||The case company is one of the top five packaging and testing factories in the world. The industry has strict manufacturing requirements. To ensure the manufacturing quality, the company must have strict internal policies for controlling the manufacturing processes to meet customer demands. The case company has installed both highly automated equipments and computer integrated manufacturing (CIM) systems for high quality production. Because production quality is highly correlated with equipment stability, it is critical for the company to achieve high levels of equipment stability and utilizations for avoiding product deficits. |
However, it is difficult to identify the root cause of problems within limited time and to act properly to resolve the problems. In most cases, the problems may be resolved by implementing expert system (ES) or case-base reasoning (CBR) systems. However, there still are problems lacking proper resolving procedures because the low frequencies problems and insufficient experiences. For resolving these types of problems, new methods are needed.
The main purpose of this study is to develop reasonable mechanisms and systems to resolve these problems in the production line. By timely analyzing relevant raw data to predict the occurrence of problems in advance, the equipment can be stopped to resolve the problems in time before incurring serious manufacturing interruptions and product deficits. Beside, reducing the frequency of abnormal events will result in good product quality and production efficiency, obtaining the trust of customers. The company also has created graphical user interface (GUI) to monitor the actual performance of all equipments with more convenience in real time. All pre-defined event can be traced and monitored by the system. With the system, it has become easy to identify production and equipment abnormal situations and then have correct instructions and actions taken. This also reduces the troubleshooting time. According to implementation results, the methods developed in this case should provide a new model for decision-making and actions for the manufacturing control of the industry.
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