MES-based large discrete equipment manufacturing quality traceability management system

Abstract

The invention discloses an MES-based large discrete equipment manufacturing quality traceability management system, and relates to large discrete equipment manufacturing, and the system comprises the steps: enabling production equipment of a production field to be connected to an MES system, and collecting the state of process-level production equipment and workpiece quality data in real time; collected human, machine and material information is integrated with a QIS system, the incidence relation between product structure data and quality inspection standards is established, full-process tracing of product key elements, the production process and quality information is achieved, and transparent management is conducted on the whole production process. The system can well solve the quality tracing management problem of a production site, is reasonable in design and simple and convenient to operate, remarkably improves the quality management efficiency, and reduces the rejection rate and the workload of quality management personnel.

Description

Technical Field

[0001] The present invention relates to the manufacturing of large discrete equipment, and particularly to a quality traceability management system for the manufacturing of large discrete equipment based on MES. Background Art

[0002] The statements in this section only provide background information related to the present disclosure and may not constitute prior art.

[0003] The MES system (Manufacturing Execution System) is one of the key systems for modern manufacturing enterprises to manage the production process. It integrates a series of functions such as enterprise production planning and scheduling, quality control, equipment management, and material management, aiming to achieve the intelligence and high efficiency of the production process.

[0004] The quality traceability system needs to be able to achieve forward and backward product quality traceability, form traceability for the quality data of each product, including blank quality data, processing process quality data, and completed quality data, form reports, and perform certain analysis on the reports. Currently, there are generally problems with the consistency and standardization of process data throughout the factory, manifested in insufficient informatization coverage of quality data, incomplete traceability data, inconsistent identification, and lack of a unified traceability platform. The existing problems include:

[0005] 1. Multiple head management and abstract monitoring of production operations: For production, quality, logistics and other operations, managers of each department need to monitor through inspections. After an anomaly occurs, decisions and handling are made through collaborative processes. The management process relies on the experience and subjective judgment of personnel, and the handling process is often after the fact, lacking overall control and error correction capabilities for the entire production process.

[0006] 2. Difficulty in internal traceability management: When problem tracing, improvement analysis, or business performance evaluation is required, the granularity and standardization degree of data in each department vary greatly, the relevance is weak, and a large amount of manual statistics and analysis processes are required. The depth and scope of traceability are limited, and the timeliness is weak, resulting in management decisions tending to be qualitative analysis and continuous improvement lacking data support.

[0007] 3. High management cost for external output data management: When delivering product process files according to customer requirements, the responsible department needs to collect process data from the source, including incoming material information, processing process and quality data, assembly and test data, etc. The data record forms provided by each department may have different formats, and the information may be incorrect, missing, requiring the responsible department to repeatedly sort, confirm, and revise, resulting in high management costs and there is also a risk of file errors and omissions. Summary of the Invention

[0008] The objective of the present invention is: in view of the problems existing in the prior art, to provide a quality traceability management system for large-scale discrete equipment manufacturing based on MES, which solves the above problems.

[0009] The technical solution of the present invention is as follows:

[0010] A quality traceability management system for large-scale discrete equipment manufacturing based on MES, comprising:

[0011] Connect the production equipment at the production site to the MES system, and collect the status of process-level production equipment and workpiece quality data in real time;

[0012] Integrate the collected information of people, machines, and materials with the QIS system, establish the correlation relationship between product structure data and quality inspection standards, realize the full-process traceability of key product elements, production processes, and quality information, and conduct transparent management of the entire production process.

[0013] Further, the production equipment includes: a barcode scanner, a PDA, a workstation all-in-one machine, and a camera.

[0014] Further, it can realize forward and reverse product quality traceability, and form traceability for the quality data of each product.

[0015] Further, forming traceability for the quality data of each product includes:

[0016] Trace the blank quality data, processing process quality data, and completed quality data, form a report, and analyze the report.

[0017] Further, it includes the following functions:

[0018] Realize the traceability of quality inspection information during the production process by integrating with the QIS system, and can trace and query all quality data forward and backward according to product structure data;

[0019] Realize the query of full records of defects during the production process by integrating with the QIS system, and also provide a basis for subsequent process review and subsequent statistics;

[0020] Support the real-time query of inspection data at the production site;

[0021] Support the information traceability of products in both forward and reverse directions;

[0022] Provide the product electronic resume management function and query function, support multi-dimensional data query and summary; support manually arranging and publishing the product electronic resume according to the collected quality information;

[0023] Be able to give an alarm for abnormal results according to the inspection data combined with the standard data.

