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5个步骤实现离散制造的产品质量管控

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离散制造是什么?

离散制造的产品往往由多个零件经过一系列并不连续的工序加工最终装配而成,主要是通过对原材料物理形状的改变、组装成为产品,使其增值,产品由元件、配件、零件构成部件、组件再构成产品,典型的离散制造行业包括汽车、船舶以及各类电子产品等。



流程制造VS离散制造





流程制造:基于工艺流程的严格要求,天然具备「人、机、料、法」紧密耦合的特性。


离散制造:产品零部件众多且各零部件的加工过程彼此独立,规格型号因合同不同而有一定差异,对各种要素条件耦合的要求松散得多,因此存在更大的容错空间,产品质量难以管控。


如何有效管控离散制造的产品质量?


依托于智能制造三大切入点(精益生产、制造协同、整合运营)为核心,详细记录生产过程的人、机、料等各类数据,以生产消耗为主线,以质量追溯全流域为核心,以工艺规范为指导,结合数据自动采集手段,提炼出以下五个步骤,达到全流程质量数据管控的效果。

①基础建设,网络联动


建立覆盖整个车间的工业级局域网络,为建设车间全流程质量数据管控系统平台打下基础。




②搭建标准体系


通过数字化搭建质量标准体系,实现客户工艺规程文件的制定、审批、修改等相关功能,为现场质量管理提供流程引导和标准操作规范,实现整个车间的质检计划制定、质检作业任务执行、质量过程记录、产品交付等产品全质量生命周期的管控,同时达到现场无纸化作业的目的。



③数据采集自动化


通过更换或者改造目前无输出接口的测量设备或仪表,实现车间各类设备的联网改造,并进行数据的自动采集,包括数字化量具、多媒体、环境参数、各类生产设备工作过程中的数据,达到全过程采集的目的,并对异常情况进行实时报警。




④任务可视化


通过客户提供的产品图纸或模型、工艺文件、作业指导书等技术文件信息,基于工艺路线信息对技术文件进行模型搭建,与生产、检验等生产任务进行关联,实现生产现场对作业指导信息的可视化查询和浏览,对设备部件、原材料采用扫描条码的方式识别,同时通过视频、图片、文字描述等多种方式对操作进行直观有效的展现,采用实时提醒及自定义流程管控等措施,实现车间内生产过程的规范化执行,避免因人为疏忽出现的遗漏、超时等错误



⑤质量追溯痕迹化


对相关人员、量具、物料和安装附件的基本信息进行管理,便于根据型号、工序、时间等信息进行检索、追溯与复查生产数据,每一个制作过程的衔接,可以追溯到这个芯片具体生产设备、操作员以及出现问题的环节,保证质量问题的可追溯,有利于数据分析并指导决策。

提供全方位多层次多组织质量追溯,可追溯到产品购买者、生产部门、原材料以及原材料供应商、现有库存等,快速定位问题出现的环节,预估损失,为售后及质量索赔提供依据。

高效、低耗、灵活、准时


高效、低耗、灵活、准时地生产合格产品,降低劳动强度,是生产管理永恒不变的主题。利用软件功能平台将采集到的数据进行统一分析和处理,建立整个应用系统平台的业务服务集合池,通过“大数据”管理装配过程、优化生产,集中提供业务服务,通过系统平台将生产过程智能化,达到高效率高质量的生产目的,将“大数据”的优势发挥出来。


这样,才能体现生产过程数字化的意义。





想要了解更多?
联系我们,获取离散制造全流程质量数据管控系统完整方案。鹦鹉螺设备管理专家将竭诚帮助您。
联系电话:028-81132890
公司网址:www.nom100.com
公司地址:四川省深圳市成华区东三环二段龙潭工业园华盛路58号46栋



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