A tartary buckwheat tea quality improvement production process management method based on SPC technology

Abstract

The application discloses a method for improving the quality of tartary buckwheat tea based on SPC technology, which comprises the following steps: S100, determining the key steps that may affect the quality of tartary buckwheat tea according to the production process of tartary buckwheat tea; S200, collecting process data, drawing a histogram of the process data and analyzing the histogram; S300, performing process capability analysis according to the histogram and the analysis control chart, and judging whether the process is in a statistical steady state and whether the process capability is sufficient; S400, converting the analysis control chart into a control control chart, and finding and analyzing the reasons for the statistical out-of-control state; S500, repeating step S400 until the process reaches a statistical control state; and S600, continuously monitoring the production process by using the control control chart, eliminating the influence of the out-of-control state, and improving the quality of tartary buckwheat tea. The application can collect, analyze and monitor the production process data, find abnormal fluctuations in the process in time, eliminate the out-of-control factors by taking targeted measures, and realize the stable control of the process.

Description

Technical Field

[0001] This invention relates to a production process management method for improving the quality of buckwheat tea based on SPC technology, belonging to the field of buckwheat tea production technology. Background Technology

[0002] As a nutritious and healthy beverage, the quality and safety of buckwheat tea during its production process are of great concern. Aflatoxin and heavy metal contamination are significant factors affecting the quality and safety of buckwheat tea. Aflatoxin is a potent carcinogen, and the accumulation of heavy metals in the body can cause serious health hazards. Furthermore, the stability of the buckwheat tea production process directly impacts the consistency of product quality. Currently, the control of aflatoxin and heavy metals during buckwheat tea production relies heavily on post-production testing, making it difficult to detect and address problems in a timely manner during production, thus leading to higher product quality risks. Summary of the Invention

[0003] The purpose of this invention is to provide a production process management method for improving the quality of buckwheat tea based on SPC technology. This method can promptly detect abnormal fluctuations in the process by collecting, analyzing, and monitoring production process data, and take targeted measures to eliminate out-of-control factors, thereby achieving stable process control.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0005] A method for improving the quality of buckwheat tea production process based on SPC technology includes the following steps:

[0006] S100: Based on the production process of buckwheat tea, identify the key steps that may affect the quality of buckwheat tea; S200: Collect process data and plot histograms and control charts for analysis; S300: Perform process capability analysis based on the histograms and control charts to determine whether the process is in a statistical steady state and whether the process capability is sufficient; S400: Convert the control charts for analysis into control charts for control, and identify and analyze the causes of statistical runaway states; S500: Repeat step S400 until the process reaches a statistically controlled state; S600: Apply control charts for control to continuously monitor the production process, eliminate the impact of runaway states, and improve the quality of buckwheat tea.

[0007] By applying the aforementioned SPC technology to control harmful substances such as aflatoxin and heavy metals in the production of buckwheat tea, and combining it with SPC control of key quality-related indicators such as sensory indicators (e.g., color, aroma, taste) and physicochemical indicators (e.g., moisture content, ash content, flavonoid content), the optimal process parameter ranges, operating procedures, and monitoring requirements for each key step are summarized, forming a standardized production process document for buckwheat tea. This standardized production process can guide the standardized operation of the production process, achieve effective control over the entire production process, stabilize product quality, and ensure the consistency and safety of each batch of product.

[0008] The aforementioned method for improving the quality of buckwheat tea production process management based on SPC technology includes the following steps: S100, identifying key steps potentially susceptible to aflatoxin contamination based on the buckwheat tea production process; S200, collecting process data and plotting histograms and analytical control charts; S300, performing process capability analysis based on the histograms and analytical control charts to determine whether the process is in statistical steady state and whether its capability is sufficient; S400, converting the analytical control chart into a control chart, identifying and analyzing the causes of statistical runaway states; S500, repeating step S400 until the process reaches statistical control; S600, continuously monitoring the production process using the control chart to eliminate the impact of runaway states and ensure that the aflatoxin content in the buckwheat tea is below 5 μg / kg. The control chart is used to continuously monitor the production process, recording relevant data and aflatoxin content detection results for key steps according to the set monitoring frequency (at least per batch), and promptly plotting the data points on the control chart. If data points are found to exceed control limits or a non-random out-of-control pattern is observed, the anomaly handling procedure should be initiated immediately to analyze the cause of the out-of-control situation and take measures such as adjusting process parameters, strengthening equipment maintenance, and improving environmental conditions to eliminate the impact of the out-of-control state and ensure that the aflatoxin content in buckwheat tea is below 5 μg / kg.

