Production quality traceability analysis method and system based on operation data

Abstract

The application discloses a production quality traceability analysis method and system based on operation data, relates to the technical field of production quality traceability, and comprises the following steps: analyzing the defect type distribution approximation degree between different historical defect detection records in a factory, analyzing the defect correlation degree between production equipment and historical defect products in a defect record set, and obtaining key production equipment; obtaining defect detection records of the factory in a current period, analyzing the defect type distribution similarity degree between the defect detection records and the defect record set, obtaining the equipment operation records of the key production equipment of the similar defect record set in the current period, tracing the production quality of the defect products in the defect detection records, and obtaining target production equipment; obtaining production plan data of the target production equipment in the current period, dispatching maintenance personnel of the factory to overhaul the target production equipment, and optimizing and adjusting product production lines in the factory.

Description

Technical Field

[0001] This invention relates to the field of production quality traceability technology, specifically to a production quality traceability analysis method and system based on operational data. Background Technology

[0002] The quality of products produced in a factory determines the foundation of a company's development and survival. Factories need to rework or scrap defective products, which greatly increases the total cost of production and processing. In addition, a large number of defective products in the factory production process will affect customers' trust in the factory, causing customers to leave. In some cases, the factory may even face huge compensation claims due to major safety accidents caused by users using defective products.

[0003] Currently, the main method for tracing the production quality of products manufactured in factories is to assign batch numbers to the products and record information such as production time to achieve batch-by-batch traceability. However, this method leads to difficulties in integrating batch information and relies on manual recording and scanning, which is prone to errors, especially in high-speed production. Furthermore, the root cause of product quality problems often lies with the industrial equipment used in the production process. However, current equipment analysis of industrial equipment only uses thresholds to determine whether there are problems with the equipment, failing to effectively combine product production quality traceability analysis with equipment operation data. This not only wastes a lot of time and energy in inspecting the production chain but also fails to effectively solve product production quality problems. Summary of the Invention

[0004] The purpose of this invention is to provide a production quality traceability analysis method and system based on operational data to solve the problems raised in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a production quality traceability analysis method based on operational data, the method comprising:

[0006] Step S100: Obtain historical defect detection records in the factory, analyze the degree of similarity in defect type distribution among different historical defect detection records in the factory, and collect historical defect detection records with similar product defect distribution to obtain a defect record set;

[0007] Step S200: Obtain the production equipment and production batch information of historical defective products in the defect record set; based on the production batch information, obtain the historical equipment operation records of the production equipment; analyze the degree of defect correlation between the production equipment and the historical defective products in the defect record set to obtain the key production equipment.

[0008] Step S300: Obtain the factory's defect detection records in the current cycle, analyze the similarity of defect type distribution between the defect detection records and the defect record set to obtain a similar defect record set, obtain the equipment operation records of the key production equipment in the similar defect record set in the current cycle, trace the production quality of defective products in the defect detection records, and obtain the target production equipment.

[0009] Step S400: Obtain the production plan data of the target production equipment in the current cycle, dispatch the factory's maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory.

[0010] Furthermore, step S100 includes:

[0011] Step S101: Obtain all historical defect detection records of the factory, wherein the historical products detected in each historical defect detection record are all of the same product model;

[0012] Obtain the total number M of historical defective products with detected defects from a specific historical defect detection record. sum Obtain the total number A of historical products inspected in a specific historical defect inspection record, and calculate the product defect ratio B = M for that historical defect inspection record. sum / A;

[0013] Step S102: When the product defect ratio is greater than the preset threshold, it is determined that there is a defect in a certain historical product in a certain historical defect detection record, and the certain historical defect detection record is retained; otherwise, the certain historical defect detection record is removed.

[0014] Step S103: Obtain several retained historical defect detection records, and obtain the total number of historical defective products corresponding to each defect type from the retained historical defect detection records;

[0015] The total number of historical defective products corresponding to a certain defect type in the historical defect detection record is obtained, and the ratio of this number to the number of each detected historical product in the historical defect detection record is used to obtain the type proportion of a certain defect type in the historical defect detection record. When the type proportion of a certain defect type is greater than a preset proportion threshold, the certain defect type is recorded as the target defect type in the historical defect detection record. Several target defect types in the historical defect detection record are obtained and aggregated according to the size of the type proportion to obtain the target defect type set.

