JP5091709B2 - Statistical quality process control management method and statistical quality process control management apparatus - Google Patents

Description

  The present invention relates to an integrated production management system, and more particularly to a statistical quality process control management method and statistical quality process control management apparatus using statistical process control (SPC).

  A statistical method for suppressing variations that are problems of quality control is called statistical quality control (SQC) or statistical process control (SPC).

  This statistical quality control begins with two researches, Dr. Schuhart's control chart method conducted at Bell Laboratories in the United States, and sampling tests with HF Dodge and HG Roming. It is said that the control charts and statistical methods were applied to industry in the United States and then began to spread in Japan in the 1950s.

  On the other hand, the functional chemical industry, which is the industrial field where the present invention was born, was reported in 2002 by the Ministry of Economy, Trade and Industry's Functional Chemical Industry Study Group as “Customers based on materials and material technology based on chemical technology. It is defined as an industry that creates and proposes added value to society by proposing solutions. Here, a functional chemical such as a semiconductor material is a chemical that achieves a specific product function with a pinpoint (high accuracy), and is distinguished from a general “chemical industrial product”.

  Specifically, as the background of the present invention, the following technical management related to quality control required for companies that become functional chemical industries (hereinafter referred to as “functional chemical companies”). There were issues and problems.

(1) In the manufacturing process based on the quality standard document to meet various needs while many new products are required for functional chemical companies, it is easy to change the quality standard standard for each management process. In many cases, high-precision statistical quality control has not been realized, and defective products have returned to the initial stage of the launch of new products.
(2) Statistical quality control directly related to the manufacturing process could not be performed, and corrective measures such as quality preventive maintenance and omission of calibration of quality measuring instruments could not be implemented promptly.
(3) It was impossible to stop shipping and stop manufacturing by agile lot tracking linked to statistical quality control information of products including materials and intermediate products in the manufacturing process.

Various proposals have been made on the problems related to the above (1) and (2).
In Patent Document 1, a statistical quality control method has been proposed for the purpose of detecting the tendency or fluctuation of quality characteristics in the production line at an early stage and preventing the occurrence of quality troubles in advance for the problem of (1). Proposals have been made within a range limited to the same lot or to lots before and after.

  Further, in Patent Document 2, with respect to the problems (1) and (2), there is a proposal to provide an abnormality determination method and system in an SPC analysis system that performs data transfer between a past database server and a client. .

As a related patent, the technique of Patent Document 3 relates to an error correction system when statistical quality control (SPC) sensor data is erroneously input in a printing environment, and aims at stable feedback control. This is different from the subject of the present invention. In addition, the technique of Patent Document 4 aims to improve the detection accuracy of QC trend abnormality while suppressing the occurrence of unnecessary alarms.
JP 2002-149222 A Japanese Patent Laid-Open No. 2004-55644 JP 2005-331944 A Japanese Patent Laid-Open No. 2005-93686

  However, since Patent Document 1 has limited lots, the technical problem (1) is different from quality control by a control chart or the like which is high-precision statistical quality control required for the functional chemical company. There is a problem that is not a means to realize statistical quality control of the manufacturing process.

  Patent Document 2 aims at automating abnormality determination, and quality management that focuses on customer needs based on consistent quality standards in the management process units in all manufacturing processes required for functional chemical companies, and products In the inspection pass / fail judgment, there is a problem that an effective proposal for a quick corrective action when an abnormality occurs that is directly connected to a manufacturing process that does not generate a defective product is not made.

  Patent Document 3 has a control limit update means, but there is a problem that an effective proposal to the functional chemical industry that requires strict statistical quality control based on pre-registered quality standard standards has not been made. .

  Also, in any of Patent Document 1 to Patent Document 4, shipping stoppage by flexible lot tracking linked to statistical quality control information of products including materials and intermediate products of the manufacturing process, which is the technical problem (3), is described above. In addition, there was a problem that was not a mechanism that could realize an integrated production management system in statistical quality control that realized manufacturing stoppage.

  Therefore, even with the methods of Patent Document 1 to Patent Document 4, (1) a manufacturing process based on quality standard standards to meet various needs in the market for many new products required by functional chemical companies However, it is not possible to implement high-accuracy statistical quality control that makes it easy to change the quality standard for each management process, and it is an effective SPC for the occurrence of defective return at the initial stage of the launch of a new product. No management method has been proposed. In addition, (2) statistical quality control directly related to the manufacturing process could not be performed, and corrective measures such as quality preventive maintenance and omission of calibration of quality measuring instruments could not be implemented promptly. In addition, as a functional element in the integrated production management system, there is a problem that (3) stop shipping and stop manufacturing by agile lot tracking linked to statistical quality control information of products including materials and intermediate products in the manufacturing process cannot be realized. It was.

  The present invention is an invention for solving the above-mentioned problems, and it is possible to manage a statistical quality process capable of managing all of the management processes from the start of manufacturing to the management process to be managed or from the management process to the end. It is an object of the present invention to provide a process control management method and a statistical quality process control management apparatus.