[0024] Furthermore, the product structure data includes: model, material, production batch, and process document.

[0025] Furthermore, it supports the traceability of product information in both forward and reverse directions, including:

[0026] The relationship between component assembly and production, processing process information, production quality information, and process exception information.

[0027] Furthermore, it supports multi-dimensional data query and summary, including:

[0028] It supports multi-dimensional data query and summary by project, product, order, serial number, and batch number.

[0029] Furthermore, the quality management module of the MES system receives the quality inspection results transmitted by the QIS system and traces the quality of the product.

[0030] Furthermore, the traceability of the product quality includes the following aspects:

[0031] Quality technical standard management, in-process quality inspection, final quality inspection, SPC control chart reception, quality traceability management, support for on-site actual measurement data collection, and quality prediction analysis and improvement.

[0032] Furthermore, the in-process quality inspection includes:

[0033] It supports different inspection business scenarios, online submission for inspection function, automatic sampling inspection, witness reminder, and process locking.

[0034] Furthermore, the quality traceability management includes:

[0035] It supports the function of tracing and querying quality information according to product structure data in both forward and reverse directions;

[0036] It supports the traceability of product information in both forward and reverse directions;

[0037] It provides the function of product electronic resume management;

[0038] The data collection methods include:

[0039] Integrate with inspection equipment or digital measurement tools to automatically obtain inspection data;

[0040] Integrate with the existing test systems in each workshop to obtain test data;

[0041] According to the defined inspection item requirements, the inspector manually enters the inspection results at the terminal;

[0042] Quality prediction analysis and improvement include: quality alarm, quality error prevention, and quality report.

[0043] The beneficial effects of the present invention compared with the existing technologies are as follows:

[0044] (1) Real-time traceability of quality information: It replaces the traditional production process record card that relies on post-event records and obtains quality information in a timely manner.

[0045] (2) Improvement of quality management efficiency: In-process inspection during the production process needs to comprehensively judge whether to release subsequent processing in combination with information such as technical requirements, processing environment, and materials. By collecting quality information in real time through the MES system, it automatically or helps quality personnel determine whether to release.

[0046] (3) Reduction of the scrap rate: By real-time monitoring of nonconforming product anomalies, timely restricting the transfer of nonconforming products, and avoiding quality accidents where products in the nonconforming product handling process flow into the next process. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a block diagram of a quality traceability management system for large-scale discrete equipment manufacturing based on MES;

[0048] Figure 2 It is a general diagram of the quality management and traceability process;

[0049] Figure 3 It is a general architecture diagram of the MES system. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0050] It should be noted that relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including a..." does not exclude the existence of additional identical elements in the process, method, article or device including the said element.

[0051] The features and performance of the present invention will be further described in detail below in conjunction with the embodiments.

[0052] Embodiment 1

[0053] Please refer to Figures 1-3 , a quality traceability management system for large-scale discrete equipment manufacturing based on MES, including:

[0054] Connect production equipment such as barcode scanners, PDAs, workstation all-in-one machines, and cameras at the production site to the MES system to collect data such as the status of process-level production equipment and workpiece quality in real time;

[0055] Integrate the collected information on people, machines, and materials with the QIS system, establish the association relationship between product structure data and quality inspection standards, realize the full-process traceability of key product elements, production processes, and quality information, conduct transparent management of the entire production process, and improve the intelligent level of production operations.

[0056] In this embodiment, it should be noted that the quality traceability management system needs to be able to achieve forward and backward product quality traceability, form traceability for the quality data of each product, including blank quality data, processing process quality data, and completed quality data, and form reports, and conduct certain analysis on the reports. For the welding branch factory, it also needs to include the traceability of information such as welds, welding materials, raw material welding parameters, and personnel qualifications. Through the traceability system, the factors affecting quality in the production process can be analyzed, problems can be found and processed and improved to continuously improve product quality.

