發展遠端即時製程監控與生產規格評估控制機制

藍天雄

育達商業科技大學 資訊管理系

苗栗縣36143造橋鄉

談文村學府路168

tslan@ydu.edu.tw

 

陳雅雯

仁德醫護管理專科學校

苗栗縣35664後龍鎮

溪洲里七鄰砂79-9

yawen.chen0323@gmail.com

 

摘要

本研究旨在針對整流二極體後段製程中的測試、包裝作業,進行整流二極體特性參數(順向導通電壓VF、逆向崩潰電壓VR、逆向洩漏電流IR)及產量資訊之收集與分析,並使用美商國家儀器(National InstrumentsNI)的虛擬儀表圖型化發展環境(LabVIEW)開發遠端控制架構的操作平台,提供使用者圖型化操作、資料儲存分析與規格評估之介面,藉以發展「遠端即時製程監測與生產規格自動調校機制」。

本研究擬透過多個串列設備連結無線網路,並建立一套整合式圖型化操作介面,同時透過無線乙太網路,使操作者藉由無線射頻辨識系統(RFID)讀入欲生產之產品批號後,自動將預設之內部生產規格,透過RS-232傳送給測試包裝機的兩部二極體特性測試儀,並在後續的生產過程中,即時將兩部二極體特性測試儀之測試結果讀回、紀錄、分析;再將測試規格結果計算出的中心值,加減三個標準差作為新測試規格之上下限,重新回傳給第一部二極體特性測試儀,並於生產過程中,依所設定之時間長度進行重複自動調校;當批量生產結束時,即將整體測試結果之紀錄,轉換為次數頻率表儲存於資料庫內,以供未來查詢之用;同時第二部二極體特性測試儀亦將取代傳統之人工品管作業,期能將生產之二極體直接出貨,節省昂貴的人工費用,降低生產成本。

透過本研究所擬之即時製程能力評估方式,將收集到的整流二極體特性參數,經由統計運算,自動調校成符合該批量製程能力之生產規格,並即時回饋至測試儀表中;所生產之產品除可符合該批量之製程能力水準外,更可有效的降低重工率,提升出貨品管時之通過率。

藉由本研究所擬之「遠端即時製程監測與生產規格自動調校機制」,對生產測試所得之產品規格資料進行分析與自動評估,同時配合資料庫系統,進行長期歷史資料的監控與儲存;並透過製程能力評估的方式,針對整流二極體特性參數自動調校,進而改善生產技術及製程參數,建立整流二極體特性參數規格最佳化方案,進而以更有效的生產設備管理、提高生產效率並整合生產流程。

 

關鍵詞:遠端監控、即時評估、製程能力、人機介面。

 

 

 

Abstract

The purpose of this project is mainly focused on both collection and analysis of testing and packaging processes of rectifier diodes parameters Forward Voltage VF, Reverse Voltage VR, Reverse Leakage Current IR as well as the production yield for the production process of rectifier diodes. The LabVIEW by NI National Instruments Virtual Instrument is selected as the operating platform for the control framework in providing users with graphical manipulation, data collection, data analysis, and specifications evaluation of the proposed “Real-Time Remote Process Monitoring and Automated Production Specification Adjustment Scheme”.

Through the internet server, an integrated graphical human-machine interface allows the operator to receive production batch information by RFID Radio Frequency Identification System reader. The pre-configured production specifications will then be automatically transmitted to the designated Diode Characteristics Tester via RS-232. The test results will be read, recorded, and analyzed during the continuous production process. The range of the computed centre within three standard deviations from the test results is therefore settled as new test specifications and then re-transmitted to the second Polar Body Characteristics Tester. During the production process, the adjustment process can be automatically repeated based on the specified length of time. At the end of the production, the entire record to the test results will then be converted into a conversion table by using the number of frequency and stored in the database for further need.

With the proposed real-time production specification evaluation technique on the internet, the testing data from rectifier diodes can be automatically assessed to adjust the manufacturing capability via the man-machine interface and saved into a database system. Therefore, the long-term monitoring and historical data storage can be utilized as process capability assessment to achieve the optimum rectifier diode characteristic parameters. With the historical data collected, the management can moreover realized the information of equipment status to enhance the production efficiency and the integration of production processes.

The increased shipments through the quality standards can furthermore be effectively advanced. Thus, the cost as well as time for the rectifier diodes manufacturing are therefore greatly minimized.

 

Keywords: remote monitoring, real-time assessment, process capability, human-machine interface