  It is also assumed that the following issues that are characteristic of functional chemical companies will be solved. Originally, business departments, factories, billing departments, product departments, etc. have been maintained for a certain period of time in terms of corporate operations, and so far they have been regarded almost fixedly in the production structure of production departments. However, the current functional chemical companies are constantly required to change in response to changes in the resource and energy situation, and the production structure of the chemical industry is always required to change dynamically. Therefore, a new integrated production management system that supports them has a mechanism that can easily cope with changes such as reform, abolition, and expansion of business divisions, factories, accounting departments, and product departments. The statistical quality process control management method according to the present invention also has a purpose of serving as an element function constituting such an integrated production management system.

  In order to achieve the above-mentioned object, the statistical quality process control management device is a manufacturing process management unit having a business division, factory, accounting department, product department, etc. Collect the quality characteristics that are the test items of the manufacturing process and the elapsed time, perform statistical processing, and within the allowable range based on the quality standard that can be handled in advance for each customer in the management process unit Statistical quality process management analysis and evaluation is performed based on the statistical processing results related to the manufacturing process, and the statistical quality of all the management processes from the start of manufacturing to the management process or the end in the product quality pass / fail judgment of the final product The management information must be managed at the time of the manufacturing process in accordance with quality control that conforms to a predetermined quality standard. And butterflies.

  According to the present invention, it is possible to manage the statistical quality process of all the management steps from the start of manufacturing to the management step to be managed or the end thereof.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments for carrying out the invention will be described with reference to the drawings. This is merely an example, and the technical scope of the present invention is not limited to this.

  FIG. 1 is a block diagram schematically showing the overall configuration of a statistical quality process control management apparatus according to an embodiment of the present invention. The statistical quality process control management device 100 automatically analyzes and evaluates the statistical quality process management based on the statistical processing result related to the manufacturing process related to the management process, and manufactures from the start of manufacturing in the product quality pass / fail judgment of the final product. It is a device that performs quality control (quality control) that matches the predetermined quality standards at the time of the manufacturing process, which is the object of quality control, for statistical quality control information for all management steps in the middle or until the end. . The statistical quality process control management is called SQPC (Statistical Quality Process Control) in order to distinguish it from statistical quality management (SQC) or statistical process management (SPC).

  Specifically, a quality performance / preventive management request operation is performed through the input / output means 1 and 2 from the manufacturing department and the quality assurance department in the manufacturing process corresponding to each manufacturing department. For example, the quality assurance department performs statistical quality process control management (SQPC) product inspection pass / fail judgment management in the manufacturing process, SPC judgment information management request operation, and the like through the input / output means 1. The control means 10 that accepts these requests activates the quality performance / prevention management means 11 in response to the request, and activates the product inspection pass / fail determination management process 12 and the SPC determination information management process 13 in response to the requested operation instruction. The statistical quality process control management apparatus 100 outputs the statistical quality information of all the management processes up to the management process at that time as the evaluation result of the quality characteristic multidimensional analysis based on the quality standard standard document. The statistical quality process control management device 100 is realized by an information processing device such as a personal computer or a server, for example.

  At this time, quality characteristic multidimensional analysis information (including product relations and material relations), quality standard reference information, and product process management process information required by the statistical quality process control management apparatus 100 include a lot of quality characteristics. They are stored in the dimension analysis DBs 21 and 22, the quality standard standards DB 24, and the manufacturing process management process DB 23, and can be automatically input by the quality characteristic multidimensional analysis information acquisition means 14. The material quality record information and the product quality record information are stored in the material quality record DB 31 and the product quality record DB 32, and can be automatically input by the record information acquisition means 15. In addition, the used material information and the shipping result information are stored in the used material DB 41 and the shipping result DB 42, and can be automatically input by the used material information / shipping result information acquisition means 16. Here, each database of quality characteristic multidimensional analysis DBs 21 and 22, manufacturing process management process DB 23, quality standard reference document DB 24, material quality results DB 31, product quality results DB 32, used materials DB 41, and shipping results DB 42 is an integrated database 200. Managed as. DB is an abbreviation for Data Base.

  Note that the quality characteristic multidimensional analysis information is analysis information used for quality characteristic multidimensional analysis based on the quality standard standards for statistical quality information of all management processes up to the management process at the time of inspection. In general, multidimensional analysis refers to analyzing data collected from databases in various ways. The shipment record information is shipment record information of a product or a semi-finished product (intermediate product) manufactured in a management process of a certain manufacturing process. For example, the functional chemical product that is the target product of the present invention is mainly a material (material) delivered to a semiconductor manufacturer or an automobile manufacturer, specifically, a functional resin.

  FIG. 2 is a block diagram showing the functional development of the statistical quality process control management apparatus. The function of the statistical quality process control management apparatus 100 is also positioned as an element function of the total production management system. In the present embodiment, the integrated production management system is configured so as to be closely linked to the function of the product defect integration management apparatus 300 relating to lot tracking. That is, when the product defect integration management apparatus 300 receives the lot tracking instruction from the lot tracking unit 108 of the statistical quality process control management apparatus 100, the product defect integration management apparatus 300 tracks the defective lot and manages the product regarding the product defect.

