JP2004273544A - Quality control system, quality control method, quality control transaction program, and recording medium recording the program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a quality control system which can be set up for production processes in a short period of time independently of the process of an equipment-type industry and the production process of an assembly-type industry and is not required to be set up again even the production processes are modified. <P>SOLUTION: The quality control system prepares by defining the features of production processes, in which points for collection and collected information contents on non-defective records, defective records, reconditioning records, tuning records, and discarding records as quality information are specified, as patterned process standard models. An interface unit 7 is provided between various quality information collecting units 6 and the quality control system, whereby a new quality control system can be easily set up again conforming to new production processes by replacing process standard models with new ones corresponding to the modification of the production processes even when the quality control system is set up once. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention records a quality management system, a quality management method, a quality management processing program, and a quality management processing program for collecting and managing quality information such as inspection results, repair results, defective results, and adjustment results in a factory. It relates to a recording medium.
[0002]
[Prior art]
Many systems that support production, such as a quality control system, a process management system, and a facility management system, are often specialized for production equipment and processes. Therefore, when there is a change in the production equipment or the process, a large number of man-hours and a change cost are required to deal with the change. As a system for solving this problem, a production support system particularly suitable for a device-type industry such as a semiconductor has been proposed (for example, see Patent Document 1). The purpose of this production support system is to reduce man-hours and costs required for changing or expanding the functions of the system by providing an interface for each production facility.
[0003]
[Patent Document 1]
JP-A-9-11092 (pages 5 to 6, FIG. 1)
[0004]
[Problems to be solved by the invention]
However, in the above-described conventional production support system, since each production facility has an interface, control of each interface is required, and there is a problem that initial system construction is complicated.
[0005]
Further, since the above-mentioned conventional production support system is intended for a device-type industry such as a semiconductor, "(1) Most defective products are discarded. (2) Quality information is always obtained from the equipment." The system is constructed based on the prerequisites unique to the equipment industry. On the other hand, in the assembly type industry such as home appliances, in addition to the process similar to the device type industry represented by semiconductor devices, "(1) When a defective product comes out, repair or adjustment is performed and re-input is performed. (2) Discard defective products only when repair or adjustment is not possible (3) In the assembly-type industry, there are processes where humans perform work and inspections, and not all quality information can be obtained from equipment. There is a process unique to the assembly type, such as "No." In the assembly type industry, a system specialized in production equipment and processes is developed, and there is a problem that the construction of the system requires a lot of man-hours and costs. Was.
[0006]
The present invention has been conceived in order to solve such a problem. The object of the present invention is to make it possible to construct a system in a short period of time regardless of the production process of the device type industry and the production process of the assembly type industry. It is an object of the present invention to provide a quality management system, a quality management method, a quality management processing program, and a recording medium on which the quality management processing program is recorded, which does not require the reconfiguration of the system even if the system changes.
[0007]
[Means for solving the problem]
The quality management system of the present invention is a quality management system that manages a production quality state in each production process constituting a production line, and includes an input unit for inputting data related to the production process, and quality information in each production process. A quality information collection unit that collects non-defective results, defective results, repair results, adjustment results, and disposal results, and an interface that adds quality information collection point information to the quality information collected by the quality information collection unit to form manufacturing quality information Unit, storage unit for storing data and manufacturing quality information, and using the manufacturing quality information to calculate the manufacturing quality status of the production line, such as product-specific quality history, lot-based quality information, and process-specific defect occurrence information And a calculation unit that performs the calculation.
[0008]
In this case, the quality information may be collected based on a computer system combining a plurality of process standard models in which each production process is patterned. Further, the process standard model may have a configuration in which the characteristics of the production process in which the quality information collection points and the information content to be collected are specified are defined and patterned. For example, there are device inspection models that perform inspections using devices to determine the quality of products and store the inspection results for each product as numerical values, human inspection models that perform inspection by humans and determine the quality of products, and defective products. In the case of discarding model to discard all cases, repair type model to repair defective products, adjustment of parts that can be adjusted until the inspection is within the allowable range based on the actual defect if it is determined to be defective by the device type inspection model Adjustable model to be performed.
[0009]
According to the present invention having such features, when constructing a quality management system, rather than constructing a system specialized for the production process, the quality information collection point and the information content to be collected are specified. By defining and preparing a process standard model that defines and patterns the characteristics of the production process, and by providing an interface between various different quality information collection means, quality control that supports various forms of production processes A system can be constructed.
