Integrated Product and Process Control for Sustainable Semiconductor Manufacturing

Semiconductor fabrication is a manufacturing sequence with hundreds of sophisticated unit operations and it is always challenged by strategy development for ensuring the yield of defect-free products.In this paper,an advanced control strategy through integrating product and process control is established.The proposed multiscale scheme contains three layers for coordinated equipment control,process control and product quality control.In the upper layer,online control performance assessment is applied to reduce the quality variation and maximize the overall product performance （OPP）.It serves as supervisory control to update the recipe of the process controller in the middle layer.The process controller is designed as an exponentially weighted moving average （EWMA） run-to-run controller to reject disturbances,such as process shift,drift and tool worn out,that are exerted to the op-eration.The equipment in the process is individually controlled to maintain its optimal operational status and maximize the overall equipment effectiveness （OEE）,based on the set point given by the process controller.The ef-ficacy of the proposed integrated control scheme is demonstrated through case studies,where both the OPP （for product） and the OEE （for equipment） are enhanced.

Change and control of nitrogen in molten steel production process

The change and control of nitrogen content in molten steel was investigated through the production process of "LDBAr-LF-RH-CC". Results show that nitrogen content reduces gradually in converter-steelmaking stage, rises rapidly from the end of converter process to the end of argon station process, continues to increase in ladle furnace process, and decreases slightly in RH refining stage. Since nitrogen is removed mainly by BOF steelmaking and vacuum refining operations, nitrogen in molten steel should be removed as much as possible in these two operations. However, nitrogen uptake should be minimized in other operations of molten steel production process.

Research on Production Process Control Method Combined Stochastic Process Algebra and Stochastic Petri Nets

A hierarchical closed-loop production control scheme integrating scheduling,control and performance evaluation is discussed.Firstly,the production process is divided into two main hierarchies:the lower level is the physical operation level and the upper one is the management level.Secondly,the schedule template for the management level and the activity template for the physical operation level are constructed separately,the tasks in the schedule have the ability to make partial decisions,and the per- formance parameters are introduced into activity template.Thirdly,the two levels use different model representations:stochastic process algebra for the management level whose output is the control commands and stochastic Petri net for the physical operation lev- el which is the execution of the control commands.Then,the integration of the two levels is the control commands mapping into the lower physical operations and the responses feeding back to the upper decision-making that are defined by some transition functions. Under the proposed scheme,the production process control of a flexible assembly is exemplified.It is concluded that the process con- trol model has partial ability to make decision on-line for uncertain and dynamic environments and facilitates reasoning about the be- haviors of the process control,and performance evaluation can be done online for real-time scheduling to ensure the global optimiza- tion.

Study on Quality and Safety Trust Early Warning of Dairy Products Based on Statistical Process Control

In order to solve such problems as lack of dynamic evaluation system in evaluation of quality and safety trust of dairy products,and weak awareness of prevention,it is necessary to introduce the statistical process control into the quality and safety trust evaluation system of dairy products,and establish quality and safety trust early warning model for dairy products,so as to determine the control limit of control chart and carry out early warning according to eight criteria. According to the empirical results,the statistical process control is helpful for finding the hidden process risks and providing the necessary basis for enterprises taking positive measures to raise the confidence of consumers.

Assessing the Awareness and Usage of Quality Control Tools with Emphasis to Statistical Process Control (SPC) in Ethiopian Manufacturing Industries