[0016] Step S104: Obtain the target defect type set of several historical defect detection records, and obtain the target defect type set U of the retained b-th historical defect detection record. bObtain the target defect type set U of the retained c-th historical defect detection record. c Among them, the target defect type set U b With the target defect type set U c Among the first k target defect types, there are identical target defect types, where k is a preset value. The analysis focuses on the similarity in defect type distribution between the b-th historical defect detection record and the c-th historical defect detection record. The specific analysis process is as follows:

[0017] Calculate the approximate defect value D between the b-th historical defect detection record and the c-th historical defect detection record. (b,c) =(U c ∩U b ) / (U c ∪U b When the defect approximation D (b,c) If the defect type is greater than the preset defect approximation threshold, the defect type distribution between the b-th historical defect detection record and the c-th historical defect detection record is determined to be approximately similar.

[0018] Acquire several historical defect detection records that have a similar defect type distribution to the b-th historical defect detection record and aggregate them to obtain a defect record set. Then, extract several target defect types with the same type from the top k target defect types of the several historical defect detection records in the defect record set, and denote these several target defect types as the key target defect types of the defect record set.

[0019] Furthermore, step S200 includes:

[0020] Step S201: Obtain the factory's defect record set, obtain several historical defect detection records from the defect record set, and obtain the historical defect products whose defect types are the same as the key target defect types in the defect record set from the several historical defect detection records;

[0021] Step S202: Obtain the production batch information of each historical defective product, and based on the production batch information, obtain the historical equipment operation records of the production equipment that processed the product batch to which the historical defective product belongs, and record them as marked historical equipment operation records;

[0022] Obtain the historical equipment operation records of each marked production equipment, and obtain the product defect rate of the historical products produced by each marked historical equipment operation record. The product defect rate is the ratio of the number of historical defective products to the number of historical products in the batch of products processed by the historical marked historical equipment operation records.

[0023] The average values ​​of various operating parameters of the production equipment are obtained from the operation records of each marked historical equipment, and then aggregated to obtain the marked parameter set of the production equipment;

[0024] Step S203: Obtain several historical equipment operation records of the production equipment, wherein the product type of the historical products processed by the production equipment in the several historical equipment operation records is the same as the historical defective products, and the product defect rate of the historical products obtained from the several historical equipment operation records is less than a preset threshold.

[0025] The average values ​​of various operating parameters are obtained from several historical equipment operation records and recorded as the reference values ​​for the production equipment.

[0026] Step S204: Analyze the degree of defect correlation between the key target defect types of production equipment and historical defective products in the defect record set. The specific analysis process is as follows:

[0027] Calculate the characteristic value F = |EE′| / E′ of the operating parameters in the marked historical equipment operation records in the marked parameter set, where E is the average value of the operating parameters in the marked historical equipment operation records, and E′ is the reference value of the operating parameters in the production equipment;

[0028] Obtain the correlation value r between the operating parameters of the production equipment and the defect type of the key target;

[0029] Obtain the defect correlation values ​​between various operating parameters of the production equipment and the defect types of critical targets, and calculate the defect correlation value L = max{r} between the production equipment and the defect types of critical targets. i Let r = {i = 1, 2, ..., m}, where m is the total number of operating parameters of the production equipment, and r = ... i This is the correlation value between the i-th operating parameter of the production equipment and the type of critical target defect;

[0030] When the defect association value L is greater than the preset defect association threshold, it is determined that there is a defect association between the production equipment and the key target defect type in the defect record set, and the production equipment is recorded as the key production equipment of the key target defect type in the defect record set;

[0031] Obtain several operating parameters of critical production equipment whose defect correlation values ​​are greater than the defect correlation threshold, and record these operating parameters as critical operating parameters of critical production equipment.

[0032] Furthermore, step S300 includes:

[0033] Step S301: Obtain the factory's defect detection records in the current cycle, wherein the products detected in the defect detection records have the same product model as the historical defective products in the defect record set, and obtain the defect record sets for each product model;

[0034] Step S302: Obtain several defective products from the defect detection records within the current cycle of the factory, and obtain the key target defect type corresponding to each defect record set;

[0035] When the proportion of a certain key target defect type in a certain defect record set is greater than the preset proportion threshold among the defect types of several defective products, it is determined that the defect detection record is similar to the defect type distribution of a certain defect record set, and the certain defect record set is recorded as a similar defect record set.

[0036] Step S303: Trace the production quality of defective products to obtain the target production equipment. The specific process is as follows:

[0037] Obtain the sets of similar defect records from the defect detection records, and obtain the equipment operation records of the key production equipment in the current cycle from the sets of similar defect records;

[0038] The average value of each key operating parameter of the key production equipment is obtained from the equipment operation record. The comparison value of each key operating parameter of the key production equipment is obtained. The characteristic value of each key operating parameter of the key production equipment in the equipment operation record is obtained. When the characteristic value of a certain key operating parameter is greater than the preset threshold, the key production equipment is identified as the target production equipment.

