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MANUFACTURING SYSTEM
Agenda
Thesis Objective & Scope.
Motivation.
Why Flexible Manufacturing System?
QCES Parameters & Assumptions.
Assumptions
QCES: A Framework for KB- DSS.
Why Control Chart Patterns?
Control Charts Patterns Identification Techniques.
Pattern Identification Attributes (Features).
The Computer Program (Analytical Part).
QCES Rule-Base Building.
CASE STUDIES.
1
Motivation
To date, quality control methods remain underutilized.
Expertise is needed in quality control.
Application
pp of Expert
p System
y ((ES)) in q
qualityy control
activities is important in FMS.
Most of the research efforts focus on obtaining good rules to
help construct good quality control diagnostic system.
Most of the recent research suggests a framework of ES to
develop statistical process control applications.
Motivation (Cont.)
Most applications of ES in manufacturing concluded that
the ES technology allows for implementation of
sophisticated and efficient process control systems.
The new philosophy of manufacturing control became in
demand when FMSs were installed.
All researchers that discussed pattern recognition
concentrated on only six patterns: systematic, trends
(upward & downward), stratification, cyclic, and natural
pattern.
Fully
Automated FMS Costly
System
Utilize Advanced
Technology
2
QCES Parameters &
Assumptions
QCES is concerned with the analysis of control charts
for variables (X-bar and R charts).
QCES is based on the 3 sigma limits.
I t
Interpretation
t ti ini QCES ddepends d on th
the AT&T rules
l
and on the identification of the chart pattern.
QCES identified the last six patterns as unknown.
Attribute-value triple mode was used to represent the
knowledge base of the ES part.
Production rule was used to build the rule base.
QCS
Inference
Characteristics
Engine
Computations
Input Data
User
Interface
3
Control Charts Patterns
Identification Techniques
Work on patterns identification in quality control charts
have taken four main directions:
Expert System. (QE Interpretation)
Computer Vision. (QE Interpretation)
Neural Network. (Time & Effort)
Feature-Based Method.(More Accurate)
B ild a Database
Build D t b
Pattern Identification
Attributes (Features)
Test of normality
Slope
Moving Average
Xi>Xi+1 and Xi+1<Xi+2 for all samples
9 points Consecutive above CL or lower CL
9 points Consecutive below CL + σ
8 of points Lie on warring Limits Zone
Points > 5 σ + CL
15 Points consecutive in Zone C
4
Decision Tree of the
Pattern Identification
SQC
Chart
Test of Normality
Fail Pass
Moving Average
Normal
Increased
Decreased Pattern
Increasing Others
Trend Decreasing
Xi>Xi+1 and Xi+1 < Xi+2 Trend
For all Xi’s
Pass
Fail
Systematic X i > X + 2σ or
Pattern
X i < X − 2σ
p = 8 points
Fail
Pass
Mixture
X i < X − 1σ or X i > X + 1σ
p = 1 5 points
Startis-
fication More than one point
>5σ
Fail Pass
9 Consecutive Points
Freaks < X − 2σ
Fail Pass
Sudden Shift
in level 9 Consecutive Points >
X + σ or > X − σ
Fail Pass
Unknown
Gradual Pattern
Change
5
QCES Rule-Base Building
Collect data (assignable causes) related
to the unusual patterns
Develop a rule-base
Verify rule-base
CASE STUDIES
CASE STUDY I
(SQC Handbook)
Samp Sample Size
le No. 1 2 3 4 5
1 11.1 9.4 11.2 10.4 10.1
2 9.6 10.8 10.1 10.8 11.0
3 9.7 10.0 10.0 9.8 10.4
4 10.1 8.4 10.2 9.4 11.0
5 12.4 10.0 10.7 10.1 11.3
6 10 1
10.1 10 2
10.2 10 2
10.2 11 2
11.2 10 1
10.1
7 11.0 11.5 11.3 11.0 11.3
8 11.2 10.0 10.9 11.2 11.0
9 10.6 10.4 10.5 10.5 10.9
10 8.3 10.2 9.8 9.5 9.8
11 10.6 9.9 10.7 10.2 11.4
12 10.8 10.2 10.5 8.4 9.9
13 10.7 10.7 10.8 8.6 11.4
14 11.3 11.4 10.4 10.6 11.1
15 11.4 11.2 11.4 10.1 11.6
16 10.1 10.1 9.7 9.8 10.5
17 10.7 12.8 11.2 11.2 11.3
18 11.9 11.9 11.6 12.4 11.4
19 10.8 12.1 11.8 9.4 11.6
20 12.4 11.1 10.8 11.0 11.9
6
CASE STUDY I
(Computer Implementation)
CASE STUDY I
(Consultation Session)
CASE STUDY II
(Conventional M/C)
7
CASE STUDY II
(Computer Implementation)
CASE STUDY II
(Consultation Session)
2.50
2.00
1.50
1.00
0.50
0.00
Z
(
8
CASE STUDY III
(Computer Implementation)
DISCUSSION
Case Study I
Item R Chart X-bar Chart
Case Study III
Center line No Difference No Difference Item R Chart X-bar Chart
9
DISCUSSION (Cont.)
Three case studies were used for verification.
In Case Study II, the causes of out-of-control were fired as
follows: rotation of fixture, tool in need of sharpening,
wear off tool,
l use off defective
d f i raw materials,i l andd machine
hi
in need of repair.
There is no significant difference in the results of the
characteristics of the control charts.
The normality test was also performed to verify the EQCS
decisions.
Conclusion
In this research, a quality control expert system (QCES)
framework was developed. This framework integrates
statistical quality control system with expert system
((Hybrid
y DSS).) The pproposed
p framework:
Allows for the identification of instability patterns of control
charts.
Helps to develop an on-line statistical quality control and process
diagnostic system for FMS.
Makes on-line quality control and adaptive sampling plans more
effective in FMS.
Was applied and verified in three different case studies.
Thank You
10