[0009] In the aforementioned method for improving the quality of buckwheat tea production process based on SPC technology, step S100 further includes the following: The main conditions for aflatoxin contamination are the humidity of the buckwheat tea and the humidity of the environment. Based on the fact that higher humidity in both the buckwheat tea and the environment increases the probability of aflatoxin contamination, the raw material storage stage and the pre-processing stage of buckwheat tea are identified as key steps for aflatoxin contamination. Through on-site investigation, process document analysis, and expert consultation, key steps potentially susceptible to aflatoxin contamination, such as raw material storage, soaking, drying, and packaging, are identified. Process parameters (such as storage temperature, humidity, soaking time, drying temperature and time), environmental parameters (such as temperature and humidity of the production workshop, cleanliness, etc.), and corresponding aflatoxin content data for each key step are collected. Data collection follows random sampling principles to ensure data representativeness.

[0010] In the aforementioned method for improving the quality of buckwheat tea production process management based on SPC technology, the process data collected in step S200 refers to time, moisture content of buckwheat tea, and ambient temperature and humidity during production. Histograms are plotted using the collected data to visually represent the distribution of aflatoxin content. Analytical control charts, including XR and XS control charts, are also plotted. The control charts are used to determine whether the process is in a statistically stable state. If out-of-control points exist, the causes related to personnel operation, equipment operation, and environmental changes are investigated and rectified. Simultaneously, process capability analysis is performed, calculating process capability indices such as Cpk, Ppk, Ca, and Cp to determine if the process capability is sufficient to meet the aflatoxin content control requirements. The validated and stable analytical control charts are converted into control charts for subsequent process monitoring, continuously identifying and analyzing the causes of statistically out-of-control states until the process reaches a statistically controlled state.

[0011] In the aforementioned method for improving the quality of buckwheat tea production process management based on SPC technology, the method for determining whether the process is in a statistical steady state in step S300 is as follows: almost all data points fall within the control limits; the arrangement of data points shows no abnormal patterns; the method for determining whether the process capability is sufficient in step S300 is as follows: calculate the process capability index Cp: the calculation formula is Cp = T / (6σ), where T is the difference between the upper and lower limits of the specification. The larger the Cp value, the stronger the process capability. Cp ≥ 1.33 indicates good process capability.

[0012] In the aforementioned method for improving the quality of buckwheat tea production process management based on SPC technology, step S400, which involves converting the analytical control chart into a control chart, employs the following method: S410, collecting data and drawing the analytical control chart: In the initial stage of the production process, at least 25 subgroups are continuously collected, and an analytical control chart is drawn; S420, analyzing process stability: Using the outlier criteria of the control chart, the data points are analyzed to determine whether they fluctuate randomly within the control limits, thus determining whether the process is in a statistically controlled state, i.e., without abnormal factors and only with normal fluctuations; S430, assessing process capability: After confirming that the process has reached a statistical steady state, the process capability index is calculated; the inherent fluctuation of the process is assessed to determine whether it is small enough, i.e., it has reached a technical steady state; S440, formal handover and conversion: When the process is confirmed to have reached both statistical and technical steady states, a formal handover can be carried out; S450, entering daily monitoring: In the control chart stage, new production data is continuously collected and drawn on the chart.