[0039] Furthermore, step S400 includes:

[0040] Step S401: Obtain the production plan data of each target production equipment in the current cycle, and obtain the planned quantity and planned production time of the products to be produced and processed by the target production equipment in the current cycle from the production plan data;

[0041] Step S402: Dispatch factory maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory. The specific optimization and adjustment process is as follows:

[0042] Find the production equipment whose processing procedures are the same as those of the target production equipment in the current cycle. When the ratio of the planned quantity of products to the planned production time of the production equipment is less than the production rate threshold of the production equipment, it is determined that the production equipment has the auxiliary capability to the production of the target production equipment. The production equipment is recorded as the auxiliary production equipment of the target production equipment. The products that the target production equipment plans to produce are transported to the auxiliary production equipment, and the auxiliary production equipment produces and processes the products.

[0043] The above steps not only involve repairing the target production equipment, but also take into account that the target production equipment cannot continue to process products during the repair process. Therefore, by acquiring auxiliary production equipment for the target production equipment, the auxiliary production equipment can assist the target production equipment, thereby reducing the impact of equipment repair on the factory's production plan.

[0044] To better implement the above methods, a production quality traceability analysis system based on operational data is also proposed. The system includes a defect type approximation analysis module, a defect correlation analysis module, a production quality traceability module, and a production adjustment module.

[0045] The Defect Type Approximation Analysis Module is used to analyze the degree of similarity in the distribution of defect types among different historical defect detection records in the factory, and to collect historical defect detection records with similar product defect distribution states to obtain a defect record set.

[0046] The defect correlation analysis module is used to analyze the degree of defect correlation between production equipment and historical defective products in the defect record set to identify key production equipment.

[0047] The production quality traceability module is used to acquire the factory's defect detection records in the current cycle, and trace the production quality of defective products in the defect detection records based on the equipment operation records of key production equipment in the current cycle to obtain the target production equipment.

[0048] The production adjustment module is used to dispatch factory maintenance personnel to inspect and repair target production equipment, obtain production plan data for the target production equipment in the current cycle, and optimize and adjust the product production lines in the factory.

[0049] Furthermore, the defect type approximation analysis module includes a defect type division unit and a defect type approximation analysis unit;

[0050] The defect type classification unit is used to classify the defect types in the historical defect detection records according to the type ratio of the defect types in the historical defect detection records, so as to obtain the target defect type;

[0051] The defect type approximation analysis unit is used to analyze the degree of approximation of defect type distribution among different historical defect detection records, and to aggregate several historical defect detection records with similar defect type distributions to obtain a defect record set.

[0052] Furthermore, the defect correlation analysis module includes a parameter set acquisition unit and a defect correlation analysis unit;

[0053] The parameter set acquisition unit is used to obtain the average value of various operating parameters of the production equipment from the various marked historical equipment operation records of the production equipment, and to collect them to obtain the marked parameter set of the production equipment.

[0054] The defect correlation analysis unit is used to analyze the degree of defect correlation between production equipment and key target defect types in the defect record set, and to identify key production equipment.

[0055] Furthermore, the production quality traceability module includes a similarity analysis unit and a production quality traceability unit;

[0056] The similarity analysis unit is used to analyze the similarity of defect type distribution between defect detection records and defect record sets in the factory, and to obtain similar defect record sets.

[0057] The production quality traceability unit is used to obtain the equipment operation records of key production equipment in the current cycle of similar defect record sets, trace the production quality of defective products in the defect detection records, and obtain the target production equipment.

[0058] Furthermore, the production adjustment module includes a production adjustment unit;

[0059] The production adjustment unit is used to acquire information on each target production equipment in the factory during the current cycle, and based on the production plan data of the target production equipment during the current cycle, dispatch the factory's maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production lines in the factory.

[0060] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention realizes intelligent traceability of product production quality during the factory production process. Considering that the defect conditions of different historical defective products in the historical defect detection records are different, the historical defect detection records with similar product defects are obtained to obtain a defect record set. Subsequently, by analyzing the production batch information of historical defective products in the defect record set, the production equipment that processed the historical defective products can be quickly identified. Because different defect record sets have different key target defect types, by obtaining the key production equipment of the defect record set, it is only necessary to perform defect type detection on the defective products produced in the factory to quickly locate the corresponding key production equipment. By analyzing the operating status of the key production equipment in the current cycle, the production quality of the factory can be accurately traced to find the root cause of the production quality problem of the defective products, i.e., the target production equipment of this application. Furthermore, through equipment maintenance and product production line adjustment, the normal and efficient operation of factory production can be ensured to the greatest extent. Attached Figure Description