[0010]
Further, the quality information collecting unit includes at least one or more quality information collecting means suitable for each production process, and the interface unit selectively collects the quality information collected by using the quality information collecting means. Points may be added to form manufacturing quality information. In this case, the quality information collecting means can use at least one or more quality information collecting means of a manual input by a terminal, a direct collection from a production facility, a barcode, and a memory tag.
[0011]
Further, the quality control method of the present invention is a quality control method for managing a production quality state of a product in each production process constituting a production line. Collecting quality information, adding quality information collection point information to the quality information to form manufacturing quality information, storing given data and manufacturing quality information, and manufacturing the product using the manufacturing quality information. Calculating the production quality status of the production line, such as individual quality history, quality information for each lot, and defect occurrence information for each process.
[0012]
Further, the quality management program according to the present invention includes a step of inputting data related to the production process, a step of collecting quality information in each production process, and a process of adding information of a quality information collection point to the quality information to produce quality information. Forming the product line, storing the given data and manufacturing quality information, and using the manufacturing quality information to store the manufacturing quality status of the production line, such as the product-specific quality history, lot-level quality information, and process-specific defect occurrence information. And calculating. The quality management program can be provided by being recorded on a computer-readable recording medium.
[0013]
Here, examples of the recording medium include a semiconductor storage element such as a mask ROM and a flash ROM, a hard disk, a flexible disk, an MO disk, a CD-ROM, a DVD-ROM, a magneto-optical disk, an IC card, and a magnetic tape. Alternatively, another recording medium may be used as long as the program can be recorded.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to FIGS.
[0015]
FIG. 1 shows the overall configuration of the quality management system of the present invention.
[0016]
The quality management system according to the present invention can be roughly classified into a given data input unit 1, a storage unit 2 (for example, a magnetic disk), a calculation unit 3, a display unit 4, a printing unit 5, and a quality information collection unit 6 (for example, a terminal input unit). Etc.), and an interface unit 7.
[0017]
That is, the given data such as the line name and the device name input from the given data input unit 1 are stored in the storage unit 2, and the non-defective results, the defective results, the repair results, and the adjustments collected by the quality information collecting unit 6. From the results, the results of disposal, and the like (hereinafter, also referred to as “quality information”), the interface unit 7 is used to form manufacturing quality information in which quality information collection points are added to the quality information, and the manufacturing quality information is temporarily stored in the storage unit 2. Keep it. Based on the stored manufacturing quality information, the calculating unit 3 calculates manufacturing quality status such as manufacturing history of each product, quality information of each lot, and defect occurrence information of each process. It is displayed on the display unit 4 and printed by the printing unit 5. FIG. 1 shows a process A, a process B, a process C, and a process D which constitute a production line in which a manufacturing quality state is managed in a lower portion thereof.
[0018]
FIG. 2 to FIG. 11 are explanatory diagrams of a process standard model for performing quality control by classifying into five patterned models based on the characteristics of the production process. FIGS. 2, 3, 6, 8, and 10 show manufacturing quality collection points in each process standard model and information contents collected at the collection points.
[0019]
In the process standard model of this embodiment, the inspection method includes an apparatus inspection model shown in FIG. 2 and a human inspection model shown in FIG. 3, and a disposal method shown in FIG. There are a mold model, a repair model shown in FIG. 8, and an adjustment model shown in FIG. The operations relating to FIGS. 2 and 3 are operations in which the next step such as assembling and molding is one operation and does not branch into a plurality as in inspection.
[0020]
Hereinafter, each model will be described.
[0021]
The apparatus inspection model shown in FIG. 2 is used for an inspection in which an inspection is performed by an apparatus to determine the quality of a product and an inspection result for each product can be expressed as a numerical value. As an example, there are an output signal inspection of an electronic component and a rated input inspection of a home electric appliance. In the system inspection model, the quality of the product is checked by comparing the inspection result of the product with the inspection standard inside the inspection device, and the output of the system inspection model is a non-defective product shown in FIG. The results are collected separately into the results and the defective results shown in FIG. Further, after repairing or adjusting the defective product, there is a re-input point P2 at which a repaired or adjusted product is input in order to perform inspection again. Furthermore, even if it is a non-defective product, an inspection result of each product is statistically analyzed, and if there is a sign of abnormality, a warning is issued and a defect can be predicted in advance. Since the system inspection model is generally expensive, it is desirable to use only the important inspection points.
