CN110458469B - Basic diagnosis system, equipment and method for printing and dyeing design and production process - Google Patents
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Abstract
The application discloses a basic diagnosis system, equipment and method in printing and dyeing design and production processes, and the scheme comprises the following steps: collecting original data of an information system of a printing and dyeing enterprise; determining the current laboratory quality problem according to the original data, and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the diagnosis result of the design process; determining a currently existing production problem and determining a main production element causing the production problem from production elements affecting production as a production process diagnosis result; and finally feeding back the design process diagnosis result and the production process diagnosis result. Therefore, the scheme can determine the problems existing in the printing and dyeing design and production process according to the original data of the printing and dyeing enterprise, and determines the design elements really causing the laboratory quality problems and the production elements really causing the production problems on the basis, so that the printing and dyeing enterprise is helped to find out the problems existing in the product design and production process, and the production efficiency is improved.
Description
Technical Field
The application relates to the technical field of computers, in particular to a basic diagnosis system, basic diagnosis equipment and a basic diagnosis method for printing and dyeing design and production processes.
Background
Problems often occur in the design and production processes of printing and dyeing enterprises, resulting in low efficiency. Therefore, it is a very necessary process in the art to perform an analytical diagnosis of raw data of a printing and dyeing enterprise to determine key factors causing problems.
However, the traditional diagnosis scheme is usually realized manually, on one hand, the factors causing problems in the design and production processes are more, and the equipment scale of printing and dyeing enterprises is larger, so that the diagnosis workload is huge; on the other hand, the manual diagnosis is low in standardization degree and efficiency, and has high requirements on diagnosis experience. Therefore, the traditional diagnosis scheme is inefficient and difficult to meet the current requirements of printing and dyeing enterprises.
Disclosure of Invention
The application aims to provide a basic diagnosis system, basic diagnosis equipment and a basic diagnosis method in a printing and dyeing design and production process, and the basic diagnosis system, the basic diagnosis equipment and the basic diagnosis method are used for solving the problems that the traditional diagnosis scheme is low in efficiency and difficult to meet the current requirements. The specific scheme is as follows:
in a first aspect, the present application provides a system for basic diagnosis of printing design and production process, comprising:
a data acquisition module: the system is used for collecting original data of the printing and dyeing enterprise information system;
designing a process diagnosis module: the system comprises a data processing unit, a data processing unit and a data processing unit, wherein the data processing unit is used for determining the current laboratory quality problem according to the original data and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the design process diagnosis result, wherein the laboratory quality problem comprises that the occurrence frequency of color difference problems exceeds a first preset threshold and/or the sampling frequency exceeds a second preset threshold;
a production process diagnostic module: the method is used for determining the current existing production problem according to the original data and determining the main production element causing the production problem from the production elements influencing the production as the diagnosis result of the production process, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems;
a diagnostic result feedback module: for feeding back the design process diagnostic result and the production process diagnostic result.
Preferably, the data acquisition module is specifically configured to:
collecting original data of an information system of a printing and dyeing enterprise, and performing data cleaning and association on the original data, wherein the information system of the printing and dyeing enterprise comprises any one or more of the following items: ERP, SFC, MES, PLM, APS, SCM, CRM, the raw data comprising any one or more of: fabric, color measurement, process, dye formula, auxiliary agent formula, centralized control, quality, repair, energy consumption, pollution discharge, personnel and customer requirement data.
Preferably, the design elements affecting laboratory quality include any one or more of: fabric, color, dye, auxiliary agent, sample machine, formulator, temperature control information and pH value;
the production elements that affect production include any one or more of: machine vat, surface fabric, dyestuff, auxiliary agent, technology, colour, customer, cloth length, cloth weight.
Preferably, when the laboratory quality problem includes that the occurrence frequency of the color difference problem exceeds a first preset threshold and the proofing frequency exceeds a second preset threshold, the design process diagnosis module includes a color difference problem diagnosis unit and a proofing frequency diagnosis unit;
wherein, if the currently considered production factor is the fabric type, the color difference problem diagnosis unit is configured to: counting the occurrence frequency of color difference problems under each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the occurrence frequency of the color difference problems exceeding a first preset threshold value to serve as a color difference problem diagnosis result;
if the currently considered production factor is the fabric type, the proofing number diagnostic unit is used for: and counting the number of proofing times of each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the proofing times exceeding a second preset threshold value to serve as a proofing time diagnosis result.
Preferably, when the production problems comprise printing and dyeing quality problems, production energy consumption problems and centralized control problems, the production process diagnosis module comprises a printing and dyeing quality problem diagnosis unit, a production energy consumption problem diagnosis unit and a centralized control problem diagnosis unit;
wherein, if the currently considered production factor is a fabric type, the printing quality problem diagnosis unit is configured to: counting the one-time success rate, the number of times of feed back repair and the number of times of color difference color change of each fabric type in the existing fabric types within a preset time range, and determining the fabric type which leads the one-time success rate to be lower than a third preset threshold, and/or the number of times of feed back repair exceeds a fourth preset threshold, and/or the number of times of color difference color change exceeds a fifth preset threshold, so as to be used as a diagnosis result of the printing and dyeing quality problems.