[0061] Figure 1This is a flowchart of the production quality traceability analysis method based on operational data according to the present invention;

[0062] Figure 2 This is a schematic diagram of the production quality traceability and analysis system based on operational data according to the present invention. Detailed Implementation

[0063] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0064] Example: Figures 1-2 As shown, the present invention provides a technical solution, a production quality traceability analysis method based on operational data, the method comprising:

[0065] Step S100: Obtain historical defect detection records in the factory, analyze the degree of similarity in defect type distribution among different historical defect detection records in the factory, and collect historical defect detection records with similar product defect distribution to obtain a defect record set;

[0066] Step S100 includes:

[0067] Step S101: Obtain all historical defect detection records of the factory, wherein the historical products detected in each historical defect detection record are all of the same product model;

[0068] Obtain the total number M of historical defective products with detected defects from a specific historical defect detection record. sum Obtain the total number A of historical products inspected in a specific historical defect inspection record, and calculate the product defect ratio B = M for that historical defect inspection record. sum / A;

[0069] Step S102: When the product defect ratio is greater than the preset threshold, it is determined that there is a defect in a certain historical product in a certain historical defect detection record, and the certain historical defect detection record is retained; otherwise, the certain historical defect detection record is removed.

[0070] Step S103: Obtain several retained historical defect detection records, and obtain the total number of historical defective products corresponding to each defect type from the retained historical defect detection records;

[0071] For example, the types of defects include product damage, product functional defects, etc.

[0072] The total number of historical defective products corresponding to a certain defect type in the historical defect detection record is obtained, and the ratio of this number to the number of each detected historical product in the historical defect detection record is used to obtain the type proportion of a certain defect type in the historical defect detection record. When the type proportion of a certain defect type is greater than a preset proportion threshold, the certain defect type is recorded as the target defect type in the historical defect detection record. Several target defect types in the historical defect detection record are obtained and aggregated according to the size of the type proportion to obtain the target defect type set.

[0073] Step S104: Obtain the target defect type set of several historical defect detection records, and obtain the target defect type set U of the retained b-th historical defect detection record. b Obtain the target defect type set U of the retained c-th historical defect detection record. c Among them, the target defect type set U b With the target defect type set U c Among the first k target defect types, there are identical target defect types, where k is a preset value. The analysis focuses on the similarity in defect type distribution between the b-th historical defect detection record and the c-th historical defect detection record. The specific analysis process is as follows:

[0074] Calculate the approximate defect value D between the b-th historical defect detection record and the c-th historical defect detection record. (b,c) =(U c ∩U b ) / (U c ∪U b When the defect approximation D (b,c) If the defect type is greater than the preset defect approximation threshold, the defect type distribution between the b-th historical defect detection record and the c-th historical defect detection record is determined to be approximately similar.

[0075] For example, U c ={a,b,c,e,f,g},U b ={e,k,p,r,a,b}, calculate the approximate defect value D between the b-th historical defect detection record and the c-th historical defect detection record. (b,c) =3 / 9 = 1 / 3;

[0076] Obtain several historical defect detection records with a defect type distribution similar to the b-th historical defect detection record and aggregate them to obtain a defect record set. Obtain several target defect types with the same type from the first k target defect types of several historical defect detection records in the defect record set, and denote these several target defect types as the key target defect types of the defect record set.

[0077] Step S200: Obtain the production equipment and production batch information of historical defective products in the defect record set; based on the production batch information, obtain the historical equipment operation records of the production equipment; analyze the degree of defect correlation between the production equipment and the historical defective products in the defect record set to obtain the key production equipment.

[0078] Step S200 includes:

[0079] Step S201: Obtain the factory's defect record set, obtain several historical defect detection records from the defect record set, and obtain the historical defect products whose defect types are the same as the key target defect types in the defect record set from the several historical defect detection records;

[0080] Step S202: Obtain the production batch information of each historical defective product, and based on the production batch information, obtain the historical equipment operation records of the production equipment that processed the product batch to which the historical defective product belongs, and record them as marked historical equipment operation records;

[0081] For example, production batch information includes:

[0082] Product batch number / production date of historically defective products: This can determine which production batch the product belongs to and the specific time period during which it was produced;

[0083] The product's serial number can be used to obtain the production time, processing path, and production equipment of a single product.

[0084] Product defect types: including the specific types of defects in the product;

[0085] Obtain the historical equipment operation records of each marked production equipment, and obtain the product defect rate of the historical products produced by each marked historical equipment operation record. The product defect rate is the ratio of the number of historical defective products to the number of historical products in the batch of products processed by the historical marked historical equipment operation records.