[0013] The aforementioned method for improving the quality of buckwheat tea production process management based on SPC technology includes the following steps: S100, identifying key steps that may lead to heavy metal contamination based on the buckwheat tea production process; S200, collecting process data and plotting histograms and analytical control charts based on the process data; S300, performing process capability analysis based on the histograms and analytical control charts to determine whether the process is in a statistical steady state and whether the process capability is sufficient; S400, converting the analytical control charts into control charts to identify and analyze the causes of statistical runaway states; S500, repeating step S400 until the process reaches a statistically controlled state; S600, continuously monitoring the production process using control charts to eliminate the impact of runaway states and reduce the heavy metal content to below national standards.

[0014] A detailed understanding of the buckwheat tea production process was conducted to identify key steps that could lead to heavy metal contamination, such as raw material procurement, processing equipment contact, and production water. Data on the background heavy metal content in raw materials, the material and usage of processing equipment, the heavy metal content in production water, process parameters at each stage of production, and the heavy metal content of the final product were collected. Histograms and analytical control charts were created based on the collected data to analyze whether the process was in a statistically steady state. For out-of-control situations, the causes, such as raw material suppliers, equipment wear, and water pollution, were identified and rectified. Process capability analysis was conducted to assess the existing production process's ability to control heavy metal content. If the process capability was insufficient, key control steps in the production process were optimized. The analytical control charts were converted into control charts for actual production, and the process was continuously optimized until it reached a state of statistical control.

[0015] Control charts are used to continuously monitor the production process, and the heavy metal content of raw materials, production water, intermediate products, and final products is tested regularly. Relevant data are recorded and plotted on the control charts. Once an out-of-control situation is detected, the cause is investigated in a timely manner and corresponding corrective measures are taken, such as changing raw material suppliers, repairing or replacing processing equipment, and purifying production water, to reduce the risk of heavy metal contamination of buckwheat tea and ensure that the heavy metal content in buckwheat tea is reduced to below the national standard.

[0016] Compared with existing technologies, this invention can promptly detect abnormal fluctuations in the production process by collecting, analyzing, and monitoring production process data, and take targeted measures to eliminate uncontrollable factors, thus achieving stable process control. Applying SPC technology to the standardized production process of buckwheat tea, through process analysis and continuous monitoring, effectively controls harmful substances such as aflatoxin and heavy metals, ensuring that aflatoxin content is below 5 μg / kg and heavy metal content meets national standards, thereby improving product safety. Simultaneously, a standardized production process has been established, effectively stabilizing product quality and improving consistency. Furthermore, the application of SPC technology can promptly detect abnormal fluctuations in the production process, avoiding the generation of batches of substandard products, reducing production costs, and demonstrating significant economic and social benefits. Attached Figure Description

[0017] Figure 1 This is the Xbar-R control chart for aflatoxin before adjustment;

[0018] Figure 2 This is the adjusted Xbar-R control chart for aflatoxin;

[0019] Figure 3 This is the Xbar-R control chart of Pb before adjustment;

[0020] Figure 4 This is the Xbar-R control chart of Pb after adjustment;

[0021] Figure 5 This is the Xbar-R control chart of Cd before adjustment;

[0022] Figure 6 This is the Xbar-R control chart for Cd after adjustment. Detailed Implementation

[0023] Example 1: Application of SPC technology in aflatoxin control during buckwheat tea processing

[0024] (1) Process analysis stage:

[0025] A detailed investigation was conducted on the production process of buckwheat tea, identifying raw material storage, soaking, drying, and packaging as key steps potentially susceptible to aflatoxin contamination. Process parameters and aflatoxin content data for each key step in the production process were collected from 25 batches of products, with five samples randomly selected from each batch for testing.

[0026] Histograms were plotted using the collected data, showing that aflatoxin levels were mainly concentrated between 2-4 μg / kg. Control charts for XR analysis revealed that three data points exceeded the control limits, which was found to be caused by excessive humidity in the raw material storage environment. To address this issue, the humidity control equipment in the raw material storage workshop was adjusted to strictly control the humidity below 50%.