Preferably, the production energy consumption problem diagnosis unit is configured to: counting the actual energy consumption value of the unit cloth length within a preset time range, and determining the main production elements causing the actual energy consumption value of the unit cloth length to exceed the recommended energy consumption value as a production energy consumption problem diagnosis result, wherein the actual energy consumption value comprises any one or more of the following items: power consumption, water consumption and steam consumption;
the centralized control problem diagnosis unit is used for: counting the occurrence frequency of the centralized control problem within a preset time range, and determining the main production elements causing the occurrence frequency of the centralized control problem to exceed a sixth preset threshold value as a diagnosis result of the centralized control problem, wherein the centralized control problem comprises any one or more of the following items: too fast temperature rise, too slow temperature rise, too long heat preservation time, too short heat preservation time, too high heat preservation temperature, too low heat preservation temperature, too large temperature fluctuation, too fast temperature reduction and too slow temperature reduction.
Preferably, the diagnostic result feedback module is specifically configured to:
and generating a visual chart according to the design process diagnosis result and the production process diagnosis result, and sending the visual chart to a target terminal to realize display.
In a second aspect, the present application provides a device for basic diagnosis of printing design and production process, comprising: the printing design and production process basic diagnosis system is described above.
In a third aspect, the present application provides a method for basic diagnosis of printing design and production process, comprising:
collecting original data of an information system of a printing and dyeing enterprise;
determining the current laboratory quality problems according to the original data, and determining the main design elements causing the laboratory quality problems from the design elements influencing the laboratory quality as the diagnosis result of the design process, wherein the occurrence frequency of the laboratory quality problems including color difference problems exceeds a first preset threshold, and/or the sampling times exceeds a second preset threshold;
determining a current production problem according to the original data, and determining a main production element causing the production problem from production elements influencing production as a production process diagnosis result, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems;
and feeding back the design process diagnosis result and the production process diagnosis result.
The application provides a basic diagnosis system, equipment and method for printing and dyeing design and production process, and the scheme comprises the following steps: collecting original data of an information system of a printing and dyeing enterprise; determining the current laboratory quality problem according to the original data, and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the diagnosis result of the design process, wherein the laboratory quality problem comprises that the occurrence frequency of the color difference problem exceeds a first preset threshold value, and/or the sampling frequency exceeds a second preset threshold value; determining a current production problem according to the original data, and determining a main production element causing the production problem from production elements influencing the production as a production process diagnosis result, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems; and finally feeding back the design process diagnosis result and the production process diagnosis result.
Therefore, the scheme can determine the problems existing in the printing and dyeing design and production process according to the original data of the information system of the printing and dyeing enterprise, and on the basis, the main design elements really causing the quality problems of the laboratory and the main production elements really causing the production problems are determined, so that the printing and dyeing enterprise is helped to quickly find out the problems existing in the product design and production process, and the production efficiency is obviously improved.
Drawings
For a clearer explanation of the embodiments or technical solutions of the prior art of the present application, the drawings needed for the description of the embodiments or prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic diagram of a system architecture of a first embodiment of a basic diagnostic system for printing design and manufacturing processes provided herein;
FIG. 2 is a schematic diagram of a second system architecture of an embodiment of a basic diagnostic system for printing design and manufacturing processes provided herein;
FIG. 3 is a statistical chart of the number of rework feed cylinders versus the number of normal cylinders in a second embodiment of a basic diagnostic system for printing design and manufacturing processes provided herein;
FIG. 4 is a diagram illustrating a relationship between a customer and a color difference problem in a second embodiment of a basic diagnostic system for printing design and manufacturing processes;
FIG. 5 is a statistical chart of the first success rate of each fabric type in a second embodiment of a basic diagnostic system for printing design and production processes provided by the present application;
FIG. 6 is a graph comparing the actual power consumption per unit cloth length to the recommended power consumption for a second embodiment of a basic diagnostic system for printing design and manufacturing processes provided herein;
FIG. 7 is a graph of water consumption per unit versus additional process in a second embodiment of a basic diagnostic system for printing design and manufacturing processes provided herein;
FIG. 8 is a statistical chart of the number of cylinders with large temperature fluctuation and the number of normal cylinders in an embodiment of a basic diagnostic system for printing design and production processes provided by the present application;
FIG. 9 is a flowchart of a basic diagnostic method for printing design and production process provided by the present application.