[0022]
The human inspection model shown in FIG. 3 is used when an inspection is performed by a person to determine the quality of a product. As an example, there are appearance inspection and sensitivity inspection of home electric appliances. These inspections are used when the inspection cannot be performed by the apparatus or when the inspection apparatus is extremely expensive and therefore substantially impossible. In the human inspection model, after the quality is judged by a person, the information is collected at the information collection point P3 into the non-defective results shown in FIG. 4 and the defective results shown in FIG. Often there are no measurements. Further, similarly to the device system inspection, there is a re-introduction point P4 at which a repaired or adjusted product is introduced in order to perform the inspection again. In some cases, a human inspection model cannot express the inspection result of a product as a numerical value, and thus it is difficult to predict an abnormality from a measurement result that can be obtained by an inspection of an apparatus.
[0023]
The disposal model shown in FIG. 6 is used when all defective products are discarded because repair and adjustment are impossible if defective products are found, as in the case of the device type industry. As an example, there are a press molding process and an injection molding process using a mold. As the quality information collection point P5, there are a disposal result shown in FIG. 7 and a defect result shown in FIG. Further, since the defect is immediately discarded, a defect is generated and at the same time, a warning of the occurrence of the defect is issued and prompt measures are taken.
[0024]
The repair model shown in FIG. 8 is used when repairing a defective product. For example, it is used in the assembly process of parts and units. In these assembling processes, there are many cases where a person can perform re-input by performing repair work such as replacement or rework of parts. If repair is not possible, the defective product is discarded. From the above, as the quality information collection point P6, there are a defect record shown in FIG. 5, a repair record shown in FIG. 9, and a discard record shown in FIG. 7, and a re-input point P7 of a repaired product also exists.
[0025]
The adjustment-type model shown in FIG. 10 automatically adjusts an adjustable portion based on the result of the failure until the inspection falls within the specification range, when the inspection is failed in the device type inspection. One example is automatic output adjustment of electronic components. If it does not fall within the specifications even after automatic adjustment, it will be discarded as defective. From the above, as the quality information collection point P8, there are a failure record shown in FIG. 5, an adjustment record shown in FIG. 11, and a discard record shown in FIG. 7, and a re-input point P9 after the adjustment also exists.
[0026]
FIG. 12 shows an example of a layout of a production factory, and FIG. 13 shows a summary of features of each process of the production factory shown in FIG. The product is supplied from step A, and is completed through step B, step C, and step D.
[0027]
In the process A, a person performs an inspection, and all defective products are discarded. For this reason, when a defect occurs, a warning is issued immediately to notify the abnormality.
[0028]
The inspection in the steps B and C is performed by an apparatus. Defective products are repaired in the repair process, and most are repaired, but some are scrapped. Inspection results are collected by the apparatus and stored as numerical data.
[0029]
In the process D, an inspection is performed by a person. Defective products are repaired in the repair process and are not discarded.
[0030]
FIG. 14 shows an embodiment in which the process standard model and the quality information collecting means according to the present invention are applied to the production factory shown in FIG.
[0031]
In the process A, a human inspection model shown in FIG. 3 and a discard model shown in FIG. 6 are used in combination. The input from the terminal 31 is used as the quality information collecting means. For example, the number of non-defective products is input from the terminal 31 as the non-defective products, and the number of defective products is input as the bad results. Since all defective products are discarded, it can be considered that the number of discards is equal to the number of defectives. In addition, the human-system inspection model can handle re-input of repaired or adjusted products, but in process A, there is no repair or adjustment for defective products, so there is no re-input.
[0032]
In the process B and the process C, the apparatus system inspection model shown in FIG. 2 and the repair type model shown in FIG. 8 are applied in combination. As the quality information collecting means, the non-defective results and the defective results are obtained from the device 32, and the repair results and the disposal results are inputted from the terminal 33. Further, since the defective product is repaired, the defective result of the repair inspection model and the defective result of the repair type model can be regarded as the same.
[0033]
In the process D, a human inspection model shown in FIG. 3 and a repair type model shown in FIG. 8 are used in combination. As the quality information collecting means, the non-defective results and the defective results are input by reading a bar code (not shown) with a bar code reader (BCR) 34, and the repair results are input from the terminal 35. In addition, since the defective product is repaired, the defective result of the human inspection model and the defective result of the repair type model can be regarded as the same, so the defective result of the repair type model is not input. Although the barcode is read by the barcode reader (BCR) 34 as the quality information collecting means of the non-defective product record and the defective product record, the memory tag may be read by the memory tag reader.
[0034]
FIG. 15 shows a modified example of the production factory layout. Conventionally, the defective product was repaired in the process B. However, in practice, most of the adjustment work was performed, so the repair was stopped and an automatic adjusting machine was introduced. Automatic adjustment is possible in most cases, but if automatic adjustment is not possible, it is discarded.
[0035]
FIG. 16 is a table summarizing the features of each process of the production factory shown in FIG.