[0027] Process capability analysis revealed an initial process Cpk of 0.85 and Ca of 46.37, indicating insufficient process capability and a deviation. By optimizing the drying temperature and time parameters—increasing the drying temperature from 80℃ to 85℃ and extending the drying time from 2 hours to 2.5 hours—and collecting and analyzing data again, the process Cpk improved to 1.44 and Ca to 58.56, indicating that the process had reached statistical control. This analysis was then used as the control chart for further control.

[0028] (2) Monitoring phase:

[0029] The control charts described above were used to continuously monitor the subsequent 30 batches of production. For each batch, parameters such as raw material storage humidity, drying temperature and time, and aflatoxin content were recorded. During this period, two batches were found to have data points close to the control limits. Timely inspection revealed that this was due to unstable equipment operation; after equipment repair, the data returned to normal. The aflatoxin content of all 30 batches was below 5 μg / kg, with an average content of 2.8 μg / kg.

[0030] Example 2: Application of SPC technology in heavy metal control of buckwheat tea

[0031] (1) Process analysis stage:

[0032] The investigation identified raw material procurement, contact with processing equipment, and production water as key steps in buckwheat tea production that could lead to excessive levels of heavy metals. Data were collected on the background levels of heavy metals (lead, cadmium, mercury) in 20 batches of raw materials, the heavy metal content in production water, the operating time of processing equipment, and the heavy metal content in the finished products.

[0033] Control charts for XS analysis revealed an out-of-control state in the process, which was found to be caused by excessive lead content in some batches of raw materials. The solution was to change the raw material supplier, selecting materials with lower heavy metal content, and to strengthen incoming raw material inspection.

[0034] Process capability analysis was performed. Before optimization, Ppk = 0.79. After optimization, Ppk increased to 1.23, and the process reached statistical steady state, thus generating a control chart for control purposes.

[0035] (2) Monitoring phase:

[0036] Control charts were used to monitor the subsequent production process, and the heavy metal content of raw materials, production water, and products was tested for each batch. After 40 consecutive batches were monitored, the lead, cadmium, and mercury content in the products all met the requirements of GB 2762-2017 "National Food Safety Standard: Limits of Contaminants in Food," and no cases of heavy metal exceeding the limits were found.

[0037] Example 3: Application of SPC (Self-Process Control) technology in the standardized production process of buckwheat tea

[0038] Based on the application results of SPC technology in Examples 1 and 2, and combined with the SPC control data of sensory and physicochemical indicators of buckwheat tea, a standardized production process for buckwheat tea is summarized as follows:

[0039] Raw material procurement: Select buckwheat raw materials with low background heavy metal content. Upon entering the factory, the aflatoxin content is less than 2μg / kg and the heavy metal content meets the relevant standards.

[0040] Raw material storage: The storage temperature should be controlled at 15-20℃, the humidity should be controlled below 50%, and the storage time should not exceed 3 months;

[0041] Soaking: Use purified water for soaking, soaking time is 1-1.5 hours, soaking temperature is 25-30℃;

[0042] Drying: Drying temperature 85℃, drying time 2.5 hours, the moisture content of the product after drying is controlled below 8%;

[0043] Packaging: The packaging workshop has a cleanliness level of 100,000, the packaging materials meet the safety standards for food contact materials, and the packaging materials are promptly stored in the warehouse.

[0044] Fifty batches of buckwheat tea were produced according to this standardized production process. The aflatoxin content of the products was all below 5μg / kg, the heavy metal content met the national standards, the sensory and physicochemical indicators were consistent, and the product qualification rate reached 100%.

Claims

1. A method for managing the production process of buckwheat tea based on SPC technology to improve its quality, characterized in that, Includes the following steps: S100 identifies key steps that may affect the quality of buckwheat tea based on the production process. S200: Collect process data, plot histograms and control charts for analysis of the process data; S300: Based on histograms and analytical control charts, perform process capability analysis to determine whether the process is in a statistical steady state and whether the process capability is sufficient. S400 converts the analytical control chart into a control chart for control purposes, and finds and analyzes the causes of the out-of-control state. S500, repeat step S400 until the process reaches statistical control; The S600 uses control charts to continuously monitor the production process, eliminating the impact of out-of-control conditions and improving the quality of buckwheat tea.