Detailed Description
In order that those skilled in the art will better understand the disclosure, the following detailed description will be given with reference to the accompanying drawings. It is to be understood that the embodiments described are only a few embodiments of the present application and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
In recent years, a large amount of funds are invested in some printing and dyeing enterprises to introduce high-end equipment and information systems, such as color measuring instruments, ERP systems, MES systems, automatic weighing systems, centralized control systems and the like, but the collected data only stay in a viewing stage, most of the collected data are not correlated, and systematic data analysis and comparison, knowledge mining and extraction and production flow simulation are not performed, so that the equipment and the data cannot fully play roles. Aiming at the problem, the core of the application is to provide a basic diagnosis system, equipment and method for printing and dyeing design and production processes, and the system, the equipment and the method help printing and dyeing enterprises to quickly find out the most obvious problem in the product design and production processes by acquiring the original data of the printing and dyeing enterprises, analyzing the relation between design elements and the occurrence frequency of color difference problems, the laboratory sample making times and the relation between production elements and printing and dyeing quality, production energy consumption and centralized control problems, so that the enterprises are motivated to firstly put digital modification on the most obvious factors influencing the product quality and the production efficiency. Therefore, the aims of improving the one-time dyeing success rate of printing and dyeing enterprises, saving raw material consumption, reducing production energy consumption and water consumption, improving product quality and reducing pollution discharge are fulfilled.
Referring to fig. 1, a first embodiment of a basic diagnostic system for printing design and production processes provided in the present application is described as follows, and the first embodiment includes:
the data acquisition module 101: the system is used for collecting original data of the printing and dyeing enterprise information system;
specifically, the raw data in a preset time range may be collected from systems of the printing and dyeing enterprise, such as ERP, SFC, MES, PLM, APS, SCM, CRM, and the like, and the raw data may specifically include any one or more of the following: fabric, color measurement, process, dye formula, auxiliary agent formula, centralized control, quality, repair, energy consumption, pollution discharge, personnel and customer requirement data. As a preferred embodiment, after the raw data is acquired, the raw data may be preprocessed, such as data cleaning, data association, etc., to ensure the reliability of the subsequent diagnosis result.
Design process diagnostic module 102: the system comprises a data processing unit, a data processing unit and a data processing unit, wherein the data processing unit is used for determining the current laboratory quality problem according to the original data and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the design process diagnosis result, wherein the laboratory quality problem comprises that the occurrence frequency of color difference problems exceeds a first preset threshold and/or the sampling frequency exceeds a second preset threshold;
in this embodiment, the design element refers to one or more factors that are determined according to historical data, have a certain influence on laboratory quality, and may cause a problem on laboratory quality, where the design element may include any one or more of the following: fabric, color, dye, auxiliary agent, sample machine, formulator, temperature control information and pH value.
The laboratory quality problem may specifically include an excessively high occurrence frequency of the color difference problem, an excessively large number of proofing times, and the like. Specifically, according to the historical data, the frequency of occurrence of the color difference problem and the number of times of sampling under different design element categories such as fabrics, colors, dyes, auxiliaries, hand sample machines, formulators and the like in a period of time are statistically analyzed. Therefore, the main design elements in the design elements such as fabric types, color types, dye types and the like which cause high occurrence frequency and high proofing times of color difference problems are identified, so that enterprises can purposefully make targeted laboratory proofing design adjustment, and the one-time proofing success rate is improved.
The production process diagnostic module 103: the method is used for determining the current existing production problem according to the original data and determining the main production element causing the production problem from the production elements influencing the production as the diagnosis result of the production process, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems;
the production element refers to one or more factors which are determined according to historical data and have certain influence on the production process and can cause production problems, and specifically, the production element can comprise any one or more of the following items: machine vat, surface fabric, dyestuff, auxiliary agent, technology, colour, customer, cloth length, cloth weight.
The production problems can specifically comprise the problems of printing and dyeing quality, production energy consumption, centralized control, pollution discharge and the like, wherein the problems of printing and dyeing quality comprise the problems of one-time dyeing success rate, more times of repairing and feeding, more times of color difference and color pattern, cylinder blockage, end breakage and the like; the production energy consumption problems comprise power consumption, water consumption, abnormal steam consumption and the like; the centralized control problems comprise the problems of too fast temperature rise, too slow temperature rise, too long heat preservation time, too short heat preservation time, too high heat preservation temperature, too low heat preservation temperature, larger actual temperature fluctuation, too fast temperature reduction, too slow temperature reduction and the like.
That is to say, in this embodiment, the primary success rate, the feeding and returning times, and the color difference and color pattern times of different production elements such as the fabric and the cylinder are statistically analyzed through the raw data, and on the basis, the fabric type, the cylinder number, the process flow, the color and the like with higher frequency of occurrence of quality problems such as more returning and feeding times, color difference and color pattern and the like and lower primary success rate are determined to be used as the diagnosis result of the production process.
The diagnostic result feedback module 104: for feeding back the design process diagnostic result and the production process diagnostic result.
Finally, the diagnosis result can be remotely fed back to enterprise management personnel in real time in a visual chart form through a mobile phone, a computer, a large screen and other clients, so that the enterprise can find the problems in the design and production processes in time according to the feedback result, find the main design elements or production elements causing the problems, make targeted production adjustment or process optimization, and reduce the occurrence of design and production problems.