Introduction: The present work was devoted to assess the awareness and usage of quality control tools with the emphasis on statistical process control in Ethiopian manufacturing industries. Semi structured questionnaire has been employed to executive and technical managers of manufacturing industries of various size and specialism across the country. Stratified random sample method by region was used to select sample industries for the study. The samples used for this study are industries mainly from Oromiya, Addis Ababa, Tigray, Amara, SNNP and Diredawa regions proportional to their size of the available industries. Methods: Exploratory method and descriptive statistics was used for data analysis. Available documents and reports related to quality control policy of the selected companies were investigated. Results and Discussions: The number of manufacturing industries involved in this study was 44. Of the sampled manufacturing industries about 60% are from Oromiya and Addis Ababa regions. It has been reported that 100% of the respondents said that the importance of quality control tools is very important to their organizations’ productivity and quality improvement (Figure 3). Quality control professionals were also asked the extent to which quality control system is working in their industry and majority of the respondents (45%) have indicated that quality control system is working to some extent in their respective industries (Figure 18). Conclusions and Recommendations: Most of the quality department of the industries did not fully recognize the importance of statistical process control as quality control tools. This is mainly due to lack of awareness and motivation of the top managements, shortage of man power in the area, and others together would make it difficult to apply quality control tools in their organization. In general, the industries in Ethiopia are deficient in vigor and found to be stagnant hence less exposed to a highly competitive market and don’t adopt the latest quality control techniques in order to gain knowledge about systems to improve quality and operational performance. We conclude that quality management system has to be established as an independent entity with a real power and hence the quality control department which is responsible for quality can make an irreversible decision with respect to quality of any given product. Moreover, the concerned bodies (government and ministry of industries) should give attention and work together with universities to ensure how these statistical process control techniques could be incorporated in a curriculum of the universities at higher levels in degree and masters programs. Furthermore, different trainings which could improve quality and efficiency of their respective management system should be given as short and long term to the employees including top and middle managers found in various industries relevant to their process.

Distributed Stretching Control of Web Production System

The stretching process,as a key phase of web production system,pursues the target velocities of rollers and the web tensions of spans between the successive rollers to guarantee proper stretching ratios. This requires the stable velocities and velocity ratios of large number rollers separated throughout the workshop. To this goal,a distributed cooperative controller is designed to coordinate the velocities of the rollers to the desired values as well as the target ratios between the upper and lower rollers. During the whole evolution,only the neighbor rollers can exchange the working information,and neither global information nor central controller is required. It is proven that all the rollers asymptotically achieve the desired velocity ratios via the proposed control law,which is also demonstrated by numerical simulation.

流程工业一体化安全管控探讨

化工、冶金、石化、钢铁、造纸、电力等流程工业是国家经济社会发展的重要支柱,其安全高效生产具有重要的战略意义。流程工业生产过程工艺繁多、流程长、工序关联耦合,从原料到产品涉及诸多物理化学变化、物质转移转化和能量转换转移等多源、多尺度与多时空因素的交互作用,影响生产安全、物效能效与生态环境。如何实现流程工业一体化安全管控,是一个长期存在又不断变化的问题。一体化安全管控困难的本质在于物质流能量流到数字流的映射、数字流到高质量信息流的转化、信息流到控制流的转换等问题。探讨如何突破物质流、能量流到数字流映射过程的数字化鸿沟,突破数字流到高质量信息流转变的数智化壁垒、信息流到控制流转换的数滞化障碍,保障物质流能量流不失控、数字流信息流不失真、控制流不失误,提出了流程工业一体化安全管控的“五流三化三不”新思路,以期为流程工业一体化安全管控提供新的框架体系基础,促进流程工业的可持续发展。

动物源性补片产品的研究现状和安全性思考

随着经济发展和技术进步,越来越多的动物源性补片产品应用于组织和器官修复替代的医学领域。动物源性补片由于结构组成和生产工艺的复杂性,其在实际应用中仍存在力学强度不足、降解速率快、有害可沥滤物检出等问题。其中,产品生产工艺是影响产品质量的关键要素。该文重点综述了目前国内动物源性补片的生产工艺和质量控制的关键点,以期为该类产品的质量控制和监督管理提供新思路。

香菇工厂化生产研究进展

香菇是我国食用菌中年产量最大的单品。随着产业的发展,集约化、工厂化生产逐渐成为一种趋势。“集中制棒,分散出菇”成为我国香菇栽培的主流模式。相关研究和生产应用取得了较大进步,该文从品种选育、生产过程调控等方面对此进行了综述,以期为香菇工厂化生产提供参考依据。

