invention.

[0033] Figure 6 This is a schematic diagram of the present invention. Detailed Implementation

[0034] To enable those skilled in the art to better understand the solutions of the embodiments of the present invention, the examples of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0035] Step 1: Inspectors use handheld devices equipped with the system's app to scan the VIN barcode on the vehicle, directly retrieving the vehicle's original configuration information. At different inspection stations, the system automatically displays the corresponding process inspection items for each configuration. The inspector issues a pass or fail instruction. If a fail is determined, a quality issue record is directly generated. Note: The original configuration information for the user's vehicle comes from the order system. The process inspection items matched to the configuration come from a pre-set database.

[0036] Step 2: Configure rules for alarm triggering, and set the trigger threshold and associated alarm path for each rule level. The associated personnel are identified by their mobile phone numbers. The five alarm levels, from lowest to highest, correspond to Engineer, Manager, Senior Manager, Factory Manager, and General Manager in Charge. See Table 1 for details.

[0037]

[0038] Table 1

[0039] Step 3: Based on the quality problem database generated in Step 1 and the rule base set in Step 2, monitor them independently using multiple threads on the server.

[0040] First, retrieve all quality issue records from the current shift in Step 1 and count them by frequency, severity, and responsibility. Then, match the count against the rule set in Step 2. If the count is greater than or equal to the minimum threshold or less than or equal to the maximum threshold in the rule, an alarm event is generated. If the current shift ends, the count is reset to zero for the next shift. Note: Shifts are preset parameters; a maximum of three shifts (morning, afternoon, and evening) are allowed per day, and each shift is counted independently.

[0041] Step 4: Based on the alarm event generated in Step 3, the server asynchronously pushes the message to the WeChat Official Account. The Official Account will obtain the recipient's openid from their mobile phone number, enabling precise template message delivery. Note: The recipient must have registered and followed the Official Account using the mobile phone number set in Step 2.

[0042] Step 5: Based on the mini-program ID and alarm event ID received in Step 4, you can jump to the corresponding WeChat mini-program to view the alarm event. The responsible person directly fills in the measures, which are saved to the server via the WeChat mini-program. The server traces the source of the quality problem and distributes the measures to the inspector's handheld terminal, the on-site large screen, and the corresponding manager's WeChat. The mini-program ID clearly identifies the application that will carry out subsequent actions. The alarm event ID clearly identifies the specific alarm event that was opened.

[0043] Step Six: Based on the collected data of the responsible person's response actions (response time, completion time, etc.) from Step Five, automatically calculate the response rate for alarm events, using this as a process indicator. Simultaneously, based on the quality issue data generated in Step One, automatically calculate the quality evaluation index (DR) according to daily, weekly, and monthly time dimensions.

[0044] Based on the control logic diagram shown above, the structure, features, and effects of the present invention have been described in detail. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, shall not exceed the scope covered by the specification and figures and shall be within the protection scope of the present invention.

Claims

1. A digital system for improving manufacturing quality in C2B manufacturing, characterized in that: The following modules are interconnected and inspected: the terminal APP module: by scanning the vehicle's VIN code, the content and standards that need to be inspected at the current workstation are obtained, and the inspector is provided with them for comparison to generate a quality problem record; Alarm module: Includes an alarm threshold setting submodule and an automatic frequency monitoring submodule, used to monitor the frequency of quality problems according to preset alarm triggering rules and generate alarm events. The alarm triggering rules define several alarm levels associated with organizational levels. Each level includes minimum and maximum thresholds and the corresponding alarm sender. The organizational levels from low to high correspond to engineer level, manager level, senior manager level, factory manager level, and general manager in charge level. Response module: Includes alarm delivery display and responsible person's response. It is used to accurately send alarm events to the responsible person's WeChat and the manager's large screen according to the alarm level. The responsible person can directly respond and provide feedback on the WeChat mini program. Automatic Quality Indicator Evaluation Module: Used to automatically calculate and evaluate process data in various dimensions on a daily, weekly, and monthly basis.

2. An operation method of a digital system for improving manufacturing quality in C2B manufacturing according to claim 1, characterized in that, The specific steps include the following: Step 1: The inspector uses a handheld terminal device equipped with the digital system app to scan the VIN barcode on the user's vehicle to directly retrieve the original configuration information of the user's vehicle. At different inspection stations, by scanning the VIN code on the chassis, the handheld terminal device automatically displays the process inspection items and standards corresponding to each configuration of the vehicle. The inspector visually compares the physical condition with the condition displayed on the handheld device and gives instructions for compliance or non-compliance. If it is determined to be non-compliant, a quality problem record is directly generated, which includes at least the current shift, workshop workstation, location, defect type, level, and responsible department information. The data is transmitted to the alarm server to generate an alarm. If it is determined to be compliant, the next item of the inspection will be displayed in the APP for comparison. Step 2: Configure rules for alarm triggering. The rules define several alarm levels, each level including minimum and maximum thresholds and the corresponding alarm sender. Step 3: Based on the quality problem data generated in Step 1 and the rule base set in Step 2, monitor the frequency of occurrence independently through multiple threads on the server to see if it reaches the threshold of the rules. Step 4: Based on the alarm event generated in Step 3, the server asynchronously pushes it to the WeChat Official Account. The WeChat Official Account will obtain the openid of the responsible recipient in the Official Account based on the recipient's mobile phone number to achieve accurate template message push. Step 5: Based on the mini-program ID and alarm event ID in the WeChat official account message received in Step 4, jump to the corresponding WeChat mini-program to view the alarm event; the responsible recipient directly fills in the handling measures and saves them to the server through the WeChat mini-program. The server traces the source of quality problems in reverse and distributes measures to the inspectors' handheld terminals, on-site large screens, and the corresponding managers' WeChat accounts. Step 6: Based on the collected data of the responsible person's response actions in Step 5, including response time and completion time, automatically calculate the response rate for alarm events, using this as a process control point; at the same time, based on the quality problem data generated in Step 1, automatically calculate the quality evaluation index DR according to the time dimensions of daily, weekly, and monthly.

3. The method of operating a digital system for improving manufacturing quality in C2B manufacturing according to claim 2, characterized in that: In step 1, the original configuration information of the user vehicle comes from the enterprise order system, and the process inspection items matched by the configuration come from the preset process database.

4. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 2, characterized in that: In step 1, the inspection stations include at least the body delivery station, painting delivery station, interior 1 station, interior 2 station, exterior 2 station, chassis station, electronics and electrical station, final assembly delivery station, rain-drying drum station, four-wheel alignment station, and final delivery station.

5. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 2, characterized in that: In step 2, the rule has five levels, which correspond to engineer level, manager level, senior manager level, factory manager level and general manager level in charge, from low to high.

6. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 4, characterized in that: The associated personnel are identified by their mobile phone numbers.

7. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 2, characterized in that: The specific process of step 3 is as follows: First, obtain all quality problem records in the current shift from step 1, and count them according to frequency, level, and responsibility; match them according to the rule base set in step 2, and generate an alarm event when the count is greater than or equal to the min threshold or less than or equal to the max threshold in the rule; if the current shift ends, the count is reset to zero and restarted for the next shift.

8. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 6, characterized in that: The shift schedule is a preset parameter, with a maximum of three shifts per day: morning, noon, and evening, and each shift is counted independently.

9. The method of operating the digital system for improving manufacturing quality in C2B manufacturing according to claim 4, characterized in that: The responsible recipient needs to register a WeChat official account in advance using the mobile phone number set in step 2.

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