The basic diagnosis system for the printing and dyeing design and the production process comprises a data acquisition module, a design process diagnosis module, a production process diagnosis module and a diagnosis result feedback module, and is used for realizing that: firstly, collecting original data from an information system of a printing and dyeing enterprise, and cleaning and associating the data; secondly, analyzing the relation between the design factors and the quality problems of the laboratory, and helping printing and dyeing enterprises to quickly find out the most obvious problems in the printing and dyeing design process; analyzing the relation between the production factors and the problems of printing and dyeing quality, production energy consumption, centralized control and pollution discharge, and helping printing and dyeing enterprises to quickly find out the most obvious problems in the printing and dyeing production process; and finally, the diagnosis result is fed back to enterprise managers in a clear and visual chart form through the clients such as mobile phones, computers and the like.
Therefore, the scheme helps printing and dyeing enterprises to quickly find out the most obvious problems in the printing and dyeing design process by analyzing the relation between the design factors and the laboratory quality problems; by analyzing the relation between the production factors and the printing and dyeing quality problem, the production energy consumption problem, the centralized control problem and the pollution discharge problem, the printing and dyeing enterprise is helped to quickly find out the most obvious problem in the printing and dyeing production process, and the repeated occurrence of the design and production problems is reduced or avoided. By the mode, the purposes of improving the one-time dyeing success rate of printing and dyeing enterprises, saving raw material consumption, reducing production energy consumption and reducing discharge capacity are achieved.
The second embodiment of the basic diagnostic system for printing and dyeing design and production processes provided by the present application is described in detail below, and the second embodiment is implemented based on the first embodiment and is expanded to a certain extent based on the first embodiment.
Referring to fig. 2, the second embodiment specifically includes:
the data acquisition module 201: the system is used for collecting original data of an information system of a printing and dyeing enterprise, and performing data cleaning and association on the original data, wherein the information system of the printing and dyeing enterprise comprises any one or more of the following items: ERP, SFC, MES, PLM, APS, SCM, CRM, the raw data comprising any one or more of: fabric, color measurement, process, dye formula, auxiliary agent formula, centralized control, quality, repair, energy consumption, pollution discharge, personnel and customer requirement data;
design process diagnostic module 202: the system comprises a data processing unit, a data processing unit and a data processing unit, wherein the data processing unit is used for determining the current laboratory quality problem according to the original data and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the design process diagnosis result, wherein the laboratory quality problem comprises that the occurrence frequency of color difference problems exceeds a first preset threshold and/or the sampling frequency exceeds a second preset threshold; the design elements affecting laboratory quality include any one or more of: fabric, color, dye, auxiliary agent, sample machine, formulator, temperature control information and pH value;
the production process diagnostic module 203: the method is used for determining the current existing production problem according to the original data and determining the main production element causing the production problem from the production elements influencing the production as the diagnosis result of the production process, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems; the production elements that affect production include any one or more of: machine vat, surface fabric, dyestuff, auxiliary agent, technology, colour, customer, cloth length, cloth weight.
The diagnostic result feedback module 204: and the visual chart is used for generating a visual chart according to the design process diagnosis result and the production process diagnosis result and sending the visual chart to a target terminal to realize display.
The design process diagnosis module 202 is mainly used for analyzing a relationship between a design factor and a laboratory quality problem, and when the laboratory quality problem includes that the occurrence frequency of a chromatic aberration problem exceeds a first preset threshold and the number of proofing times exceeds a second preset threshold, the design process diagnosis module 202 includes a chromatic aberration problem diagnosis unit 2021 and a proofing time diagnosis unit 2022.
Wherein, if the currently considered production factor is the fabric type, the color difference problem diagnosis unit 2021 is configured to: counting the occurrence frequency of color difference problems under each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the occurrence frequency of the color difference problems exceeding a first preset threshold value to serve as a color difference problem diagnosis result;
if the currently considered production factor is the fabric type, the proofing times diagnostic unit 2022 is configured to: and counting the number of proofing times of each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the proofing times exceeding a second preset threshold value to serve as a proofing time diagnosis result.
In general, the diagnostic process of the design process diagnostic module 202 includes the following three steps:
firstly, the laboratory design data in the original data is collected, cleaned, associated and filled.
Then, the diagnosis of the color difference problem is realized based on the color difference problem diagnosis unit 2021, mainly the problem that there is color difference between the color of the sample produced by the vat and the original shape of the customer. Specifically, assuming that the currently considered design factor is the type of fabric, the analysis process includes: according to historical data, the frequency of occurrence of the laboratory proofing color difference problem under each type of fabric within one day, one week or one month is statistically analyzed, and a chart is drawn, so that the specific fabric with the most serious color difference problem or the fabric type with the color difference problem occurrence frequency exceeding a first preset threshold value is found out to serve as a color difference problem diagnosis result. Other design elements and analysis processes of laboratory quality problems are similar and will not be described in detail herein.
