Multi-Step Production Control Using Raw Material Property Routes
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Solution Overview
Problem
In production systems handling multiple steps, stabilizing the quality of the final product is challenging due to the mutual effects of various processes, and adjusting control target values dynamically is difficult.
Innovation Solution
A control device determines control target values based on past production results and manufacturing conditions, classifying lots into groups and routes to ensure product quality, using sensors and inspection devices to adjust operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed control target values are set uniformly for each device, then device operation is simplified, but product quality cannot be stabilized when raw material properties vary
Solution Approach 1:
The control target values are changed from fixed to dynamic, allowing them to be adjusted based on actual raw material properties. The system dynamically determines appropriate control target values by referencing past production data and current material characteristics, enabling quality stabilization without uniform fixed controls.
Solution Approach 2:
The system incorporates feedback mechanisms by collecting and analyzing past production results and current raw material properties. This feedback loop enables the control device to learn from historical data and adjust control target values appropriately, resolving the contradiction between quality precision and control complexity.
2Manufacturing precision
If control target values are adjusted dynamically based on raw material properties, then product quality is stabilized, but control system complexity increases
Solution Approach 1:
The system performs preliminary analysis of raw material properties before production and pre-determines appropriate control target values based on past production data. This preliminary action reduces the complexity of real-time control decisions while maintaining quality stabilization benefits.
Solution Approach 2:
The system creates a database of past production results and control target value combinations. By copying and referencing this historical data, the system avoids recreating control strategies from scratch, reducing computational complexity while maintaining dynamic adaptation to material variations.
3Manufacturing precision
If multiple production steps are coordinated to improve overall process, then product quality is stabilized, but experimentation with individual step controls becomes difficult
Solution Approach 1:
The system segments the production process into individual steps while maintaining overall coordination. By analyzing and controlling each step separately based on its specific characteristics and past performance, the system enables both coordinated quality improvement and flexible experimentation with individual step controls.
Solution Approach 2:
The system enables independent parameter changes at each production step by determining control target values specifically for each step based on past results and current material properties. This allows flexible experimentation with individual step parameters while maintaining overall process coordination for quality stabilization.
Data Source
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AI summary
The present invention addresses the problem of stabilizing the qualities of products which are manufactured by a plurality of steps. The present invention is a production system for producing products from raw materials by a production process including a plurality of steps, and is provided with: a plurality of production facilities that perform the steps; and a control device that determines control target values which are respectively set for the plurality of production facilities. When information about the properties of a raw material which is charged in the production process is acquired, the control device determines a control target value to be set for at least any one of the plurality of production facilities, by referring to information about group combinations specified in accordance with the relative merits of the manufacturing condition routes followed by respective lots during the production process, the routes being respectively set for a plurality of groups which are classified on the basis of raw material properties each formed of a combination of a plurality of property items of one or more types of raw materials, the relative merits of the routes being determined on the basis of quality items of the lots, classified for each of inter-step combinations of a plurality of groups which are classified on the basis of manufacturing conditions at the steps.