  Here, the statistical quality process control management device 100 uses the management screen (see FIG. 6) of the product inspection pass / fail judgment management unit 102 or the SPC judgment information management unit according to the quality performance / prevention management menu of the quality performance / prevention management unit 101. The management screen 103 (see FIGS. 4 and 5) is called up. The product inspection acceptance / rejection determination management unit 102 performs inspection data management via the product-related inspection data list unit 104 and the material-related inspection data list unit 106. In addition, the product inspection pass / fail judgment management unit 102 performs SPC analysis / evaluation management via the product-related SPC analysis / evaluation management unit 105 and the material-related SPC analysis / evaluation management unit 107. The quality record / prevention management unit 101 is shown mainly as a function of the management screen in the quality record / prevention management unit 11 of FIG.

  The SPC analysis / evaluation management units 105 and 107 perform SPC analysis by exchanging information with the manufacturing process management process DB 23, the quality standard reference document DB 24, the product quality characteristic multidimensional analysis DB21, and the material quality characteristic multidimensional analysis DB22.・ Perform evaluation management. Further, the SPC analysis / evaluation management units 105 and 107 request the lot tracking unit 108 for defect lot information.

  The inspection data list sections 104 and 106 manage inspection data by exchanging information with the manufacturing process management process DB 23, the quality standard reference DB 24, the product quality characteristic multidimensional analysis DB21, and the material quality characteristic multidimensional analysis DB22. To do.

  Furthermore, on the management screen (see FIG. 4) of the SPC determination information management unit 103, it is possible to call up a screen of related examination data, correlation coefficient, and multidimensional analysis.

  FIG. 3 is a schematic diagram showing a processing flow of the quality performance / prevention management function. This will be described with reference to FIGS. 1 and 2 as appropriate. The quality performance / prevention management function of the statistical quality process control management apparatus 100 includes Step A to Step E. In the first step A, the quality record / prevention management unit 101 receives a screen call request from the quality record / prevention management menu. In the next step B, a screen request is determined, parameters necessary for the call are acquired, and the screen is called. At this time, based on the determination of the screen request, the management screen call of the product inspection pass / fail determination management unit 102 in step C or the management screen call of the SPC determination information management unit 103 in step D is executed.

  Here, in step E, based on the SPC determination information, the used material information, the shipping record information, etc. as required according to the request category, the product defect integration management apparatus 300 accompanying the lot tracking (shipping stop) of the lot tracking unit 108 is performed. It is also possible to link to functions.

  Detailed steps of the product inspection pass / fail judgment management in step C are shown in step C10. The product inspection acceptance / rejection determination management unit 102 determines whether or not the inspection acceptance / rejection determination is necessary in Step C10. If the inspection acceptance / rejection determination is necessary, the product inspection acceptance / rejection determination management unit 102 executes Step C20. In step C <b> 20, the product inspection pass / fail determination management unit 102 determines whether or not automatic classification of the manufacturing process management process defined for each management process is necessary (YOUHI = 1: required). When the automatic classification of the management process is necessary, the process proceeds to Step C50. In step C50, the next management process is automatically classified based on the management limit range of the manufacturing quality standard for each individual customer corresponding to the manufacturing process management process. The detailed flow of step C50 will be described later with reference to FIG.

  By executing step C50, a predetermined parameter is set as a result of automatic classification within the control limit range of the predetermined control process. In step C60, the parameter of the automatic classification result is determined. If the result is NG, an automatic classification error message is output in step C90, and the process proceeds to step C30.

  Further, in step C30, the determination process (see FIG. 9) of the product inspection pass / fail determination management unit 102 that performs statistical quality process control is executed for the statistical quality information of all the management processes up to the management process at the time of inspection. The In step C40, whether or not SPC analysis / evaluation is necessary is determined in the management process. If the SPC analysis / evaluation is necessary, the process proceeds to step C70. In step C70, the product inspection pass / fail judgment management unit 102 can output a warning or an abnormal message according to the SPC judgment classification.

  In step C80, it is determined whether or not there is a request for displaying a list of corrective actions for SPC determination information. For example, when a corrective action button on the product inspection pass / fail judgment management screen (see FIG. 6) is pressed, the request is accepted and step C95 is executed. Here, in step 95, corrective actions for the SPC determination category are displayed in a list with a high possibility (such as descending frequency) (see FIG. 11).

  FIG. 4 is a layout diagram illustrating a screen example of SPC determination information management. The screen 28 shown in the figure is a screen displayed on the display unit of the input / output means 1 and 2 (see FIG. 1). The screen 28 includes a screen title part 281, a common selection part 282, a detail part 283, a SPC analysis / evaluation management procedure button setting part 284, and an operation button setting part 285.