Finally, the proofing number diagnostic unit 2022 realizes the proofing number diagnostic analysis. The laboratory quality problem can be reflected by the number of proofs, if the quality problem does not exist, the proofs do not need to be repeated, and the goal of the embodiment is to reduce the number of proofs of printing and dyeing enterprises. Therefore, assuming that the currently considered design factor is the fabric type, the number of proofing times under each type of fabric can be counted, and the fabric type with higher proofing times or with the proofing times exceeding a second preset threshold value is found out to be used as a proofing time diagnosis result. The printing and dyeing enterprises can further find out the reason that the number of times of proofing of the fabric is higher, and improve the reason, thereby improving the production efficiency of the enterprises. The analysis process of other design elements and the sampling times is similar to that of the design elements, and is not described in detail herein.
When the production problem includes a printing and dyeing quality problem, a production energy consumption problem, and a centralized control problem, the production process diagnosis module 203 includes a printing and dyeing quality problem diagnosis unit 2031, a production energy consumption problem diagnosis unit 2032, and a centralized control problem diagnosis unit 2033;
wherein, if the currently considered production factor is a fabric type, the printing quality problem diagnosis unit 2031 is configured to: counting the one-time success rate, the number of times of feed back repair and the number of times of color difference color change of each fabric type in the existing fabric types within a preset time range, and determining the fabric type which leads the one-time success rate to be lower than a third preset threshold, and/or the number of times of feed back repair exceeds a fourth preset threshold, and/or the number of times of color difference color change exceeds a fifth preset threshold, so as to be used as a diagnosis result of the printing and dyeing quality problems.
The production energy consumption problem diagnosis unit 2032 is configured to: counting the actual energy consumption value of the unit cloth length within a preset time range, and determining the main production elements causing the actual energy consumption value of the unit cloth length to exceed the recommended energy consumption value as a production energy consumption problem diagnosis result, wherein the actual energy consumption value comprises any one or more of the following items: power consumption, water consumption and steam consumption;
the centralized control problem diagnosis unit 2033 is configured to: counting the occurrence frequency of the centralized control problem within a preset time range, and determining the main production elements causing the occurrence frequency of the centralized control problem to exceed a sixth preset threshold value as a diagnosis result of the centralized control problem, wherein the centralized control problem comprises any one or more of the following items: too fast temperature rise, too slow temperature rise, too long heat preservation time, too short heat preservation time, too high heat preservation temperature, too low heat preservation temperature, too large temperature fluctuation, too fast temperature reduction and too slow temperature reduction.
The above-mentioned printing quality problem diagnosis unit 2031, production energy consumption problem diagnosis unit 2032, and centralized control problem diagnosis unit 2033 are described in further detail below:
for the print quality issue diagnostic unit 2031, in some specific embodiments, it may be used to: according to the original data, the frequency of problems such as one-time success rate, feeding and repairing times, color difference and color pattern times and the like under different production factors such as the fabric and the machine cylinder in a period of time is statistically analyzed, so that the production factors such as the fabric type with more repairing and feeding times, the color difference and color pattern times and the low one-time success rate, the machine cylinder number, the process flow, the color type and the like are identified and used as the diagnosis result of the printing and dyeing quality problems. The analysis processes of the feeding and rework times, the color difference and color pattern times, and the one-time success rate in the printing and dyeing quality problem diagnosis unit 2031 are respectively described as follows:
analysis of the reconditioned charge: when the production element is the fabric, firstly extracting the field data of the fabric, the repair material and the like in the original data; counting and analyzing the number of the repair feeding cylinders and the number of the normal cylinders under various types of fabrics within a target time range; it is plotted as a relational analysis chart. The process of feed recovery cylinder analysis of other production elements is similar and will not be described further herein. Referring to fig. 3, fig. 3 is a statistical graph of the number of returned feeding cylinders and the normal number of cylinders of each color within 6, 11 and 7, 11 days in 2019 for a certain printing and dyeing enterprise, and the feeding frequency of the visible color BS is obviously higher than that of other colors, so that the printing and dyeing enterprise can be prompted to pay attention to the dyeing design and production of the color, the number of returned feeding cylinders of the color is reduced, and the production efficiency of the enterprise is effectively improved.
Color difference and flower color analysis: firstly, determining possible quality problems of products, such as color difference, color pattern, cylinder blockage, broken ends and the like, according to original data; when the production factor is the fabric type, extracting field data such as fabric and quality problems in the production data, and counting and analyzing the frequency of occurrence of quality problems such as color difference, color spots and the like of various types of fabrics within a target time range; this was plotted into an analysis chart. Other production elements are similar to the analysis process of the fabric and are not repeated. Referring to fig. 4, fig. 4 is a relationship diagram of customers and color difference problems in 2019 and 6 months of a certain printing and dyeing enterprise, and it can be seen that the customer color difference ratios of numbers 220 and 108 are high, so that prompt information can be generated to prompt the two customers that the requirements on colors are high, or the colors of cloth of the two customers are difficult to make, and a dye house needs to pay attention.