[0086] The average values ​​of various operating parameters of the production equipment are obtained from the operation records of each marked historical equipment, and then aggregated to obtain the marked parameter set of the production equipment;

[0087] For example, various operating parameters include equipment voltage, equipment current, etc.

[0088] Step S203: Obtain several historical equipment operation records of the production equipment, wherein the product type of the historical products processed by the production equipment in the several historical equipment operation records is the same as the historical defective products, and the product defect rate of the historical products obtained from the several historical equipment operation records is less than a preset threshold.

[0089] The average values ​​of various operating parameters are obtained from several historical equipment operation records and recorded as the reference values ​​for the production equipment.

[0090] Step S204: Analyze the degree of defect correlation between the key target defect types of production equipment and historical defective products in the defect record set. The specific analysis process is as follows:

[0091] Calculate the characteristic value F = |EE′| / E′ of the operating parameters in the marked historical equipment operation records in the marked parameter set, where E is the average value of the operating parameters in the marked historical equipment operation records, and E′ is the reference value of the operating parameters in the production equipment;

[0092] For example, if the average value E of the operating parameters in the historical equipment operation records is 10, and the reference value E′ of the operating parameters in the production equipment is 20, then the characteristic value F of the operating parameters in the historical equipment operation records in the marked parameter set is calculated as F = |20-10| / 20 = 0.5.

[0093] Obtain the correlation value r between the operating parameters of the production equipment and the defect type of the key target;

[0094] For example, the formula for calculating the correlation value r between the operating parameters of production equipment and the type of critical target defect is:

[0095]

[0096] Where j is the total number of historical device operation records in the tag parameter set; F i G represents the characteristic value of the operating parameter of the i-th marked historical device operating record in the marked parameter set; i G represents the product defect rate of historical products produced by the i-th marked historical equipment operation record; △ The average product defect rate of historical products produced by each marked historical equipment operation record; F △ This is the average value of the characteristic values ​​of the operating parameters in the operating records of each marked historical device.

[0097] Obtain the defect correlation values ​​between various operating parameters of the production equipment and the defect types of critical targets, and calculate the defect correlation value L = max{r} between the production equipment and the defect types of critical targets. i Let r = {i = 1, 2, ..., m}, where m is the total number of operating parameters of the production equipment, and r = ... i This is the correlation value between the i-th operating parameter of the production equipment and the type of critical target defect;

[0098] When the defect association value L is greater than the preset defect association threshold, it is determined that there is a defect association between the production equipment and the key target defect type in the defect record set, and the production equipment is recorded as the key production equipment of the key target defect type in the defect record set;

[0099] Obtain several operating parameters of critical production equipment whose defect correlation values ​​are greater than the defect correlation threshold, and record these operating parameters as critical operating parameters of critical production equipment;

[0100] Step S300: Obtain the factory's defect detection records in the current cycle, analyze the similarity of defect type distribution between the defect detection records and the defect record set to obtain a similar defect record set, obtain the equipment operation records of the key production equipment in the similar defect record set in the current cycle, trace the production quality of defective products in the defect detection records, and obtain the target production equipment.

[0101] Step S300 includes:

[0102] Step S301: Obtain the factory's defect detection records in the current cycle, wherein the products detected in the defect detection records have the same product model as the historical defective products in the defect record set, and obtain the defect record sets for each product model;

[0103] Step S302: Obtain several defective products from the defect detection records within the current cycle of the factory, and obtain the key target defect type corresponding to each defect record set;

[0104] When the proportion of a certain key target defect type in a certain defect record set is greater than the preset proportion threshold among the defect types of several defective products, it is determined that the defect detection record is similar to the defect type distribution of a certain defect record set, and the certain defect record set is recorded as a similar defect record set.

[0105] Step S303: Trace the production quality of defective products to obtain the target production equipment. The specific process is as follows:

[0106] Obtain the sets of similar defect records from the defect detection records, and obtain the equipment operation records of the key production equipment in the current cycle from the sets of similar defect records;

[0107] The average value of each key operating parameter of the key production equipment is obtained from the equipment operation record. The comparison value of each key operating parameter of the key production equipment is obtained. The characteristic value of each key operating parameter of the key production equipment in the equipment operation record is obtained. When the characteristic value of a certain key operating parameter is greater than the preset threshold, the key production equipment is determined to have an impact on the production quality of the product in the current cycle. The key production equipment is recorded as the target production equipment.