The main purpose of this screen is to display a list of SPC determination information, and has the following functions.
(1) Product basic information corresponding to the search condition specified by the common selection unit 282 corresponding to the screen title portion 281, inspection information, and management process, inspection department, test item, and SPC determination that are detailed information of the inspection information A list of SPC determination information as results can be displayed.
(2) The SPC analysis / evaluation management procedure button setting unit 284 has buttons for calling SPC determination information management, inspection data list, SPC analysis / evaluation management, correlation coefficient matrix, and multidimensional analysis management. Can be displayed.

  The button setting unit 284 of the SPC analysis / evaluation management procedure confirms the list display of the SPC determination information result by the inspector and the inspection data list, SPC analysis / evaluation for further detailed SPC analysis / evaluation. In order to perform management, correlation coefficient matrix, and multidimensional analysis management, a transition to the screen can be performed by pressing the button.

  The detail section 283 shows display examples of the basic product information 283a, the inspection information 283b, and the SPC determination information 283c. The screen can be updated in the previous section and the next section, and the condition of the common selection section 282 can be searched. The number of cases is also displayed.

  The basic product information 283a includes a billing department, a product name, a manufacturing date, a product classification, a packing form / dimension, and a lot number (lot number). The inspection information 283b includes a comprehensive determination result, an inspection classification, and an inspection date. The SPC determination information 283c includes a management process, an inspection department, a test item, and an SPC determination result. Note that “seven consecutive rises” in the SPC determination result means that the statistical value of the lot has risen seven times consecutively.

  FIG. 5 is a layout diagram illustrating a screen example of SPC analysis / evaluation management (product-related). This screen is displayed when the SPC analysis / evaluation button of the button setting unit 284 shown in FIG. 4 is pressed. The common selection unit 282 may be displayed by taking over the product name of the transition source of the SPC determination information management shown in FIG. 4, and the SPC analysis / corresponding to the search condition designated by the common selection unit 282 anew. It is also possible to display evaluation management (product related). The screen 28 includes a screen title part 281, a common selection part 282, an SPC analysis / evaluation management procedure button setting part 284, an operation button setting part 285, standard / actual data information 286 as detailed information, and a control chart / graph information. 287 and the like are included. Here, in the standard / result data information 286, corresponding standard information 286a, result information 286b, and inspection result details 286c for each lot are displayed.

(1) Standard / result data information 286
The standard information 286a for the test item includes an item number, an item, and a standard value. For example, the upper limit standard value of the inspection standard, the lower limit standard value of the inspection standard, the central standard value of the inspection standard, and the standard unit are included. is there. The actual result information 286b includes an item number, an item, and a statistical value, and includes, for example, the number of target lots, an upper management limit value, and a lower management limit value. The inspection result details 286c for each target lot includes an item number, a lot number, a manufacturing date, a test value, and a determination result.

(2) Control chart / graph information 287
The control chart for the test item is a graph for determining whether or not the manufacturing process is in a statistical control state. The X (X-R) control chart is used to determine whether the variation of the quality characteristic value, which is a combination of the average value (X bar) and the control chart of the range (R), is the cause of abnormality or the cause. It is a quality control tool. The control chart is plotted on a line graph against two control limit lines (upper control limit, lower control limit) and one center line, and the statistical value of variation in quality characteristic values exceeds a predetermined value, If it goes outside the control limit line, it indicates that there was an abnormal cause.

In addition, the following selection display can be performed as the management width. Here, the X-axis of the graph indicates lot number.
(A) When the management width is the control limit • Upper limit line: average value + moving range average value × α
・ Center line: Average value ・ Lower limit value: Average value−Movement range average value × α
(B) When control width is inspection standard ・ Upper limit line: Inspection standard upper limit value ・ Center line: Inspection standard reference value ・ Lower limit value: Inspection standard lower limit value (c) When control width is product standard ・ Upper limit line: product standard Upper limit ・ Center line: Product standard reference value Lower limit: Product standard lower limit

  The X-Rs control chart is a combination of control charts of individual values (X) and ranges (Rs). Here, (Rs) indicates the range of standard deviation.

  FIG. 6 is a layout diagram showing a screen for product inspection pass / fail determination. The screen 29 shown in the figure is a screen displayed on the display unit of the input / output means 1 and 2 (see FIG. 1). The screen 29 includes a screen title portion 291, a common selection portion 292, an operation button setting portion 295, basic information 293 that is detailed information, pass / fail judgment information 294, test item-specific test value information 296, and X / Xbar management diagram 297. Etc. are included. The purpose of this screen is to manage product inspection pass / fail judgment, and display basic inspection information 293 corresponding to the lot number corresponding to the search condition specified by the common selection unit 292 corresponding to the screen title portion 281. The pass / fail judgment information 294 can be displayed or set.

  The test item-specific test value information 296 includes test item information, test item-specific information, SPC determination information including corrective actions, and previous result information, and an X / Xbar management chart 197 is displayed when a test item is selected. Can do. Here, an X control chart is displayed when the number of tests = 1, and an Xbar control chart is displayed when 2 or more.

  Moreover, although this screen is an inspection pass / fail determination function for product-related items, a screen for an inspection pass / fail determination function related to semi-finished products and materials is also prepared. Further, the comprehensive determination of the pass / fail determination information 294 is automatically determined comprehensively based on all the test items leading to the management process and the SPC determination information result, but can be set by the comprehensive determiner. It is like that.

