In this article we introduce a new quality control model for complex manufacturing system which has the potential to enable enterprise to protect itself from harmful non-conformance in a way like biological system. The model is based on danger theory. In the proposed quality control model, a co-stimulation is necessary to confirm the danger implied by the presence of a detected quality variation, anomalies that are not confirmed by signal 2, or harm were not considered as faults. With the multiple confirmation mechanism and dynamic detector update, the range of quality defects space is reduced. High levels of quality defects detection is made possible at reasonable computational cost. The architectures and behavior of the proposed quality model resembles the structure and behavior of biological immune system, which may improve the reliability and efficiency of the manufacturing system, especially for the highly dynamic complex manufacturing system.
The basic method of statistic process control is to eliminate variation and put process under statistic control. The negative effect of the method is that it leads to the neglect of the valuable information contained in process variation, thus missing the opportunity for process optimization. But variation is not necessarily harmful, from the biological evolution point of view, variation is the driving force of evolution. Inspired by biological evolution mechanism, a method of adaptive optimization based on process variation is proposed. A data mining technologyassociation rules mining technology is adopted to analyze the SPC data and excavate association rules in the quality parameters. Then the association rules are evaluated and utilized to improve production processes. The method expand the stability-oriented quality control system to stability-optimizationcombined system and continual quality management improvement is realized by iteration of this data driven process. A case study of injection molding process optimization is provided to illustrate application of the presented method.
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