[0108] Step S400: Obtain the production plan data of the target production equipment in the current cycle, dispatch the factory's maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory;

[0109] Step S400 includes:

[0110] Step S401: Obtain the production plan data of each target production equipment in the current cycle, and obtain the planned quantity and planned production time of the products to be produced and processed by the target production equipment in the current cycle from the production plan data;

[0111] Step S402: Dispatch factory maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory. The specific optimization and adjustment process is as follows:

[0112] Find the production equipment whose processing procedures are the same as those of the target production equipment in the current cycle. When the ratio of the planned quantity of products to the planned production time of the production equipment is less than the production rate threshold of the production equipment, it is determined that the production equipment has the auxiliary capability to the production of the target production equipment. The production equipment is recorded as the auxiliary production equipment of the target production equipment. The products that the target production equipment plans to produce are transported to the auxiliary production equipment, and the auxiliary production equipment produces and processes the products.

[0113] To better implement the above methods, a production quality traceability analysis system based on operational data is also proposed. The system includes a defect type approximation analysis module, a defect correlation analysis module, a production quality traceability module, and a production adjustment module.

[0114] The Defect Type Approximation Analysis Module is used to analyze the degree of similarity in the distribution of defect types among different historical defect detection records in the factory, and to collect historical defect detection records with similar product defect distribution states to obtain a defect record set.

[0115] The defect correlation analysis module is used to analyze the degree of defect correlation between production equipment and historical defective products in the defect record set to identify key production equipment.

[0116] The production quality traceability module is used to acquire the factory's defect detection records in the current cycle, and trace the production quality of defective products in the defect detection records based on the equipment operation records of key production equipment in the current cycle to obtain the target production equipment.

[0117] The production adjustment module is used to dispatch factory maintenance personnel to inspect and repair target production equipment, obtain production plan data for the target production equipment in the current cycle, and optimize and adjust the product production lines in the factory.

[0118] The defect type approximation analysis module includes a defect type division unit and a defect type approximation analysis unit.

[0119] The defect type classification unit is used to classify the defect types in the historical defect detection records according to the type ratio of the defect types in the historical defect detection records, so as to obtain the target defect type;

[0120] The defect type approximation analysis unit is used to analyze the degree of approximation of defect type distribution among different historical defect detection records, and to aggregate several historical defect detection records with similar defect type distributions to obtain a defect record set;

[0121] The defect correlation analysis module includes a parameter set acquisition unit and a defect correlation analysis unit.

[0122] The parameter set acquisition unit is used to obtain the average value of various operating parameters of the production equipment from the various marked historical equipment operation records of the production equipment, and to collect them to obtain the marked parameter set of the production equipment.

[0123] The defect correlation analysis unit is used to analyze the degree of defect correlation between production equipment and key target defect types in the defect record set to identify key production equipment.

[0124] The production quality traceability module includes a similarity analysis unit and a production quality traceability unit.

[0125] The similarity analysis unit is used to analyze the similarity of defect type distribution between defect detection records and defect record sets in the factory, and to obtain similar defect record sets.

[0126] The production quality traceability unit is used to obtain the equipment operation records of key production equipment in the current cycle of similar defect record sets, trace the production quality of defective products in the defect detection records, and obtain the target production equipment.

[0127] The production adjustment module includes a production adjustment unit;

[0128] The production adjustment unit is used to acquire information on each target production equipment in the factory during the current cycle, and based on the production plan data of the target production equipment during the current cycle, dispatch the factory's maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production lines in the factory.