  Further, in the embodiment, the item number 3 of the SPC determination information of the test value information 296 for each inspection item is an abnormal message with a lower limit of 7 stations, and an item number 4 is a warning message with a lower limit of 6 stations. Here, by pressing the corrective action button, corrective action display (sub-window (see FIG. 11) that displays a list in descending order of the frequency of the already set results) and selection setting for the SPC determination category (each message) can be performed. It has become.

  FIG. 11 is a layout diagram illustrating a screen example of a sub window of the SPC determination information correction measure list. Here, the state displayed by pressing the button of the SPC determination information column and the corrective action item in the test value information part by inspection item on the product inspection pass / fail determination management screen is shown. In the present embodiment, the list of corrective action messages can be displayed in descending order and time-series order of already set frequencies, and corrective action messages executed at that time can be set each time.

  Returning to FIG. 6, the button setting unit 295 includes a comprehensive determination registration button, an inspection data list button, an SPC determination management button, a search button, a registration button, and a menu button. For example, the screen can be called by pressing the inspection data list and SPC determination management button, and the comprehensive determination result can be registered as the final determination separately from the person-in-charge determination by pressing the comprehensive determination registration button. It has become.

  FIG. 7 is a file configuration diagram showing a manufacturing process management process, an SPC determination master, and an SPC determination result (quality result information). This will be described with reference to FIGS. 1 and 2 as appropriate. The file of the manufacturing process management process is stored in the manufacturing process management process DB, and the SPC determination master is stored in the quality standard reference document DB 24. The SPC determination result file is stored in the product quality result DB 32 in the case of a product and in the material quality result DB 31 in the case of a material.

  The manufacturing process management process file includes information on business divisions, factories, account departments, product departments, product codes, management processes, next management processes, and whether automatic classification is necessary. In the quality standard standard document corresponding to the manufacturing process management process, a control limit range which differs for each customer is defined. Further, in the manufacturing process management process, definitions are defined in advance for the pointer (linking) of the continuous next management process and the necessity of automatic classification of the next management process.

  The SPC judgment master file includes information on business divisions, factories, billing departments, product departments, product codes, management processes, test items, SPC judgment categories, SPC judgment result codes, SPC judgment result messages, and SPC judgment corrective action messages. included. In the SPC determination master, an SPC determination result code and an SPC determination result message are defined in advance for each management process and test item, an assumed SPC determination corrective action message can be defined together, and a new corrective action is additionally registered. It is possible. Here, as shown in the legend, for example, the SPC determination category is warning and abnormal, and the SPC determination result code includes 100001 (out of control limit) and 100002 (seven consecutive rises). The SPC determination corrective action message includes a measuring instrument calibration requirement.

  The SPC determination result file includes business division, factory, account department, product department, product code, management process, test item, SPC determination category, SPC determination result code, SPC determination result lot number, SPC determination date, SPC determination time) and SPC determination corrective action message information. As for the SPC determination result, the SPC determination corrective action message at that time is stored together with the lot number and the SPC determination time, and statistical processing of past corrective action messages for the SPC determination result in the management process can be performed. . Specifically, for example, it is also possible to display a list in the order in which there is a high possibility of corrective action for the SPC determination category (frequency descending order).

FIG. 8 is an explanatory diagram showing a transition diagram of the management process. Since the manufacturing process of a functional chemical product is a manufacturing process mainly including a chemical reaction, a specific example of the manufacturing process will be given first. In general, in a chemical reaction formula representing a chemical change, a substance before reaction is called a reactant X, and a substance after reaction is called a product Y. When there are a plurality of reactants and products, they are connected by +. In the case of an irreversible reaction, the arrow is represented by → (see formula (A1)).
X → Y (A1)

  For example, the manufacturing process of the component-molding synthetic resin can be roughly described in three steps. First, (1) “polymerization” which is a manufacturing process at the substance or material level as an aggregate of polymer molecules as a polymer material, and then (2) a plastic base to obtain the desired performance and function “Compounding”, which is a process of blending reinforcing materials and additives into the resin, and compounding in the case of thermoplastic resins, the base resin pellets and reinforcing materials and additives are mixed to some extent by a mixer or directly kneaded. Put in a machine and mix homogeneously while melting. Then, it is pelletized by a granulation extruder. Finally, (3) “Molding process” tailored to the application. Furthermore, for example, reinforcing materials and additives to be blended in the compound are diverse, including inorganic materials and organic materials.

  In addition to improving mechanical properties and durability, glass fiber, in particular, has excellent mechanical strength, extremely low hygroscopicity, excellent heat resistance, chemical resistance, and dimensional stability. Used as a typical reinforcement. Additives include stabilizers, plasticizers, colorants, flame retardants, antistatic agents and the like.

  Here, if a product (functional resin) having a target function F is, for example, a management process P (I, J) which is a management unit of a manufacturing process, (1) I = 1 is a manufacturing process of a synthetic resin. (2) I = 2 is “compounding” and (3) I = 3 is “molding step”.

