A method for checking and controlling consistency of environmental protection grades in a production process

Abstract

A method for verifying and controlling the consistency of environmental protection levels during the production process includes: Step 1: An environmental engineer determines the environmental protection level of materials and customer projects and records it in the MES system, generating a QR code with embedded data including the environmental protection level of the materials, and attaching a production process flow sheet containing the QR code to the materials; Step 2: During the material cutting and feeding process, a scanning device scans the QR code attached to the materials. The MES system determines whether the environmental protection level of the materials embedded in the QR code is consistent with the environmental protection level of the customer projects recorded in the MES system. If they are consistent, the MES system allows the material cutting operation to begin; Step 3: During the finished product shipping process, a scanning device scans the QR code affixed to the finished products. The MES system determines whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer projects recorded in the MES system. If they are consistent, the MES system allows the finished product shipping operation to begin. This invention improves production quality stability, increases production efficiency, reduces manpower input, and saves time.

Description

Technical Field

[0001] This invention relates to the field of polarizer production technology, and in particular to a method for verifying and controlling the consistency of environmental protection levels during the production process. Background Technology

[0002] With increasingly stringent global environmental regulations and the accelerated green transformation of the display industry, the polarizer industry faces increasingly stringent requirements for the control of hazardous substances, particularly with the continuous upgrading of EU RoHS and REACH regulations. Traditional control methods, which rely mainly on manual labor, suffer from problems such as delayed information transmission, insufficient data accuracy, and difficulties in traceability, making it difficult to meet the needs of modern enterprises for efficient and precise management.

[0003] Environmental labels on raw materials are affixed by suppliers, while those on semi-finished and finished products are affixed by internal IQC or production personnel. With so many people responsible, errors such as forgetting to affix or affixing the wrong environmental labels are very common. For materials from overseas, customs clearance issues prevent some materials from being labeled, thus failing to meet the QC080000 system requirements.

[0004] The MES system does not perform environmental protection level verification and control on shipments, and relies on manual verification of customer order information, which can easily lead to production accidents where the environmental protection level of the finished product does not meet the environmental protection level required by the customer.

[0005] Manually affixing environmental labels and verifying the environmental ratings of materials, semi-finished products, and finished products against customer requirements is not only time-consuming, labor-intensive, and inefficient, but also prone to errors and misjudgments, leading to production mistakes. Summary of the Invention

[0006] The technical problem to be solved by this invention is to overcome the defects in the existing technology and propose a method for verifying and controlling the consistency of environmental protection level in the production process. This method can completely avoid the discrepancy between the environmental protection level of the finished product and the environmental protection level of the customer's project, improve the stability of production quality, increase production efficiency, reduce manpower input, save time, realize the integration of environmental protection, quality and delivery, and reduce downtime.

[0007] To solve the above-mentioned technical problems, the present invention proposes the following technical solution: a method for verifying and controlling the consistency of environmental protection levels during the production process, comprising the following steps: Step 1: The environmental engineer assesses and determines the environmental grade of the material, records the environmental grade of the material in the MES system, generates a QR code with embedded data including the environmental grade of the material, prints out the production process flow sheet containing the QR code, and attaches the production process flow sheet to the material; The environmental engineer assesses and determines the environmental grade of the customer project according to the environmental requirements of the customer project, and records the environmental grade of the customer project in the MES system. Step 2: In the process of cutting and feeding materials, a scanning device scans the QR code on the production process flow sheet attached to the material. The scanning device reads the environmental protection level data of the material embedded in the QR code and transmits it to the MES system. The MES system determines whether the environmental protection level of the material embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the material cutting operation to start. If they are inconsistent or the MES system cannot read the environmental protection level data of the material embedded in the QR code, the MES system prohibits the material cutting operation from starting. Step 3: After the finished product is made from the material that the MES system allows to start the cutting operation, the production process flow sheet attached to the material becomes the production process flow sheet attached to the finished product. In the finished product shipping process, the QR code on the production process flow sheet attached to the finished product is scanned by a scanning device, the environmental protection level data embedded in the QR code is read and transmitted to the MES system. The MES system determines whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the finished product shipping operation to start. If they are inconsistent, the MES system prohibits the finished product shipping operation from starting.