[0057] In this embodiment, it should be noted that the quality traceability management system proposed in this embodiment can achieve effective traceability and management of quality and covers the following functions:

[0058] Realize the traceability of quality inspection information in the production process through integration with the QIS system, and be able to trace and query all quality data forward and backward according to product structure data; for example, all quality data can be traced and queried forward and backward according to product structure data through conditions such as model, material, production batch, and process document;

[0059] Realize the query of full records of defects in the production process through integration with the QIS system, and also provide a basis for subsequent process review and subsequent statistics;

[0060] Support the real-time query of inspection data at the production site;

[0061] Support forward and backward information traceability of products, including: component assembly and production relationships, processing process information, production quality information, and process exception information;

[0062] Provide product electronic resume management functions and query functions, support multi-dimensional data query and summary according to projects, products, orders, serial numbers, batch numbers, etc.; support manual compilation and release of product electronic resumes according to the collected quality information;

[0063] Be able to give an alarm for abnormal results according to inspection data combined with standard data.

[0064] In this embodiment, specifically, the quality management module of the MES system receives the quality inspection results transmitted by the QIS system and traces the quality of the products.

[0065] In this embodiment, specifically, tracing the quality of the products includes the following aspects:

[0066] Quality technical standard management: Realize the management of quality technical standards such as design standards, raw material standards, quality inspection standards, process standards, and ITP inspection plans. The quality technical standards are sourced from the design process three-dimensional integration platform;

[0067] Process quality inspection: The quality inspection information is structured; realize the control of the production process, including process inspection reporting; receiving and executing inspection results; realize the associated setting of quality inspection nodes (including on-site witness points) and processes, important node reminders, submission of on-site witness tasks, and process control of repair processes; specifically as follows:

[0068] 1. Support different inspection business scenarios such as incoming material inspection, in-process product inspection (including self-inspection, mutual inspection, special inspection, first-piece inspection, and patrol inspection), and finished product inspection;

[0069] 2. Support the online inspection submission function. Inspection tasks can be automatically sent to the terminals of relevant inspection personnel (special inspection personnel, metrology personnel) according to rules and can be assigned and received online for inspection tasks, realizing electronic inspection submission;

[0070] 3. If there are sampling requirements during the inspection process, support automatic sampling and guide the operators to conduct sampling inspections;

[0071] 4. For those with witnessing requirements, support witness reminders and process locking, and transmit the processing process information and quality information required for witnessing;

[0072] Final quality inspection: The final inspection application after the materials are completed, receiving inspection results (from QIS), triggering repair items or tasks, querying final inspection data, and receiving reports;

[0073] Receiving SPC control charts: Receive SPC charts from QIS and trace the quality status of each production stage;

[0074] Quality traceability management: Realize forward and backward product quality traceability, form traceability for the quality data of each product, including blank quality data, processing process quality data, and final quality data, and form reports and conduct certain analysis on the reports. For the welding branch factory, it is also necessary to include the traceability of information such as welds, welding materials, raw material welding parameters, and personnel qualifications; specifically as follows:

[0075] 1. Support the function of querying quality information by tracing forward and backward according to product structure data;

[0076] 2. Support the forward and reverse information traceability of products, including component assembly and production relationships, processing process information, production quality information, process exception information, etc.;

[0077] 3. Provide the function of product electronic resume management; support manually compiling and publishing product electronic resumes according to the collected quality information; support product electronic resume query, and support multi-dimensional data query and summary by project, product, order, serial number, batch number, etc.;

[0078] Support on-site actual measurement data collection; collection methods include:

[0079] Integrate with inspection equipment or digital measurement tools to automatically obtain inspection data;

[0080] Integrate with the existing test systems in each workshop to obtain test data;

[0081] According to the requirements of the defined inspection items, inspectors manually enter the inspection results at the terminal;

[0082] Quality prediction analysis and improvement: The system provides the ability of quality prediction analysis and improvement. The specific integration with inspection equipment or digital measurement tools to automatically obtain inspection data includes but is not limited to the following requirements:

[0083] Quality alarm: The system triggers quality exception warnings according to quality warning rules, and alarms through forms such as short message, email message push integration, and Andon integration, supports the monitoring of quality warnings, the handling and closing of warnings, and the automatic escalation of overdue unhandled warnings, etc.; supports functions such as quality alarm query, confirmation, and status modification.

