Modeling, Analysis, and Control of Variation Propagation in Manufacturing Processes

制造过程中变异传播的建模、分析和控制

• 批准号: 0322147
• 负责人: Shiyu Zhou
• 金额: $ 17.56万
• 依托单位: University of Wisconsin-Madison
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2003
• 资助国家: 美国
• 起止时间: 2003-09-01 至 2007-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0322147&HistoricalAwards=false
• 关键词: Modeling; Analysis; Control; Variation; Propagation

This grant provides funding for the development of a methodology for modeling, analysis, and control of variation propagation in complicated manufacturing processes. Process variation and inconsistency are the major quality concerns in a manufacturing process. For a complicated manufacturing process involving multiple operation steps, the process variation at different steps will be accumulated on the product and propagates along the process. This project aims at developing a systematic methodology to describe and reduce the process variation and hence improve the process quality. A quantitative variation propagation model will be developed. Both analytical and empirical methods based on product/process design and engineering knowledge are used to link the key process variation sources and key product quality characteristics in this model. This quantitative model allows system theory and advanced statistical techniques (e.g., variance component analysis of linear mixed models) to be adopted in order to conduct forward and backward analysis of variation propagation. The forward analysis can identify important process stages and provide guidelines for design improvement, while the backward analysis can quickly identify the root causes of quality variations. The research results will be finally validated in industrial settings.If successful, this research project will contribute to the science base of process control and quality improvement for manufacturing processes. Using the developed methodology, vast amounts of information from product design, process design, in-process sensing, and product quality inspection will be integrated under a quantitative model. This integrated model lays a foundation to develop effective techniques of variation propagation analysis and quick variation root cause identification. Effective implementation of the developed methodology in industry will provide a set of powerful tools for computer-aided product/process design and process monitoring and diagnosis for variation reduction, and thus provide a competitive boost to U.S. industry. The research accomplishments will be transferred into undergraduate and graduate curricula as well, which will generate long-term impact on the education of quality engineering and manufacturing.

该补助金为复杂制造过程中变异传播的建模、分析和控制方法的开发提供资金。过程变化和不一致性是制造过程中的主要质量问题。对于涉及多个操作步骤的复杂制造过程，不同步骤的过程变化将在产品上累积并沿过程沿着。本计画旨在发展一套系统化的方法来描述和减少制程变异，进而改善制程品质。将开发定量变化传播模型。基于产品/工艺设计和工程知识的分析和经验方法被用来链接的关键过程变异源和关键产品质量特性在这个模型中。这种定量模型允许系统理论和先进的统计技术（例如，线性混合模型的方差分量分析），以便进行变异传播的前向和后向分析。正向分析可以识别重要的过程阶段，并为设计改进提供指导，而反向分析可以快速识别质量变化的根本原因。研究结果将最终在工业环境中得到验证，如果成功，本研究项目将有助于为制造过程的过程控制和质量改进提供科学基础。使用开发的方法，大量的信息，从产品设计，工艺设计，在过程中的传感，和产品质量检测将被集成在一个定量模型。该集成模型为开发有效的变异传播分析和快速变异根源识别技术奠定了基础。在工业中有效实施所开发的方法将为计算机辅助产品/过程设计和过程监控和诊断提供一套强大的工具，以减少变化，从而为美国工业提供竞争力的提升。研究成果也将转化为本科和研究生课程，这将对质量工程和制造教育产生长期影响。