[0129] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A production quality traceability analysis method based on operational data, characterized in that, The method includes: Step S100: Acquire historical defect detection records in the factory, analyze the degree of similarity in defect type distribution among different historical defect detection records in the factory, and collect historical defect detection records with similar product defect distribution to obtain a defect record set; Step S200: Obtain the production equipment and production batch information of historical defective products in the defect record set; based on the production batch information, obtain the historical equipment operation records of the production equipment; analyze the degree of defect correlation between the production equipment and the historical defective products in the defect record set to obtain the key production equipment. Step S300: Obtain the defect detection records of the factory in the current cycle, analyze the similarity of the defect type distribution between the defect detection records and the defect record set to obtain a similar defect record set, obtain the equipment operation records of the key production equipment in the similar defect record set in the current cycle, trace the production quality of the defective products in the defect detection records to obtain the target production equipment; Step S400: Obtain the production plan data of the target production equipment in the current cycle, dispatch the maintenance personnel of the factory to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory; Step S200 includes: Step S201: Obtain the defect record set of the factory, obtain several historical defect detection records from the defect record set, and obtain each historical defect product whose defect type is the same as the key target defect type in the defect record set from the several historical defect detection records; Step S202: Obtain the production batch information of each historical defective product, and based on the production batch information, obtain the historical equipment operation record of the production equipment that processes the product batch to which the historical defective product belongs, and record it as a marked historical equipment operation record; Obtain each marked historical equipment operation record of the production equipment, and obtain the product defect rate of the historical products produced by each marked historical equipment operation record, wherein the product defect rate is the ratio between the number of historical defective products and the number of historical products in the batch of products processed by the marked historical equipment operation record; The average values ​​of various operating parameters of the production equipment are obtained from the operation records of each marked historical equipment, and then aggregated to obtain the marked parameter set of the production equipment; Step S203: Obtain several historical equipment operation records of the production equipment, wherein the product type of the historical products processed by the production equipment in the several historical equipment operation records is the same as the historical defective products, and the product defect rate of the historical products obtained from the several historical equipment operation records is less than a preset threshold. The average value of each operating parameter is obtained from the aforementioned historical equipment operation records and recorded as the reference value for the production equipment; Step S204: Analyze the degree of defect correlation between the production equipment and the key target defect types of historical defective products in the defect record set. The specific analysis process is as follows: Calculate the characteristic value F=|EE´| / E´ of the operating parameters in the marked historical equipment operation records in the marked parameter set, where E is the average value of the operating parameters in the marked historical equipment operation records, and E´ is the reference value of the operating parameters in the production equipment; Obtain the correlation value r between the operating parameters of the production equipment and the critical target defect type; Obtain the defect correlation values ​​between the various operating parameters of the production equipment and the defect type of the critical target, and calculate the defect correlation value L = max{r} between the production equipment and the defect type of the critical target. i r, i = 1, 2, ..., m, where m is the total number of operating parameters of the production equipment, r i The correlation value between the i-th operating parameter of the production equipment and the critical target defect type; When the defect association value L is greater than the preset defect association threshold, it is determined that the production equipment has a defect association with the key target defect type in the defect record set, and the production equipment is recorded as the key production equipment of the key target defect type in the defect record set. Obtain several operating parameters of the key production equipment whose defect correlation value is greater than the defect correlation threshold, and record the several operating parameters as the key operating parameters of the key production equipment; Step S300 includes: Step S301: Obtain the defect detection records of the factory in the current cycle, wherein the products detected in the defect detection records have the same product model as the historical defective products in the defect record set, and obtain each defect record set with the product model. Step S302: Obtain several defective products of the factory in the current cycle from the defect detection records, and obtain the key target defect type corresponding to each defect record set; When the proportion of a certain key target defect type in a certain defect record set to the defect types of several defective products is greater than a preset proportion threshold, it is determined that the defect detection record is similar to the defect type distribution of the certain defect record set, and the certain defect record set is recorded as a similar defect record set. Step S303: Trace the production quality of the defective products to obtain the target production equipment. The specific process is as follows: Obtain each set of similar defect records from the defect detection records, and obtain the equipment operation records of the key production equipment in the current cycle from the set of similar defect records; The average value of each key operating parameter of the key production equipment is obtained from the equipment operation record. The comparison value of each key operating parameter of the key production equipment is obtained. The characteristic value of each key operating parameter of the key production equipment in the equipment operation record is obtained. When the characteristic value of a certain key operating parameter is greater than a preset threshold, it is determined that the key production equipment has an impact on the production quality of the product in the current cycle, and the key production equipment is recorded as the target production equipment.

2. The production quality traceability analysis method based on operational data according to claim 1, characterized in that, Step S100 includes: Step S101: Obtain the historical defect detection records of the factory, wherein the historical products detected in each historical defect detection record are all of the same product model; Obtain the total number M of historical defective products with detected defects from a specific historical defect detection record. sum Obtain the total number A of historical products detected in a specific historical defect detection record, and calculate the product defect ratio B=M of that historical defect detection record. sum / A; Step S102: When the product defect ratio is greater than a preset threshold, it is determined that there is a defect in a certain historical product in a certain historical defect detection record, and the certain historical defect detection record is retained; otherwise, the certain historical defect detection record is removed. Step S103: Obtain several retained historical defect detection records, and obtain the total number of historical defective products corresponding to each defect type from the retained historical defect detection records; The total number of historical defective products corresponding to a certain defect type in the historical defect detection record is obtained, and the ratio of this number to the number of each detected historical product in the historical defect detection record is used to obtain the type proportion of the certain defect type in the historical defect detection record. When the type proportion of the certain defect type is greater than a preset proportion threshold, the certain defect type is recorded as the target defect type of the historical defect detection record. Several target defect types in the historical defect detection record are obtained and aggregated according to the size of the type proportion to obtain the target defect type set. Step S104: Obtain the target defect type set of the plurality of historical defect detection records, and obtain the target defect type set U of the retained b-th historical defect detection record. b Obtain the target defect type set U of the retained c-th historical defect detection record. c The target defect type set U b With the target defect type set U c Among the first k target defect types, there are identical target defect types, where k is a preset value. The analysis focuses on the degree of similarity in defect type distribution between the b-th historical defect detection record and the c-th historical defect detection record. The specific analysis process is as follows: Calculate the approximate defect value D between the b-th historical defect detection record and the c-th historical defect detection record. (b,c) =(U c ∩U b ) / (U c ∪U b When the defect approximation D (b,c) If the defect type distribution is greater than the preset defect approximation threshold, it is determined that the defect type distribution of the b-th historical defect detection record and the c-th historical defect detection record are approximately similar. Acquire several historical defect detection records that have a similar defect type distribution to the b-th historical defect detection record and aggregate them to obtain a defect record set. Obtain several target defect types with the same type from the first k target defect types of the several historical defect detection records in the defect record set, and record these several target defect types as the key target defect types of the defect record set.