[0008] A further limitation of the above technical solution is that the third-party testing report, material composition, content and raw material information of the material are entered into the OA system to apply for a material code. The environmental engineer evaluates and determines the environmental protection level of the material according to the prescribed environmental protection level definition and enters it into the OA system. The OA system transmits the environmental protection level information of the material to the SAP system and the SAP system transmits the environmental protection level information of the material to the MES system.

[0009] A further limitation of the above technical solution is that the environmental engineer assesses and determines the environmental level of the client project according to the client project's environmental requirements and the prescribed environmental level definition.

[0010] The above technical solution is further defined by the fact that the environmental protection level is divided into Grade A, Grade B and Grade C.

[0011] The above technical solution is further defined as follows: the environmental protection label corresponding to environmental protection level A is HSF; the environmental protection label corresponding to environmental protection level B or C is RoHS+HF.

[0012] A further limitation of the above technical solution is that the embedded data of the QR code also includes the environmental label of the material.

[0013] A further limitation of the above technical solution is that, in steps 2 and 3, the MES system issues an alarm prompt while prohibiting the initiation of material cutting operations and finished product shipping operations.

[0014] A further limitation of the above technical solution is that the scanning device is a barcode scanner.

[0015] A further limitation of the above technical solution is that the production process flow sheet is attached to the material by printing out a production process flow sheet containing the QR code using self-adhesive tape and then pasting the production process flow sheet onto the material.

[0016] A further limitation of the above technical solution is that the production process flow sheet is attached to the material in the following ways: the production process flow sheet containing the QR code is printed on ordinary paper, and the production process flow sheet is pasted onto the material with glue or double-sided tape, or the production process flow sheet is fixed onto the material with a stapler.

[0017] The present invention has the following beneficial effects: 1. The QR codes controlled by the OA system, SAP system, and MES system, along with their embedded environmental protection level data and the environmental protection level data of the customer project, cannot be altered during the material feeding and finished product shipping processes. The QR codes with embedded environmental protection level data are present throughout the entire production process, from raw materials to manufacturing, cutting, and shipping, ensuring full traceability. Each step in the aforementioned production process requires scanning the QR code, and the MES system verifies whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer project. The judgment is highly accurate and reliable, avoiding errors caused by relying on manual identification and judgment. It can completely prevent discrepancies between the environmental protection level of materials, finished products, and the environmental protection level of the customer project, improving the stability of production quality, increasing production efficiency, reducing manpower input, and saving time.

[0018] 2. The manual confirmation has been changed to system scanning, eliminating the need for personnel inspection, saving labor costs and improving accuracy. The time efficiency has been reduced from 1.4 hours (calculated according to 7 processes from incoming material inspection to outgoing inspection, with each process taking 20 minutes) to just 1 second (scanning takes 1 second).

[0019] 3. Achieve integrated functions of digital material environmental management system, with purchase ordering, incoming material inspection, and production scheduling all achieving "automatic comparison" through QR codes and MES system, realizing integrated environmental protection, quality and delivery, and reducing downtime. Detailed Implementation

[0020] To make the technical means, creative features, objectives, and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention.

[0021] This invention proposes a method for verifying and controlling the consistency of environmental protection levels during the production process, which includes the following steps: Step 1: Enter the raw material information, such as the third-party testing report, material composition, and content, into the OA system to apply for a material code. The environmental engineer will assess and determine the environmental grade of the material according to the prescribed environmental grade definition (e.g., divided into Grade A, Grade B, or Grade C) and enter it into the OA system. The OA system will then transfer the environmental grade information of the material to the SAP system. The SAP system will then transfer the environmental grade information of the material to the MES system. The MES system will generate a QR code with embedded data including the environmental grade and environmental label of the material. Print out a production process flow sheet containing the QR code using self-adhesive labels and attach the production process flow sheet to the material. The MES system will scan the QR code to enter the inventory and be able to identify the environmental grade of the material. Environmental engineers assess and determine the environmental level of a client's project (e.g., Class A, Class B, or Class C) according to the client's environmental requirements and the prescribed environmental level definition, and record the client's project's environmental level in the MES system.