If the management unit of the process is J, the production process of the functional chemical product of function F can be defined by the following general formula (A2).
F = PΣ (I, J) (A2)
Where I = 1, 2,..., N J = 1, 2,.

From the formula (A2), the production process from the start to the end of the production is expressed as a process having the order of the management process P (1,1) + P (1,2) +... + P (n, m). F, which is a product of the production process, indicates a functional chemical product having the function F (see formula (A3)).
P (1,1) + P (1,2) + ... + P (n, m) → F (A3)

In addition, the management unit of the manufacturing process can be viewed as a set of combination formulas of chemical reaction formulas (A1) representing chemical changes as a result of manufacturing work including reaction heat and catalyst processing. This is represented by the formula (A2). Note that the final management steps P ₁ (I + 1, m), P ₂ (I + 1, m), P ₃ (I + 1, m), P manufactured through the manufacturing process P (I + 1, J) shown in FIG. ₄ (I + 1, m) represents a functional chemical having different specifications F1, F2, F3, and F4.

  On the other hand, from the viewpoint of research and development processes such as new products, the characteristic of the manufacturing process of functional chemicals is to first design the structure and molecular structure of “composition” such as mixing with resins and additives on a lab scale. Thus, the product structure and the basic manufacturing process are determined, and finally the order of the reaction method, catalyst, and manufacturing process in the manufacturing facility is determined.

  As described above, at scaled-up manufacturing sites, it is also necessary to resolve new processes such as heat of reaction due to an increase in unit production, especially in the statistical quality process for managing the production process of functional chemicals. Control is essential.

  Here, when the process shifts from the manufacturing process P (I, J) to P (I + 1, J), automatic classification is performed based on the control limit, the inspection standard, the product standard, and the SPC determination result. However, classification setting by the general judge can be performed using the operation screen shown in FIG.

  FIG. 9 is a conceptual explanatory diagram illustrating product inspection pass / fail determination conditions regarding control limits, inspection standards, product standards, and SPC determination results. In FIG. 6, which is a screen layout diagram of the present implementation system, in the manufacturing process of the functional chemical product of function F, the product inspection pass / fail determination in the management process is the standard determination for each test item in the final management process (the above three levels) ) And SPC determination result search conditions are set, it is also possible to display pass / fail determination results for all management processes up to that management process at that time.

The expression of the product inspection pass / fail judgment condition in the management process P (I, J) of the X control chart can be defined by the expression (A4).

  Here, the symbol of ∩ indicates an AND condition. Satisfy both the “control limit” of various quality characteristics in the management process of the manufacturing process and the “SPC judgment result OK limit” that enables the quality control to match the predetermined quality standard for statistical quality control information This is expressed by the formula (A4).

In addition, as shown in FIG. 9, the “control limit” of various quality characteristics for the product of P (I, J) is not more than the upper limit value (K _U ) of the control limit defined by the in-house regulations and the like. More than the value (K _L ) and below the upper limit (N _U ) of the inspection limit and above the lower limit (N _L ), and further below the upper limit (G _U ) of the product limit and above the lower limit (G _L ) It is necessary to satisfy.

FIG. 10 is a schematic diagram showing a detailed flow of step C50. Step C50 is a process of automatic classification of the management process. First, the product inspection pass / fail judgment management unit 102 sets an initial value of the automatic classification result. Specifically, the automatic classification result = NG (step C 510). The quality standard standard document DB 24 (see FIGS. 1 and 7) corresponding to the manufacturing process management process defines a management limit range that differs for each customer, and repeats the automatic classification number I (from 1 to n) (Step C 520). It is determined whether it is within the range of the control limit (step C 530). If it is within the range of the control limit (K _L ≦ P (I, J) ≦ K _U ), automatic classification = I is set, and automatic classification result = OK (automatic classification result is set to OK) ( Step C 540). Then, the process proceeds to the branch destination box N (BN) (step C550) . Step C 560 indicates the point of the branch destination BN.

  The statistical quality process control management apparatus 100 according to the present embodiment collects quality characteristics, which are test items of a manufacturing process, in a management process unit in a manufacturing process managed based on a manufacturing process management process and a quality standard standard. Statistical processing is performed, and quality control is managed so as to meet a predetermined quality standard.

  Specifically, the statistical quality process control management device 100 includes manufacturing process management process information, quality standard reference information, each management process from the start of manufacturing to the process to be managed or each of the processes from the start of manufacturing to the end of manufacturing. Quality characteristic multidimensional analysis information acquisition means 14 that acquires multidimensional analysis information of quality characteristics in a management process from a database (for example, integrated database 200), material quality result information that is material quality result information, and product quality Performance information acquisition means 15 for acquiring product quality performance information, which is performance information, from the database, analysis information of quality characteristics, material quality performance information, and used material information and shipping performance information related to product quality performance information Material information / shipping result information acquisition means 16 for acquiring information from the database, and individual customers defined in advance for each management process unit Statistical quality process management analysis and evaluation is automatically performed based on statistical processing results based on quality characteristic analysis information related to the manufacturing process related to the management process to determine whether it is within the acceptable range based on the applicable quality standard. Statistical process management determination information management means (for example, SPC determination information management unit 103) for acquiring and managing statistical process management (SPC) determination information from the database, manufacturing process management process information, and quality standard reference information Based on material quality record information, product quality record information, used material information, shipment record information, and SPC determination information, each management process from the start of manufacturing to the process to be managed or the start of manufacturing to the end of manufacturing Product inspection that acquires and manages quality control pass / fail judgment information that matches all predetermined quality standards in each management process up to Comprises a determination management unit (product inspection acceptance judgment management unit 102), the.