[0084] Quality error prevention: Implement the quality error prevention function, verify the product matching relationship according to quality verification parameters, and avoid the occurrence of production failures. For example, scan the material information through functions such as QR code tracking. When there is a mismatch between the material and the order, prompt the material error in real time and do not accept the input of incorrect materials.

[0085] Quality reports: Generate various quality reports to help continuously monitor quality, analyze quality, and continuously improve. It can conduct correlation analysis in combination with production elements. Among them, quality reports include but are not limited to: order exception classification, quality exception details, quality exception count, responsible party statistics, unqualified product rate, etc.

[0086] Through on-site actual operations and feedback from workers, it is proved that this system can well solve the quality traceability management problem in the production site, and is reasonably designed and easy to operate, significantly improving the quality management efficiency and reducing the scrap rate and the workload of quality management personnel.

[0087] The above-described embodiments merely represent specific implementation manners of the present application. The description thereof is relatively specific and detailed, but it should not be construed as a limitation on the protection scope of the present application. It should be noted that for those of ordinary skill in the art, without departing from the concept of the technical solution of the present application, several variations and improvements can still be made, and these all fall within the protection scope of the present application.

[0088] This Background of the Invention section is provided to generally present the context of the present invention. Work of the presently named inventors, to the extent it is described in this Background of the Invention section, and work that is not prior art to the aspects of the present invention described in this section, is neither expressly nor impliedly admitted to be prior art to the present invention.

Claims

1. A large-scale discrete equipment manufacturing quality traceability management system based on MES, characterized by: include: Connect production equipment at the production site to the MES system to collect process-level production equipment status and workpiece quality data in real time; Integrate the collected information on people, machines and materials with the QIS system, establish the correlation between product structure data and quality inspection standards, realize full-process traceability of key product elements, production processes and quality information, and transparently manage the entire production process.

2. According to the MES-based large-scale discrete equipment manufacturing quality traceability management system of claim 1, it is characterized in that: The production equipment includes: a barcode scanner, a PDA, an all-in-one workstation and a camera.

3. According to the MES-based large-scale discrete equipment manufacturing quality traceability management system of claim 2, it is characterized in that: It can realize forward and reverse product quality traceability and trace the quality data of each product.

4. According to the MES-based large-scale discrete equipment manufacturing quality traceability management system of claim 3, it is characterized in that: Trace the quality data of each product, including: The rough quality data, processing quality data and finished quality data are traced, and reports are generated and analyzed.

5. The MES-based large-scale discrete equipment manufacturing quality traceability management system according to claim 4 is characterized in that: Features include: Through integration with the QIS system, the quality inspection information in the production process can be traced back and forth, and all quality data can be queried forward and backward according to the product structure data; Integration with the QIS system enables query of all defect records in the production process, and also provides a basis for subsequent process review and statistics; Support real-time query of production site inspection data; Supports forward and reverse product information tracing; Provide product electronic resume management and query functions, and support multi-dimensional data query and aggregation; Supports manual compilation and publishing of product electronic resumes based on collected quality information; Can give abnormal result alarm based on test data combined with standard data.

6. The MES-based large-scale discrete equipment manufacturing quality traceability management system according to claim 5 is characterized in that: Product structure data, including: model, material, production batch, and process documents.

7. The MES-based large-scale discrete equipment manufacturing quality traceability management system according to claim 5 is characterized in that: Supports product forward and reverse information traceability, including: Parts assembly and production relationship, processing information, production quality information, and process abnormality information.

8. The MES-based large-scale discrete equipment manufacturing quality traceability management system according to claim 6 is characterized in that: Supports multi-dimensional data query and aggregation, including: Supports multi-dimensional data query and summary by project, product, order, serial number, and batch number.

9. The MES-based large-scale discrete equipment manufacturing quality traceability management system according to claim 1 is characterized in that: The quality management module of the MES system receives the quality inspection results transmitted by the QIS system and traces the quality of the products.

10. A large-scale discrete equipment manufacturing quality traceability management system based on MES according to claim 9, characterized in that: Trace the quality of the product, including the following aspects: Quality technical standard management, process quality inspection, completion quality inspection, SPC control chart reception, quality traceability management, support for on-site measurement data collection and quality prediction analysis and improvement.

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