Research of On-line Quality Management System for Filter Tips based on MES
Yue Zhang, Kai-chaoYu, Wei-ping Zhang
Department of Electrical Engineering, Kunming University of Science and Technology, Kunming, China
(zhangyue22589@126.com)
Abstract – Combined with the quality management
requirements, the article took the quality management in the
productive process of filter tips in tobacco enterprises as a
research object. And it analyzes the filter tips process and
common quality problems, and then proposes a quality
management system for filter tips based on MES.
Afterwards it discusses the system requirements, the quality
control model, functional model and key technologies.
Finally, the visual, real-time and dynamic quality
management in the productive process of filter tips are
realized.
Key words – Filter tips, MES, Quality management,
System,
I. INTRODUCTION
Quality is the eternal theme of enterprises, and is also
to achieve sustainable development, to win the victory in
the next competition, more importantly, and it is the key
to improving efficiency way [1].
IT can promote the modernization of cigarette
production and quality management, and it is an effective
way to improve overall competitiveness of the cigarette
industry. At present, in the tobacco enterprises, the
management information system and automation
technology have large-scale application[2]. But ignoring
the effective co-ordination between them, it leads to
enterprises upper plans lack the effective real-time
information support and the lower levels are lack of
optimized scheduling and coordination. So companies
would be difficult to real-time reaction. Manufacturing
Execution Systems(MES), which is for shop floor
production management techniques and real-time
information system, is the information link between the
ERP and production of automatic control system [3] [4].
Quality control is an important component part of
MES. In the field of quality management, MES can
effectively integrate the process level, site quality data
acquisition, quality management of production processes
and statistical analysis of these features which belong to
the underlying control layer in tobacco enterprises [5-8].
Filter tips production as an important part of cigarette
production process, its production efficiency and finished
product quality directly affect the quality of the
cigarette[9]. So Research of On-line Quality Management
System for Filter Tips based on MES is particularly
important[10-15].
II. SYATEM REQUIREMENTS
As an important component part of the cigarette, the
quality of filter tips relates to the taste of smokers in
smoking, also whether they could play a filtering tar
droplet and reduce the role of nicotine intake. So quality
control of the filter tips is particularly important because it
is directly related to the quality of cigarettes good or bad.
During the whole process, the quality control of filter tips
working procedure is key point. It is a decisive role of
cigarettes’ qualified products.
The filter tips process in Fig. 1.
Currently, quality problems of filter tips are mainly
concentrated in draw resistance of filter rods, hardness,
circumference and length. In six production processes of
filter tips, they are quantitative indicators of Tow opening,
Plasticized, Rolling forming and Filter tips cutting.
So the four processes are critical detection points
during the On-line Quality Management System for filter
tips. Principal detection parameters is the "roll pressure,
roll ratio; plasticizer supply and the quantity supplied;
various parts of the filter tips temperature, diameter and
glue temperature; the length of filter tips and feed
frequency."
MES technology platform analyzes the real-time
effective data from the filter tips manufacturing site, then
it control the processing quality of each working
procedure timely. To eliminate quality defects in the bud,
and lower cost of quality, the platform will do real-time
monitoring, prediction, diagnosis and on line debugging.
Accordingly, the following requirements, which can
achieve its quality control, are:
A. Real-time, dynamic
At present, in most tobacco companies, quality
management mostly use Static quality management and
control by quality plan issued, production testing after
sequence and quality of statistical reports forms. So the
control effectiveness and efficiency are very restricted.
On line quality management system needs to be able to
collect real-time data from the manufacturing process.
The system grasps the quality of the state and reflects the
problem of manufacturing process. The aim is to control
the production quality dynamically.
B. Visualization
Vast amounts of quality data miscellaneous and
difficult to understand, and the data behind the
information is also difficult to express. The system can
put quality information to the tables, graphs, images and
other visualization methods people are accustomed to
Preparation
Tow Upgrade
Tow Opening
accept
Plasticized
by
Tow Collected
Glue Supply
Filter Tips Filling
Filter Tips Collected
Filter Tips Cutting
Rolling Forming
Paper Feed
Storage Curing
Fig.1. The filter tips process
making use of information technology, they can
Provide the basis for quality managers.