2. The method for managing the production process of buckwheat tea quality improvement based on SPC technology according to claim 1, characterized in that, Includes the following steps: S100, based on the production process of buckwheat tea, identifies key steps that may be contaminated with aflatoxin; S200: Collect process data, plot histograms and control charts for analysis of the process data; S300: Based on histograms and analytical control charts, perform process capability analysis to determine whether the process is in a statistical steady state and whether the process capability is sufficient. S400 converts the analytical control chart into a control chart for control purposes, and finds and analyzes the causes of the out-of-control state. S500, repeat step S400 until the process reaches statistical control; S600 uses control charts to continuously monitor the production process, eliminating the impact of runaway states and ensuring that the aflatoxin content in buckwheat tea is below 5 μg / kg.

3. The method for improving the quality of buckwheat tea production process based on SPC technology according to claim 1, characterized in that, Step S100 also includes the following: The main conditions for aflatoxin infection are the humidity of buckwheat tea and the humidity of the environment. According to the fact that the higher the humidity of buckwheat tea and the humidity of the environment, the higher the probability of aflatoxin infection, the raw material storage stage and the pre-processing stage of buckwheat tea are identified as the key steps for aflatoxin infection.

4. The method for improving the quality of buckwheat tea production process based on SPC technology according to claim 1, characterized in that, The data collected in step S200 refers to time, the moisture content of buckwheat tea, and the ambient temperature and humidity during the production process.

5. The method for managing the production process of buckwheat tea quality improvement based on SPC technology according to claim 1, characterized in that, The determination of whether the process described in step S300 is in a statistical steady state is made by the following method: all data points fall within the control limits; the arrangement of data points shows no abnormal pattern. The method for determining whether the process capability is sufficient in step S300 is as follows: Calculate the process capability index Cp: The calculation formula is Cp = T / (6σ), where T is the difference between the upper and lower limits of the specification. The larger the Cp value, the stronger the process capability. Cp ≥ 1.33 indicates good process capability.

6. The method for improving the quality of buckwheat tea production process based on SPC technology according to claim 1, characterized in that, The method for converting the analysis control chart into a control chart for control purposes as described in step S400 is as follows: S410, Collect data and draw control charts for analysis: In the initial stage of the production process, continuously collect data from no less than 25 subgroups and draw control charts for analysis; S420, Analysis of process stability: Using the outlier criteria of control charts, analyze whether the data points fluctuate randomly within the control limits to determine whether the process is in a statistically controlled state, that is, without abnormal factors and only normal fluctuations. S430, Assess Process Capability: After confirming that the process has reached statistical steady state, calculate the process capability index; assess whether the inherent fluctuations of the process are small enough, i.e., if they are small enough, then technical steady state has been reached. S440, Formal handover and transition: Once the process is confirmed to have reached both statistical and technical steady states, a formal handover can be carried out. S450, Entering Daily Monitoring: During the control chart stage, new production data is continuously collected and plotted on the chart.

7. The method for improving the quality of buckwheat tea production process based on SPC technology according to claim 1, characterized in that, Includes the following steps: S100 identifies key steps in the production process of buckwheat tea that may lead to excessive heavy metal levels. S200: Collect process data, plot histograms and control charts for analysis of the process data; S300: Based on histograms and analytical control charts, perform process capability analysis to determine whether the process is in a statistical steady state and whether the process capability is sufficient. S400 converts the analytical control chart into a control chart for control purposes, and finds and analyzes the causes of the out-of-control state. S500, repeat step S400 until the process reaches statistical control; S600 uses control charts to continuously monitor the production process, eliminating the impact of out-of-control conditions and reducing the heavy metal content to below national standards.

Images