[0036]
FIG. 17 shows an embodiment in which the process standard model and the quality information collecting means according to the present invention are applied to the production factory shown in FIG.
[0037]
In the process B, the system inspection model shown in FIG. 2 and the adjustable model shown in FIG. 10 are applied. As quality information collecting means, a good product record, a defective record, and an adjustment record are acquired from the device 41, and a discard record is inputted from the terminal 42. In addition, since the defective product is adjusted, the defective result of the device-based inspection model and the defective result of the adjustable model can be considered to be the same, so the defective result of the adjustable model is not input. The other steps A, C, and D are the same as in the application example of each model shown in FIG.
[0038]
In this way, even if the layout of the production plant changes, there is no need to rebuild the quality management system in accordance with it, just change the process standard model and quality information collection means applied according to the layout change. It is possible to build a quality control system that matches the layout of each factory.
[0039]
Finally, the processing procedure of the quality management method executed by the quality management system of the present invention will be described with reference to the flowchart shown in FIG.
[0040]
In step S <b> 1, given data such as a line name and a device name is input using the given data input unit 1 and stored in the storage unit 2.
[0041]
In step S2, the manufacturing quality information collection unit 6 collects quality information in each production process.
[0042]
In step S <b> 3, manufacturing quality information is formed from the quality information collected by the manufacturing quality information collecting unit 6 using the interface unit 7 and stored in the storage unit 2. That is, the quality information collected by the manufacturing quality information collection unit 6 does not include information indicating the collection points. As shown in FIG. 19, the interface unit 7 adds the information of the collection point to the quality information as the manufacturing quality information and stores it in the storage unit 2.
[0043]
In step S4, based on the manufacturing quality information stored in step S3, manufacturing quality status such as defect occurrence information of each production process, quality information of each lot, and quality history of each product is calculated. For example, from the manufacturing quality information shown in FIG. 19, if the manufacturing quality information is searched using the lot number and the manufacturing number as a search key, the quality history of each product can be found. The situation is known, and if the manufacturing quality information is totaled for each process, the quality status for each process can be understood.
[0044]
In step S5, the calculation result in step S4 is displayed on the screen of the computer, and printing is performed if necessary.
[0045]
The quality management system and the quality management method described above are implemented by a program for causing a quality management process for managing a quality state of a product in each production process configuring a production line to function.
[0046]
The subject of the invention may be the program itself, or the program may be stored in a computer-readable recording medium.
[0047]
In the present invention, the recording medium may be a program medium, such as a memory such as a ROM, which is necessary for the processing performed by the calculation unit (microcomputer) 3 shown in FIG. Alternatively, a program reading device may be provided as an external storage device (not shown), and the program medium may be readable by inserting a recording medium therein. In any case, the stored program may be configured to be accessed and executed by a microcomputer, or in any case, the program may be read, and the read program may be a program (not shown) of the microcomputer. The program may be loaded into the storage area and the program may be executed. It is assumed that the loading program is stored in the main unit in advance.
[0048]
Here, the program medium is a recording medium configured to be separable from the main body, such as a tape system such as a magnetic tape or a cassette tape, a magnetic disk such as an FD (flexible disk) or an HD (hard disk), a CD-ROM / An optical disk system such as MO / MD / DVD, a card system such as an IC card (including a memory card) / optical card, or a fixed program including a semiconductor memory such as a mask ROM, EPROM, EEPROM, flash ROM, etc. It may be a medium.
[0049]
Further, in the present invention, when the system configuration is connectable to a communication network including the Internet, the medium may carry the program in a fluid manner so that the program is downloaded from the communication network. When the program is downloaded from the communication network as described above, the download program may be stored in the apparatus main body in advance, or may be installed from another recording medium. The content stored in the recording medium is not limited to a program, but may be data.
[0050]
Further, in the present invention, the program itself may be the processing itself executed by the calculation unit (microcomputer) 3 shown in FIG. 1, or may be fetched by accessing a communication network including the Internet. Alternatively, it may be one that has been imported, or one that is sent from here. Further, it may be a result of processing in the quality management system based on the fetched program, that is, a program generated. Alternatively, it may be a result of processing in the quality management system when sending out from here, that is, a result generated. Note that these are not limited to programs and may be data.
[0051]
【The invention's effect】
According to the present invention, when constructing a quality management system, instead of constructing a system specialized for the production process, the characteristics of the production process that specify the collection points of the quality information and the information contents to be collected are defined. By preparing a patterned process standard model and providing interfaces with various different quality information collecting means, it is possible to construct a quality management system corresponding to various forms of production processes. In addition, even if a system has been built once, it is easy to build a quality control system that matches the new production process by replacing the process standard model with changes in the production process, making maintenance and customization easy. It can be carried out. Further, the system introduction period can be shortened and the system construction cost can be reduced.