And (3) analyzing the primary success rate: when the production element is a fabric type, extracting the data of the number fields of the fabric and the production cylinder in the original data; counting and analyzing the total cylinder times and the defective cylinder times of the production of various types of fabrics within the target time range, so as to calculate the one-time success rate of the various types of fabrics; and drawing an analysis chart of the fabric and the one-time success rate. The primary success rate analysis of other production elements such as machine cylinders, processes and the like is similar to the primary success rate analysis, and is not repeated herein. Referring to fig. 5, fig. 5 is a statistical chart of the one-time success rate of each fabric type in 2019 in 6 months for a certain printing and dyeing enterprise, and it can be seen that fabrics such as WNRO \ WTOO \ WROO \ WNOO and the like are main produced fabrics of the dyeing mill in 6 months, but the defect rate of the fabrics is also high, so that the dyeing mill can be prompted to pay attention to the design and production of the fabrics, the one-time success rate of the fabrics is improved, the production efficiency is improved, and the production cost is saved.
For the production energy consumption issue diagnostic unit 2032, in some specific embodiments, it may be implemented to: calculating the total consumption of water, electricity, steam and other energy consumption of each cylinder every day; comparing the actual unit energy consumption with the recommended unit energy consumption, and judging whether the problem of abnormal energy consumption exists or not; and when the energy consumption abnormity problem is judged to exist, determining the relation between the energy consumption abnormity problem and additional programs such as the repair feeding times and the like. The energy consumption anomaly analysis and additional program analysis processes are respectively introduced as follows:
analyzing the energy consumption abnormity: extracting power consumption data of each cylinder; counting data such as daily total electricity consumption data, total production cloth length, total production cloth weight and the like; calculating the daily actual unit power consumption value and the normal unit power consumption value; it was plotted as a comparative analysis chart. And the analysis of the abnormal energy consumption such as water consumption, steam consumption and the like is similar to the above analysis, and the detailed description is omitted. Referring to fig. 6, fig. 6 is a comparison graph of the power consumption of the actual daily unit cloth length in 2019 of a certain dyeing factory compared with the power consumption of the recommended normal unit cloth length, it can be seen that the actual daily power consumption of the dyeing factory is higher than the power consumption of the recommended normal unit cloth length, the dyeing factory needs to pay further attention to find the reason for the higher power consumption than the normal value, so as to achieve the purpose of reducing the energy consumption.
Additional program analysis: extracting power consumption data, cloth length data and defect number data of each cylinder; calculating the unit power consumption value of each cylinder in the target time range and the average unit power consumption of each cylinder corresponding to each feed back frequency; drawing a corresponding scatter diagram, and analyzing the relation between the unit power consumption and the number of times of the additional program. The analysis of the relationship between unit water consumption, steam consumption and additional program times is similar to the above, and is not repeated. Referring to fig. 7, fig. 7 is a graph showing the relationship between the unit water consumption and the additional program in 2019 of a certain dye house in 6 months, and it can be seen from fig. 7 that the corresponding average unit water consumption is correspondingly increased every time the rework charge is increased. Therefore, the current energy consumption level of a dye factory can be prompted, and the number of times of repairing and feeding materials in each cylinder is concerned and reduced, so that the purposes of energy conservation and emission reduction are achieved.
For the centralized control problem diagnosis unit 2033, in some specific embodiments, it may be implemented to: constructing a centralized control problem identification model; whether the centralized control problem exists in the centralized control data of each cylinder number or not and which type of centralized control problem belongs to are automatically identified by using the model; when the production element is the fabric, counting the frequency of various types of centralized control problems of various types of fabrics within the target time range; drawing a corresponding analysis chart. The analysis of the relationship between other production elements and the centralized control problem is similar to that, and is not described in detail herein. Specifically, the centralized control problem is classified according to a comparative analysis chart of centralized control setting data and actual temperature in the centralized control system, and the specific classification can be as follows: the temperature rise is too fast, the temperature rise is too slow, the heat preservation time is too long, the heat preservation time is too short, the heat preservation temperature is too high, the heat preservation temperature is too low, the actual temperature fluctuation is large, the temperature reduction is too fast, and the temperature reduction is too slow.
Referring to fig. 8, fig. 8 is a statistical graph of the number of cylinders with large temperature fluctuation of each cylinder from 2019, 6/9 days to 2019, 7/9 days of a certain printing and dyeing enterprise and the normal number of cylinders, and as can be seen from fig. 8, the probability that the cylinders with the cylinder numbers of 13, 27 and 9 have the centralized control problem of large temperature fluctuation is high, so that a dye house can be prompted to pay attention to the problem and see whether the cylinders need to be repaired.
In addition, the application also provides an embodiment of the printing design and production process basic diagnosis equipment, which comprises the printing design and production process basic diagnosis system.
