Abstract
Quality management is important for maximizing yield in continuous-flow manufacturing. However, it is more difficult to manage quality in continuous-flow manufacturing than in discrete manufacturing because partial defects can significantly affect the quality of an entire lot of final product. In this paper, a comprehensive framework that consists of three steps is proposed to predict defects and improve yield by using semi-supervised learning, time-series analysis, and classification model. In Step 1, semi-supervised learning using both labeled and unlabeled data is applied to generate quality values. In addition, feature values are predicted in time-series analysis in Step 2. Finally, in Step 3, we predict quality values based on the data obtained in Step 1 and Step 2 and calculate yield values with the use of the predicted value. Compared to a conventional production plan, the suggested plan increases yield by up to 8.7%. The production plan proposed in this study is expected to contribute to not only the continuous manufacturing process but the discrete manufacturing process. In addition, it can be used in early diagnosis of equipment failure.
Highlights
In the manufacturing industry, quality management is a key to competitiveness, productivity, and profit of companies because poor quality management can damage the trust and good image which a company has built up for a long time [1]
Statistical analysis was conducted on basic data, and quality was predicted with the use of a classifier
This study proposed a method for cutting a product in consideration of the defect occurrence point through quality prediction and thereby improving the yield of the continuous-flow process
Summary
Quality management is a key to competitiveness, productivity, and profit of companies because poor quality management can damage the trust and good image which a company has built up for a long time [1]. For this reason, the importance of quality management in various industries has emerged early on. Lillrank underlined that maintenance is the most important activity in quality management [2]. Bergman and Klefsgo emphasized the role of quality maintenance and repair in production [3]. In continuous-flow process manufacturing, it is very significant to manage quality and defect rate because some defects in a part is directly related to the quality of all subsequent processes
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