Based on production technology and processes for
filter tips and combined MES, discussion on-line quality
management model. It is shown in Fig.2.
C. Interaction
Managers in the traditional quality management
system is a passive acceptance of unilateral information, it
is difficult for users to interact with the management of
quality data.
As a result, enterprises must meet the demand of
quality management for filter tips, real-time dynamic
visualization and interactivity by means of On-line
Quality Management System for Filter Tips based on
MES.
Production
Start
Production
Orders
Quality Standards
Requirement
Request
Filter Tips
Quality
Completion
Analysis
Evaluation
Results
Dispatch
III. VISUAl MODEL OF QUALITY MANAGEMENT
AND CONTROL PROCESSES
A. Information Visualization Model
The online application control, namely information
visualization (IV) is applied for the filter tips quality
management system based on MES. IV refers to the use
of computer-supported, interactive visualization of
abstract data to enhance people's awareness of the abstract
information.
IV model is from the original data, data table, visual
structure and view four modules. Original data maps for
the data table through data transformation; and through
visualization, data tables map transformation for
visualization of structure, this process is the core of
information visualization; finally, set up the graphics
parameters through the view transformation and translate
the structure to the visualization view, so the users can
view the visualization of data in the database to serve a
specific task from a particular point of view. Visualization
of quality management to solve the main problem is the
quality of the data mapping, conversion and interactive
control.
B. Quality Control Processes for Filter Tips
Inspection
Evaluation
Data
Result
Data Gather
Fig.2.Quality management model
IV. FUNCTIONAL MODEL OF ON-LINE QUALITY
MANAGEMENT SYSTEM FOR FILTER TIPS
Based on the above analysis of the visualization of
information model, and combined quality management
process for filter tips, the functional model of the system
is presented. It is shown in Fig.3.
PDCA continuous quality improvement model used
in the process of quality management, and it is a basic
way to operate quality assurance system. Quality
standards is the object of quality improvement, and it
provides the standard to the entire quality management
process; quality control is part implementation quality
management, quality inspection is to check the quality
control results; quality analysis is based on processing
test,
Quality Standards
Q
Con
Quality Control
Contro
Cont
Quality Management
R
Quality Inspection
Manuf
Supp
Q
Quality Analysis
Q
Qual
Fig.3. Functional Model of On-line Quality Ma
quality standards improvements. Four parts cycle, the
product quality improve constantly.
are not processed, the system will promptly notify the
relevant modules to deal effectively with, it aims to assure
the quality of production furthest.
A. The applications of quality control function module
B. Quality inspection function module
Quality control includes two aspects. They are
manufacturing process control and auxiliary process
control. Physical indicators in manufacturing process
quality control is to collect data automatically, then draw
the control chart as well as appearance of the index
through manual inspection, and inspection data entries
system automatically which is collected from the bottom
of shop floor. When the exception occurs, the system
automatically will alarm.
In auxiliary process quality control, its job is mainly
to assess the implementation of process, to monitoring
equipment industry parameters, production and operating
environment, to confirm the raw materials. And checking
the measuring devices. When the device process
parameters overrun, it will be proposed to modify the
corresponding process parameters. If an exception occurs ,
the alarm activated alarm immediately. The same is also
true for the monitoring of production operations
environment. When needed for the production of raw
materials and components to confirm, once an exception
occurs, you will be prompted to make a re-examination
request, in order to avoid quality problems in raw
materials for production. Quality control function module
is not a single module, when these quality control links
In the MES environment, the inspection process is the
focus of the quality inspection, and it does inspection of
the manufacturing process, quality management point of
inspection, sampling the production process, and non
conforming product processing inspection.
As a data collection point, inspection of the quality
management point is to select the key points in the
production process, to compare the collected information
and operating specifications, and to make the appropriate
judgment. At the same time, in the production process of
each stage of sampling, and sampling results into the
system, at any time call access, quality inspection
situation aggregates into quality reports. When quality
inspection finds substandard products, it focus on putting
information into the system timely, and determine the
level, then it issues a re-examination request again.
C. Quality analysis module applications
In this module, the focus is on the quality factor
analysis, including product quality analysis and process
conditions.