3. The production quality traceability analysis method based on operational data according to claim 2, characterized in that, Step S400 includes: Step S401: Obtain the target production equipment of the factory in the current cycle, obtain the production plan data of the target production equipment in the current cycle, and obtain the planned quantity and planned production time of the products to be produced and processed by the target production equipment in the current cycle from the production plan data; Step S402: Dispatch maintenance personnel from the factory to inspect and repair the target production equipment, and optimize and adjust the product production line in the factory. The specific optimization and adjustment process is as follows: The production equipment whose processing steps are the same as the target production equipment in the current cycle is identified. When the ratio of the planned quantity of products to the planned production time of the production equipment is less than the production rate threshold of the production equipment, it is determined that the production equipment has the ability to assist the production of the target production equipment. The production equipment is then recorded as the auxiliary production equipment of the target production equipment. The products that the target production equipment plans to produce are transported to the auxiliary production equipment, where the auxiliary production equipment performs the production and processing.

4. A production quality traceability analysis system based on operational data, used to execute the production quality traceability analysis method based on operational data as described in any one of claims 1-3, characterized in that, The system includes a defect type approximation analysis module, a defect correlation analysis module, a production quality traceability module, and a production adjustment module; The defect type approximation analysis module is used to analyze the degree of approximation of defect type distribution among different historical defect detection records in the factory, and to collect historical defect detection records with similar product defect distribution states to obtain a defect record set. The defect correlation analysis module is used to analyze the degree of defect correlation between production equipment and historical defective products in the defect record set to identify key production equipment. The production quality traceability module is used to acquire the defect detection records of the factory in the current cycle, and trace the production quality of defective products in the defect detection records based on the equipment operation records of key production equipment in the current cycle to obtain the target production equipment. The production adjustment module is used to dispatch maintenance personnel from the factory to inspect the target production equipment, obtain the production plan data of the target production equipment in the current cycle, and optimize and adjust the product production line in the factory.

5. The production quality traceability analysis system based on operational data according to claim 4, characterized in that, The defect type approximation analysis module includes a defect type division unit and a defect type approximation analysis unit; The defect type classification unit is used to classify the defect types in the historical defect detection records according to the type ratio of the defect types in the historical defect detection records, so as to obtain the target defect type. The defect type approximation analysis unit is used to analyze the degree of approximation of defect type distribution among different historical defect detection records, and to aggregate several historical defect detection records with similar defect type distributions to obtain a defect record set.

6. The production quality traceability analysis system based on operational data according to claim 4, characterized in that, The defect correlation analysis module includes a parameter set acquisition unit and a defect correlation analysis unit; The parameter set acquisition unit is used to obtain the average value of various operating parameters of the production equipment from the various marked historical equipment operation records of the production equipment, and to collect them to obtain the marked parameter set of the production equipment. The defect correlation analysis unit is used to analyze the degree of defect correlation between the production equipment and the key target defect types in the defect record set, and to obtain the key production equipment.

7. The production quality traceability analysis system based on operational data according to claim 4, characterized in that, The production quality traceability module includes a similarity analysis unit and a production quality traceability unit; The similarity analysis unit is used to analyze the similarity of defect type distribution between defect detection records and defect record sets in the factory to obtain a similar defect record set. The production quality traceability unit is used to obtain the equipment operation records of the key production equipment in the current cycle of the similar defect record set, trace the production quality of defective products in the defect detection records, and obtain the target production equipment.

8. The production quality traceability analysis system based on operational data according to claim 4, characterized in that, The production adjustment module includes a production adjustment unit; The production adjustment unit is used to acquire information on each target production equipment in the factory during the current cycle, and based on the production plan data of the target production equipment during the current cycle, dispatch the factory's maintenance personnel to inspect and repair the target production equipment, and optimize and adjust the product production lines in the factory.

Images