The device for the basic diagnosis of the printing and dyeing design and the production process of the present embodiment is used for implementing the implementation process of the basic diagnosis system of the printing and dyeing design and the production process, so the specific implementation of the device can be seen in the previous embodiment of the basic diagnosis system of the printing and dyeing design and the production process, and therefore, the specific implementation thereof can refer to the description of the corresponding embodiments of the respective parts and will not be further described herein.
In addition, since the basic diagnostic apparatus for printing and dyeing design and production process of this embodiment is used to implement the implementation process of the basic diagnostic system for printing and dyeing design and production process, its function corresponds to that of the above system, and is not described herein again.
Finally, the application also provides an embodiment of a basic diagnosis method for printing design and production process, as shown in fig. 9, the embodiment of the method comprises the following steps:
s901, collecting original data of an information system of a printing and dyeing enterprise;
s902, determining the existing laboratory quality problem according to the original data, and determining the main design elements causing the laboratory quality problem from the design elements influencing the laboratory quality as the diagnosis result of the design process;
wherein the laboratory quality problem comprises that the occurrence frequency of the color difference problem exceeds a first preset threshold value, and/or the number of proofing times exceeds a second preset threshold value.
S903, determining the current production problem according to the original data, and determining the main production element causing the production problem from the production elements influencing production to be used as a production process diagnosis result;
wherein the production problem comprises any one or more of: printing and dyeing quality, production energy consumption, centralized control and pollution discharge.
And S904, feeding back the design process diagnosis result and the production process diagnosis result.
The method for basic diagnosis of printing design and production process of this embodiment is implemented based on the aforementioned system for basic diagnosis of printing design and production process, so the specific implementation of this method can be seen from the above section of the embodiment of the system for basic diagnosis of printing design and production process, and therefore, the specific implementation thereof can refer to the description of the corresponding section of the embodiment, and will not be further described herein.
In addition, since the basic diagnosis method for printing and dyeing design and production process of the present embodiment is used to implement the implementation process of the basic diagnosis system for printing and dyeing design and production process, the function corresponds to that of the system, and is not described herein again.
The embodiments are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same or similar parts among the embodiments are referred to each other. The device disclosed by the embodiment corresponds to the method disclosed by the embodiment, so that the description is simple, and the relevant points can be referred to the method part for description.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in Random Access Memory (RAM), memory, Read Only Memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art.
The above detailed descriptions of the solutions provided in the present application, and the specific examples applied herein are set forth to explain the principles and implementations of the present application, and the above descriptions of the examples are only used to help understand the method and its core ideas of the present application; meanwhile, for a person skilled in the art, according to the idea of the present application, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present application.
Claims (7)
1. A system for diagnosing a print design and manufacturing process, comprising:
a data acquisition module: the system is used for collecting original data of the printing and dyeing enterprise information system;
designing a process diagnosis module: the design element is used for determining the laboratory quality problem which exists currently according to the original data, and determining the design element which causes the laboratory quality problem from the design elements which affect the laboratory quality as a design process diagnosis result, wherein the laboratory quality problem comprises that the occurrence frequency of the color difference problem exceeds a first preset threshold value, and/or the sampling frequency exceeds a second preset threshold value;
a production process diagnostic module: the method is used for determining the current existing production problem according to the original data and determining the production element causing the production problem from the production elements influencing the production as the diagnosis result of the production process, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems;
a diagnostic result feedback module: for feeding back the design process diagnostic result and the production process diagnostic result;
the design elements affecting laboratory quality include any one or more of: fabric, color, dye, auxiliary agent, sample machine, formulator, temperature control information and pH value;
the production elements that affect production include any one or more of: machine cylinder, fabric, dye, auxiliary agent, process, color, customer, cloth length and cloth weight;
when the production problems comprise printing and dyeing quality problems, production energy consumption problems and centralized control problems, the production process diagnosis module comprises a printing and dyeing quality problem diagnosis unit, a production energy consumption problem diagnosis unit and a centralized control problem diagnosis unit;
wherein, if the currently considered production factor is a fabric type, the printing quality problem diagnosis unit is configured to: counting the one-time success rate, the number of times of feed back repair and the number of times of color difference color change of each fabric type in the existing fabric types within a preset time range, and determining the fabric type which leads the one-time success rate to be lower than a third preset threshold, and/or the number of times of feed back repair exceeds a fourth preset threshold, and/or the number of times of color difference color change exceeds a fifth preset threshold, so as to be used as a diagnosis result of the printing and dyeing quality problems.
2. The system of claim 1, wherein the data acquisition module is specifically configured to:
collecting original data of an information system of a printing and dyeing enterprise, and performing data cleaning and association on the original data, wherein the information system of the printing and dyeing enterprise comprises any one or more of the following items: ERP, SFC, MES, PLM, APS, SCM, CRM, the raw data comprising any one or more of: fabric, color measurement, process, dye formula, auxiliary agent formula, centralized control, quality, repair, energy consumption, pollution discharge, personnel and customer requirement data.