[Brief description of the drawings]
FIG. 1 is a functional block diagram showing the overall configuration of a production management system according to the present invention.
FIG. 2 is an explanatory diagram of an apparatus system inspection model.
FIG. 3 is an explanatory diagram of a human inspection model.
FIG. 4 is an explanatory diagram of non-defective results.
FIG. 5 is an explanatory diagram of a defective result.
FIG. 6 is an explanatory diagram of a discard type model.
FIG. 7 is an explanatory diagram of the results of disposal.
FIG. 8 is an explanatory diagram of a repair type model.
FIG. 9 is an explanatory diagram of a repair record.
FIG. 10 is an explanatory diagram of an adjustment model.
FIG. 11 is an explanatory diagram of adjustment results.
FIG. 12 is an explanatory diagram showing an example of a layout of a production factory.
13 is an explanatory diagram summarizing the features of each process of the production factory shown in FIG. 12 in a list format.
FIG. 14 is an explanatory diagram showing an example in which a process standard model and quality information collecting means are applied to the production factory shown in FIG.
FIG. 15 is an explanatory diagram showing an example of changing the layout of a production factory.
FIG. 16 is an explanatory diagram summarizing features of each process of the production factory shown in FIG. 15 in a list form.
17 is an explanatory diagram showing an example in which a process standard model and quality information collecting means are applied to the production factory shown in FIG.
FIG. 18 is a flowchart showing quality management processing by the quality management system of the present invention.
FIG. 19 is an explanatory diagram of manufacturing quality information.
[Explanation of symbols]
DESCRIPTION OF REFERENCE NUMERALS 1 given data input unit 2 storage unit 3 calculation unit 4 display unit 5 printing unit 6 quality information collection unit 7 interface unit

Claims (9)

A quality management system that manages the quality status of products in each production process constituting a production line,
An input unit for inputting data related to the production process,
A quality information collection unit that collects non-defective results, defective results, repair results, adjustment results, and disposal results as quality information in each of the production processes;
An interface unit for forming manufacturing quality information in which information of a quality information collection point is added to the quality information collected by the quality information collection unit;
A storage unit for storing the given data and manufacturing quality information,
A calculation unit that calculates the quality history of each product as the manufacturing quality status using the manufacturing quality information, the quality information of each lot, and the defect occurrence information for each process.
Quality control system characterized by comprising: The quality management system according to claim 1, wherein the quality information is collected based on a computer system in which a plurality of process standard models in which each production process is patterned are combined. 3. The quality according to claim 1, wherein the process standard model is a pattern defined by defining a characteristic of a production process in which a collection point of quality information and an information content to be collected are specified. Management system. The process standard model is an apparatus inspection model that performs inspection by an apparatus to determine the quality of a product and stores the inspection result of each product as a numerical value, a human inspection model that performs inspection by a human to determine the quality of a product, A discard model that discards all non-defective products, a repair model that repairs defective products, and can be adjusted until the inspection is within the allowable range based on the actual results of failure when judged as defective by the device type inspection model. The quality management system according to claim 3, further comprising an adjustment model for adjusting a part. The quality information collecting unit includes at least one or more quality information collecting means suitable for each production process, and the interface unit selectively adds a quality information collection point to the quality information collected by using the quality information collecting means. 2. The quality management system according to claim 1, wherein the information is added to form the production quality information. The quality information collecting means is constituted by at least one of an input means connected to a terminal to which information is manually input, an information transmitting means for directly collecting information from a production facility, a bar code, and a memory tag. The quality management system according to claim 5, wherein A quality control method for managing the quality status of products in each production process constituting a production line,
Inputting data related to the production process;
Collecting quality information in each of the production steps,
Adding quality information collection point information to the collected quality information to form manufacturing quality information;
Storing the given data and manufacturing quality information;
A step of calculating the quality history of each product as the manufacturing quality status using the manufacturing quality information, the quality information of each lot, and the defect occurrence information for each process,
Quality control method characterized by comprising: A computer-readable quality management program that manages the quality status of products in each production process that constitutes a production line,
Inputting data related to the production process;
Collecting quality information in each of the production steps,
Adding quality information collection point information to the collected quality information to form manufacturing quality information;
Storing the given data and manufacturing quality information;
Calculating a quality history of each product, quality information of each lot, and defect occurrence information for each process as a manufacturing quality status using the manufacturing quality information. A computer-readable recording medium on which the quality management program according to claim 7 is recorded.

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