Index related will be collected to analyze the quality
of products, then by mathematical statistics, analysis, it
finds problems, and according to the problems to
feedback and make improvements timely. To analyze the
state of the product process, we should pay attention to
the process status information, a comprehensive analysis
of the observed information and continuous improvement
can assure the product quality in the greatest degree.
V. KEY TECHNOLOGIES OF THE SYSTEM
1) Using model-driven technology to achieve the
production control based on the production model can,
providing a flexible modeling tool and managing the
entire production process by the model driven
2) Through the model-driven technology, strengthen
quality control; automatically generated quality inspection
request according to the changes in work orders,
schedules and grades, Testing equipment data and
formation the quality of data analysis and evaluation by
KPI Data feedback and automatic acquisition
3) Realize the monitoring of the production of
dynamic data, and visual display the actual situation of
filter rod production process by monitoring the screen.
4) Use the digital measuring devices, connected to
the wireless transmitter to send the digital signal, and
connected to a computer to transmit data through the
intranet on a regular spread to the enterprise server to
complete the data collected from the production site.
5) Use the real-time database technology, realize the
mass data storage and application of real-time data;
acquisition multiple quality control points in the
production process to achieve the production of dynamic
real time data acquisition, monitoring and statistical
analysis, made the production management more
scientific, organization more flexible and more timely
decision-making.
VI. CONCLUSION
The quality management of corporation is a very
complicated and important work. Quality management
level has a direct impact on the survival and development.
Quality management system is for continuous
improvement and meeting the daily production and
business needs, which can greatly enhance the
competitiveness of enterprises. The key to the
implementation of MES filter tips on-line quality
management system is to achieve effective integration of
information sharing with other MES module and the
underlying control, real-time quality monitoring by the
flow of information integration and control integration,
the entire process of production, in order to achieve
closed-loop quality control. Analysis of MES and filter
tips online quality management system processes,
functional model and key technologies, explore and
practice on these issues, I believe that the quality
management system based on MES is fine, because the
homogenization and standardization of information
technology is the best solution.
REFERENCES
[1] Gong Qingtao. Research on real-time on-line intellegence
quality control technology for the tobacco MES, [MS
Thesis], Qingdao: Ocean University of China., 2009,.1-2.
[2] Hu Jun. MES in the production process and quality control
of the cigarette industry analysis, Nanjing: Nanjing
University of Technology and Engineering, 2004,.13-15
[3] Cao Jianghui, Wang Ningsheng, manufacturing execution
system present situation and trend, 2002,pp.6-7
[4] Kaichao Yu, Wenli Shi, “Study of Engine Assembly line
Quality Management System Based on MES” in the 3rd
International Asia Conference on Industrial Engineering
and Management Innovation , 2009.06
[5] Li ronghuang, Xiang Wwenyin, Hong Zhitang. Autosupplier
quality management and quality improvement methods,
mechanical design and manufacture,2007(3) : 171-174
[6] Wang Wanlei. MES key technical research [D].dalian: dalian
university of technology, 2005. 24-28
[7] Sander Holm. A comprehensive quality management, China
Economic Publishing House,2003
[8] Liu Haibo, Yang Shiyuan. Based on quality information
technology total quality management information system
design, Shanghai: Shanghai quality magazine,2005
[9] MESA International, MES explained: A high level vision,
White paper 6(Pittsburgh: Manufacturing Execution
Systems Assoc.,1997)
[10] Maraghy, RJUrbanic. Modeling of manufacturing systems
complexity [J].CIRE2003,52(1):363-366.
[11] The Benefits of MES:A Report from the field, MESA
International white Paper numberl,5/1997,www.mesa.com
[12]McClellanM. Applying Manufacturing Execution Systems
[M].CRC Press
[13] Kelly T. Electronic date system. MES in the age of agile
manufacturing[J]. A Presentation at MESA Roundtable4,
Chicago, Sep.13,1995.
[14] Object Management Group. Manufacturing Domain Task
Force RFI-3 Manufacturing Execution Systems (MES).
OMG Document mfg/97-11-01. November 6, 1997.
[15] Computer System Inc.Integra table MES the challenge and
the opportunity, advanced manufacturing research
consulting, http://www.amrc.com,1999