[0022] Examples of the environmental protection level definitions mentioned above are as follows: Grade A: indicates that it does not contain UV-328 (2-(2H-benzotriazol-2-yl)-4,6-di-tert-pentylphenol) or TPP (triphenyl phosphate); Grade B: indicates that it does not contain UV-328 (2-(2H-benzotriazol-2-yl)-4,6-di-tert-pentylphenol) and contains TPP (triphenyl phosphate) or contains UV-328 (2-(2H-benzotriazol-2-yl)-4,6-di-tert-pentylphenol) and does not contain TPP (triphenyl phosphate); Grade C: indicates that it contains UV-328 (2-(2H-benzotriazol-2-yl)-4,6-di-tert-pentylphenol) or TPP (triphenyl phosphate).

[0023] Examples of the above environmental protection levels and corresponding environmental protection labels are as follows: The environmental protection label corresponding to environmental protection level A is: HSF; the environmental protection label corresponding to environmental protection level B or C is: RoHS+HF.

[0024] For example, when a client's project requires compliance with laws and regulations such as RoHS, HF, and REACH SVHC, the environmental engineer assesses and determines the client's project to be at level A according to the prescribed environmental level definition.

[0025] Step 2: In the material cutting and feeding process, a scanning device such as a barcode scanner is used to scan the QR code on the production process flow sheet affixed to the material. The scanning device reads the environmental protection level data of the material embedded in the QR code and transmits it to the MES system. The MES system determines whether the environmental protection level of the material embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the material cutting operation to start. If they are inconsistent, the MES system prohibits the material cutting operation and issues an alarm prompt, such as "The environmental protection level of the material does not match the environmental protection level of the customer project. Please confirm!". If the MES system cannot read the environmental protection level data of the material embedded in the QR code, the MES system prohibits the material cutting operation and issues an alarm prompt, such as "Unable to identify the environmental protection level of the material. Please confirm!".

[0026] For example: Step 1 records the customer project's environmental protection level as Grade A in the MES system. The system scans the QR code on the production process flow sheet affixed to the material. If the QR code contains an embedded environmental protection level of Grade A, the MES system determines that the embedded material environmental protection level matches the customer project's recorded environmental protection level (both are Grade A), and allows the material cutting operation to begin. If the QR code contains an embedded material environmental protection level of Grade B, the MES system determines that the embedded material environmental protection level does not match the customer project's recorded environmental protection level (one Grade B and one Grade A), and prohibits the material cutting operation from starting, issuing an alarm message such as "Material environmental protection level does not match customer project environmental protection level, please confirm!". If the MES system cannot read the embedded material environmental protection level data in the QR code, it prohibits the material cutting operation from starting and issues an alarm message such as "Unable to identify material environmental protection level, please confirm!".

[0027] Step 3: After the finished product is made from materials that have been allowed to undergo cutting operations by the MES system, the production process flow sheet affixed to the materials becomes the production process flow sheet affixed to the finished product. During the finished product shipping process, a scanning device such as a barcode scanner is used to scan the QR code on the production process flow sheet affixed to the finished product, read the environmental protection level data embedded in the QR code, and transmit it to the MES system. The MES system determines whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the finished product shipping operation to start. If they are inconsistent, the MES system prohibits the finished product shipping operation from starting and issues an alarm prompt, such as "The environmental protection level of the finished product does not match the environmental protection level of the customer project. Please confirm!".

[0028] For example, if the environmental protection level of a customer project recorded in the MES system is Grade A, and a barcode scanner is used to scan the QR code on the production process flow sheet affixed to the finished product, if the environmental protection level embedded in the QR code is also Grade A, the MES system determines that the environmental protection level embedded in the QR code matches the environmental protection level of the customer project recorded in the MES system (both are Grade A), and then the MES system allows the finished product shipment operation to begin. If the environmental protection level embedded in the QR code is Grade B, the MES system determines that the environmental protection level embedded in the QR code is inconsistent with the environmental protection level of the customer project recorded in the MES system (one is Grade B and the other is Grade A), and then the MES system prohibits the finished product shipment operation and issues an alarm message, such as "The environmental protection level of the finished product does not match the environmental protection level of the customer project. Please confirm!"

[0029] As mentioned above, the production process flow sheet is attached to the material using self-adhesive adhesive. Alternative methods include printing the production process flow sheet containing the QR code on ordinary paper and attaching it to the material with glue or double-sided tape, or using a stapler to fix the production process flow sheet to the material.