  In addition, the used material information and the shipping result information include the used material information (for example, the material lot number, the material name, and the material linked to the production lot No. in the management process corresponding to the multi-dimensional analysis information of the quality characteristics and the quality results. Used quantity, supplier) and shipping record information (for example, shipping lot number, product name, shipping quantity, shipping destination) are shown.

  In addition, in the management process of a certain manufacturing process, the used material information is manufactured by using a semi-finished product (intermediate product) and a purchased material of the previous management process, or by using a plurality of material lots (insufficient). In some cases. Since the shipment record information may be shipped in the state of a semi-finished product (intermediate product), the shipment record information in each management process is important. On the product inspection pass / fail judgment management screen 29 shown in FIG. 6, the materials used and the amount of materials used in the management process may be displayed. Further, in the management process that requires shipping, shipping record information can be displayed.

  Further, in this embodiment, the product inspection pass / fail judgment management means outputs a corrective action message associated with the SPC judgment information from the database upon receiving a corrective action confirmation instruction when the SPC judgment information is abnormal. be able to.

  In the present embodiment, the statistical quality process control management device 100 further receives the lot tracking instruction when the SPC determination information is abnormal, and the manufacturing process management process information, the quality standard reference information, Based on the material quality record information and the product quality record information, lots in which the SPC judgment information in each management process from the start of manufacturing to the process to be managed or in each control process from the start of manufacture to the end of manufacture is abnormal Lot tracking means (for example, lot tracking unit 108) for tracking is provided.

It is a block diagram which shows typically the whole structure of the statistical quality process control management apparatus which concerns on embodiment of this invention. It is a block diagram which expands and shows the function of a statistical quality process control management apparatus. It is the schematic which shows the processing flow of a quality performance / prevention management function. It is a layout figure which shows the example of a screen of SPC determination information management. It is a layout figure which shows the example of a screen of SPC analysis and evaluation management (product relation). It is a layout figure which shows the screen of product inspection pass / fail determination. It is a file block diagram which shows a manufacturing process management process, a SPC determination master, and a SPC determination performance (quality performance information). It is explanatory drawing which shows the transition diagram of a management process. It is a conceptual explanatory drawing which shows the product inspection pass / fail determination condition regarding the control limit, the inspection standard, the product standard, and the SPC determination result. It is the schematic which shows the detailed flow of step C50. It is a layout figure which shows the example of a screen of the sub window of the SPC determination information correction action list.

Explanation of symbols

1, 2 Input / output means 10 Control means 11 Quality performance / prevention management means 12 Product inspection pass / fail judgment management processing 13 SPC judgment information management processing 14 Quality characteristic multidimensional analysis information acquisition means 15 Performance information acquisition means 16 Materials used / shipping results Information acquisition means 21, 22 Quality characteristic multidimensional analysis DB
23 Manufacturing process management process DB
24 Quality Standard DB
31 Material quality record DB
32 Product Quality Results DB
41 Material DB
42 Shipping results DB
100 Statistical Quality Process Control Management Device 102 Product Inspection Pass / Fail Management Unit (Product Inspection Pass / Fail Management Unit)
103 SPC determination information management unit (SPC determination information management means)
104, 106 Inspection data list part 105, 107 SPC analysis / evaluation management part 108 Lot tracking part 200 Integrated database 281 Screen title part 282 Common selection part 283 Detailed part 284, 285 Button setting part 300 Product defect integrated management device

Claims (6)