3. The system of claim 1, wherein the design process diagnostic module includes a color difference problem diagnostic unit, a proofing number diagnostic unit when the laboratory quality problem includes a frequency of occurrence of a color difference problem exceeding a first preset threshold and a proofing number exceeding a second preset threshold;
wherein, if the currently considered production factor is the fabric type, the color difference problem diagnosis unit is configured to: counting the occurrence frequency of color difference problems under each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the occurrence frequency of the color difference problems exceeding a first preset threshold value to serve as a color difference problem diagnosis result;
if the currently considered production factor is the fabric type, the proofing number diagnostic unit is used for: and counting the number of proofing times of each fabric type in the existing fabric types within a preset time range, and determining the fabric type with the proofing times exceeding a second preset threshold value to serve as a proofing time diagnosis result.
4. The system of claim 1, wherein the production energy consumption problem diagnostic unit is to: counting the actual energy consumption value of the unit cloth length within a preset time range, and determining the production elements which cause the actual energy consumption value of the unit cloth length to exceed the recommended energy consumption value as the diagnosis result of the production energy consumption problem, wherein the actual energy consumption value comprises any one or more of the following items: power consumption, water consumption and steam consumption;
the centralized control problem diagnosis unit is used for: counting the occurrence frequency of the centralized control problem within a preset time range, and determining the production elements causing the occurrence frequency of the centralized control problem to exceed a sixth preset threshold value as a diagnosis result of the centralized control problem, wherein the centralized control problem comprises any one or more of the following items: too fast temperature rise, too slow temperature rise, too long heat preservation time, too short heat preservation time, too high heat preservation temperature, too low heat preservation temperature, too large temperature fluctuation, too fast temperature reduction and too slow temperature reduction.
5. The system of any one of claims 1-4, wherein the diagnostic result feedback module is specifically configured to:
and generating a visual chart according to the design process diagnosis result and the production process diagnosis result, and sending the visual chart to a target terminal to realize display.
6. A printing design and manufacturing process diagnostic apparatus, comprising: the textile design and manufacturing process diagnostic system of any one of claims 1-5.
7. A printing design and production process diagnosis method is characterized by comprising the following steps:
collecting original data of an information system of a printing and dyeing enterprise;
determining the current laboratory quality problems according to the original data, and determining design elements causing the laboratory quality problems from the design elements influencing the laboratory quality as the diagnosis result of the design process, wherein the laboratory quality problems comprise that the occurrence frequency of color difference problems exceeds a first preset threshold value, and/or the sampling times exceeds a second preset threshold value;
determining a current production problem according to the original data, and determining a production element causing the production problem from production elements influencing production as a production process diagnosis result, wherein the production problem comprises any one or more of the following items: printing and dyeing quality problems, production energy consumption problems, centralized control problems and pollution discharge problems;
feeding back the design process diagnosis result and the production process diagnosis result;
the design elements affecting laboratory quality include any one or more of: fabric, color, dye, auxiliary agent, sample machine, formulator, temperature control information and pH value;
the production elements that affect production include any one or more of: machine cylinder, fabric, dye, auxiliary agent, process, color, customer, cloth length and cloth weight;
when the production problems comprise printing and dyeing quality problems, production energy consumption problems and centralized control problems, the method for determining the production problems which exist currently according to the original data and determining the production elements which cause the production problems from the production elements which influence the production, and the method for determining the production elements which cause the production problems as the diagnosis result of the production process comprises the following steps: determining the printing and dyeing quality problem, the production energy consumption problem and the centralized control problem which exist at present according to the original data, and determining the production elements which cause the printing and dyeing quality problem, the production energy consumption problem and the centralized control problem from production elements which influence production so as to be used as a printing and dyeing quality problem diagnosis result, a production energy consumption problem diagnosis result and a centralized control problem diagnosis result;
wherein, if the currently considered production element is the fabric type, the determining the currently existing production problem according to the original data, and determining the production element causing the production problem from the production elements affecting the production, as the diagnosis result of the production process, includes: counting the one-time success rate, the number of times of feed back repair and the number of times of color difference color change of each fabric type in the existing fabric types within a preset time range, and determining the fabric type which leads the one-time success rate to be lower than a third preset threshold, and/or the number of times of feed back repair exceeds a fourth preset threshold, and/or the number of times of color difference color change exceeds a fifth preset threshold, so as to be used as a diagnosis result of the printing and dyeing quality problems.
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Effective date of registration: 20220713 Address after: 310000 room 306, building 3, Nanyang digital economy settlement department, Jingsi Road, Nanyang street, Xiaoshan District, Hangzhou City, Zhejiang Province Patentee after: Hangzhou Digital Textile Technology Co.,Ltd. Address before: 312000 No. 388-2, complex building, No. 586, West Ring Road, Keqiao Economic Development Zone, Keqiao District, Shaoxing City, Zhejiang Province Patentee before: Shaoxing Digital Textile Technology Co.,Ltd. |