[0030] Compared with the prior art, the present invention has the following beneficial effects: 1. The QR codes controlled by the OA system, SAP system, and MES system, along with their embedded environmental protection level data and the environmental protection level data of the customer project, cannot be altered during the material feeding and finished product shipping processes. The QR codes with embedded environmental protection level data are present throughout the entire production process, from raw materials to manufacturing, cutting, and shipping, ensuring full traceability. Each step in the aforementioned production process requires scanning the QR code, and the MES system verifies whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer project. The judgment is highly accurate and reliable, avoiding errors caused by relying on manual identification and judgment. It can completely prevent discrepancies between the environmental protection level of materials, finished products, and the environmental protection level of the customer project, improving the stability of production quality, increasing production efficiency, reducing manpower input, and saving time.

[0031] 2. The manual confirmation has been changed to system scanning, eliminating the need for personnel inspection, saving labor costs and improving accuracy. The time efficiency has been reduced from 1.4 hours (calculated according to 7 processes from incoming material inspection to outgoing inspection, with each process taking 20 minutes) to just 1 second (scanning takes 1 second).

[0032] 3. Achieve integrated functions of digital material environmental management system, with purchase ordering, incoming material inspection, and production scheduling all achieving "automatic comparison" through QR codes and MES system, realizing integrated environmental protection, quality and delivery, and reducing downtime.

[0033] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A method for verifying and controlling the consistency of environmental protection levels during production, characterized in that, It includes the following steps: Step 1: The environmental engineer assesses and determines the environmental protection level of the material, records the environmental protection level of the material in the MES system, generates a QR code with embedded data including the environmental protection level of the material, prints out the production process flow sheet containing the QR code, and attaches the production process flow sheet to the material. Environmental engineers assess and determine the environmental protection level of the client's project according to the client's environmental protection requirements, and record the environmental protection level of the client's project in the MES system; Step 2: In the process of cutting and feeding materials, a scanning device scans the QR code on the production process flow sheet attached to the material. The scanning device reads the environmental protection level data of the material embedded in the QR code and transmits it to the MES system. The MES system determines whether the environmental protection level of the material embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the material cutting operation to start. If they are inconsistent or the MES system cannot read the environmental protection level data of the material embedded in the QR code, the MES system prohibits the material cutting operation from starting. Step 3: After the finished product is made from the material that the MES system allows to start the cutting operation, the production process flow sheet attached to the material becomes the production process flow sheet attached to the finished product. In the finished product shipping process, the QR code on the production process flow sheet attached to the finished product is scanned by a scanning device, the environmental protection level data embedded in the QR code is read and transmitted to the MES system. The MES system determines whether the environmental protection level embedded in the QR code is consistent with the environmental protection level of the customer project recorded in the MES system in Step 1. If they are consistent, the MES system allows the finished product shipping operation to start. If they are inconsistent, the MES system prohibits the finished product shipping operation from starting.

2. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, The third-party testing report, material composition, content, and raw material information of the material are entered into the OA system to apply for a material code. The environmental engineer evaluates and determines the environmental grade of the material according to the prescribed environmental grade definition and enters it into the OA system. The OA system transmits the environmental grade information of the material to the SAP system and the SAP system transmits the environmental grade information of the material to the MES system.

3. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, Environmental engineers assess and determine the environmental rating of a client's project based on its environmental requirements and the defined environmental rating standards.

4. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, 2, or 3, characterized in that, Environmental protection levels are divided into Grade A, Grade B and Grade C.

5. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 4, characterized in that, The environmental label corresponding to environmental grade A is HSF; the environmental label corresponding to environmental grade B or C is RoHS+HF.

6. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, The embedded data in the QR code also includes the material's environmental label.

7. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, In steps 2 and 3, the MES system will issue an alarm while prohibiting the initiation of material cutting operations and finished product shipping operations.

8. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, The scanning device is a barcode scanner.

9. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, The production process flow sheet is attached to the material by printing out a production process flow sheet containing the QR code using self-adhesive tape and then pasting the production process flow sheet onto the material.

10. The method for verifying and controlling the consistency of environmental protection levels during the production process according to claim 1, characterized in that, The production process flow sheet can be attached to the material by printing it on ordinary paper and attaching it to the material with glue or double-sided tape, or by using a stapler to fix it to the material.