Management device for managing the manufacturing process based on the manufacturing process management process and quality standard FAS, collecting information of quality characteristics is a measurement for the test item of the manufacturing process to the management process unit, the manufacturing process Automatically based on the control limits, inspection standards, product standards, and statistical process control (SPC) judgment results specified in the in-house standard so that the products in the product meet the specified quality standards specified in the quality standard standards A statistical quality process control management method for classifying and managing quality control,
The management device includes quality characteristic multidimensional analysis information acquisition means, performance information acquisition means, used material information / shipping performance information acquisition means, statistical process management determination information management means, and product inspection pass / fail determination management means. Prepared,
The quality characteristic multidimensional analysis information acquisition means includes manufacturing process management process information, quality standard reference information, and quality in each management process from the start of manufacturing to the process to be managed or from the start of manufacturing to the end of manufacturing. Quality characteristic multidimensional analysis information acquisition step for automatically acquiring characteristic multidimensional analysis information from the integrated database,
The track record information acquisition means is a track record information acquisition step of automatically acquiring material quality track record information that is track record information of material quality and product quality track record information that is track record information of product quality from the integrated database;
The used material information / shipping result information acquisition means stores the used material information and the shipping result information related to the multi-dimensional analysis information of the quality characteristics, the material quality result information, and the product quality result information in the integrated database. Used material information / shipping result information acquisition step automatically acquired from
Whether the statistical process management determination information management means is within an allowable range based on a quality standard that can be handled by an individual customer defined in advance in the management process unit for the product of the manufacturing process . wherein a control step multidimensional analysis result Tsu line automated assay of statistical quality process control by a statistical processing result based on the information of said quality characteristics relating to the manufacturing process associated with the integrated database determination information of the SPC Statistical process management judgment information management step for managing each management process from the start of production to the process to be managed or all of the management processes from the start of production to the end of production ,
The product inspection acceptance judgment management unit, and the manufacturing process management process information, and the quality standards SFAS information, and the material quality results information, and the product quality results information, and the used material information, said shipping record information Based on the determination information of the SPC , the product of the manufacturing process is compliant with all predetermined quality standard standards in each management process from the start of manufacturing to the process to be managed or in each management process from the start of manufacturing to the end of manufacturing. A product inspection pass / fail judgment management step for automatically classifying according to management limits, inspection standards, product standards, and SPC judgment results defined in the company standard so as to match, and acquiring and managing quality control pass / fail judgment information from the integrated database; ,
A statistical quality process control management method characterized by comprising: The product inspection acceptance / rejection determination management step outputs a message of the corrective action associated with the determination information of the SPC from the integrated database upon receipt of a corrective action confirmation instruction when the determination information of the SPC is abnormal. The statistical quality process control management method according to claim 1. The management device further includes lot tracking means,
The lot tracking means receives a lot tracking instruction when the determination information of the SPC is abnormal,
Based on the manufacturing process management process information, the quality standard reference information, the material quality performance information, and the product quality performance information, each management process from the start of manufacturing to the process to be managed or manufacturing from the start of manufacturing 2. The statistical quality process control management method according to claim 1, further comprising a lot tracking step of tracking a lot in which the determination information of the SPC in each management process until the end is abnormal. In the manufacturing process managed based on the manufacturing process management process and the quality standard document, quality characteristic information, which is a measurement value for the test item of the manufacturing process , is collected in each management process unit, and the product in the manufacturing process is Quality is automatically classified based on the control limits, inspection standards, product standards, and statistical process control (SPC) judgment results specified by in-house standards so that they are within the specified quality standards specified in the quality standard specifications. A statistical quality process control management device for managing control,
Integrated database of manufacturing process management process information, quality standard standard information, and each control process from the start of manufacturing to the process to be managed or multidimensional analysis information of quality characteristics in each control process from the start of manufacturing to the end of manufacturing Quality characteristic multidimensional analysis information acquisition means to automatically acquire,
Achievement information acquisition means for automatically acquiring from the integrated database material quality record information that is material quality record information and product quality record information that is product quality record information;
Used material information / shipping result information acquisition automatically from the integrated database of used material information and shipping result information related to the multi-dimensional analysis information of the quality characteristics, the material quality result information, and the product quality result information Means,
Whether the product of the manufacturing process is within an allowable range based on a quality standard that can be handled by an individual customer defined in advance in the management process unit, the quality characteristic related to the manufacturing process related to the management process From the integrated database, the determination information of the SPC, which is a result of the automatic analysis and evaluation of the statistical quality process management based on the statistical processing result based on the multidimensional analysis information, from the start of production to the process to be managed Statistical process management determination information management means for managing each management process or all of each management process from the start of production to the end of production ;
The basis of the above production process management process information, and the quality standards SFAS information, and the material quality results information, and the product quality results information, and the used material information, said shipping record information, on the determination information of the SPC The products of the manufacturing process are stipulated in in-house standards to meet all the predetermined quality standard standards in each management process from the start of manufacturing to the process to be managed or in each management process from the start of manufacturing to the end of manufacturing . Product inspection pass / fail judgment management means for automatically classifying by control limit, inspection standard, product standard, judgment result of the SPC, and acquiring and managing quality control pass / fail judgment information from the integrated database;
A statistical quality process control management apparatus comprising: When the SPC determination information is abnormal, the product inspection acceptance / rejection determination management unit receives the corrective action confirmation instruction, and acquires and outputs the corrective action message associated with the SPC determination information from the integrated database. The statistical quality process control management device according to claim 4, wherein: The statistical quality process control management device further comprises:
When the lot tracking instruction is received when the determination information of the SPC is abnormal,
Based on the manufacturing process management process information, the quality standard reference information, the material quality performance information, and the product quality performance information, each management process from the start of manufacturing to the process to be managed or manufacturing from the start of manufacturing The statistical quality process control management apparatus according to claim 4, further comprising: a lot tracking unit that tracks a lot in which the determination information of the SPC in each management process up to the end is abnormal.

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