大型连续绿茶精制加工生产线研发

茶叶加工技术与装备是茶叶产业发展的基础,对行业发展起着举足轻重的作用。为实现绿茶加工机械自动化生产,设计了大型连续绿茶精制加工生产线,阐述了该生产线系统结构、主要生产环节及安装调试应用。基于PLC控制的大型连续绿茶精制加工生产线,主要由鲜叶上料输送机、大型滚筒杀青机、冷却回潮机、四机协同联动式揉捻机组、并列连续预烘干机组、储料仓、计量分料装置、茶叶炒干与抛光机组、筛分装置、风选装置及配套的测控系统等组成。针对绿茶加工工艺的各个环节,采用模块化设计,根据茶叶加工企业的厂房实际情况,灵活安装组线,满足企业个性化需求。基于模糊PID温度控制的大型滚筒杀青机双模糊控制技术,解决了传统杀青温度与时间无法实现精确控制的难点问题。采用链式刮板输送智能加料装置与多机联动协同连续揉捻控制技术,实现多机协同联动式自动加料连续揉捻,边进料边揉捻,揉捻均匀度高。生产线上杀青机、理条机和烘干机各环节温度采用模糊PID控制,解决了茶叶加工温度、投叶量与杀青、理条、烘干时间实时配合的问题,输入不同等级、不同重量的鲜叶可输出相适应的杀青温度和时间,实现对茶叶生产过程的精确控制,减少人为因素的干扰,实现绿茶的智能化生产。近年来,生产线用户遍布皖、苏、浙、云、贵、川、豫、湘、鄂和陕等10多个省份200余家茶叶生产企业。该生产线的推广应用,实现了茶叶规模化生产,保证了茶叶品质,对茶产业发展具有重要意义。

陶泥3D打印技术在陶瓷产品设计中的运用分析

陶泥3D打印技术是一种创新的陶瓷制品制作方法,它基于挤出成型原理,通过打印机精确控制陶泥材料的挤出和堆积,实现三维物体的构建。该技术提高了制作效率和精度,赋予设计师更大的自由度,同时减少了材料浪费。然而,它在三维建模、材料与工艺控制方面存在挑战,如模型稳定性、支撑结构设计、材料含水率控制等。在设计过程中,需要注意壁厚、支撑结构和底部处理等问题,以确保打印质量和产品的艺术性。

在线检测技术在中药饮片智能化生产与质量控制中的研究现状与展望

中药饮片产业是中药产业三大支柱之一,保证饮片的质量和安全性一直是重中之重的工作。传统的中药质量控制方法存在周期长、效率低、主观性强等问题,无法适应产业的快速发展。在线检测技术通过在线监测系统实时采集、处理和分析样品数据,能够更快速、准确地得到产品质量信息,对中药饮片的智能化生产和质量控制具有重要意义。从国家政策导向阐明中药智能化生产对中药饮片质量控制的重要性,对在线检测关键技术研究及其在饮片生产全过程中的应用进行综述,归纳当前在线检测技术在中药产业应用中存在的问题,为加快在线检测技术与饮片产业融合发展提供建议,以期为提高饮片生产效率及质量、促进饮片产业高质量发展提供参考。

畜产品加工中的常见问题及解决对策

畜产品加工在保障食品安全和提升产品质量方面面临诸多挑战。本文通过分析畜产品在加工过程中存在的原料质量控制不足、加工工艺参数优化不当及卫生安全管理体系缺陷等常见问题,提出相应的解决措施,旨在提高畜产品加工的整体水平,确保食品安全,促进行业的可持续发展。

我国辣椒生产相关标准体系现状分析与展望

辣椒全产业链标准体系的构建对于打造“三品一标”辣椒产品、促进全产业链高质量发展具有重要意义。在系统总结我国与辣椒相关的标准体系情况的基础上,重点分析了辣椒高效生产、病害防治和加工安全等方面标准化体系建设的现状和不足,并对今后在辣椒产品品质、绿色安全高效生产技术等方面的标准化体系建设进行了展望,以期为相关科学研究、技术推广、成果转化等提供借鉴与参考。

预制水产品加工技术研究进展

随着人们生活方式的转变以及对便捷生活的追求,预制菜行业快速发展,其中预制水产品因自身优势展现出其独有的竞争力。预制水产品行业的持续健康发展依赖于水产品加工技术在产品安全、营养保持和感官评价等方面的质量控制。该文对预制水产品的发展历程、概念及其分类进行概述,重点阐述了脱腥、预制加工、灭菌、包装及贮藏等加工技术在水产品预制加工中的应用,并对预制水产品的未来发展趋势进行展望。

多工序制造中的误差流模型及其应用研究进展

航空发动机结构件、汽车车身等复杂产品通常为多工序制造件,其制造过程中多种误差的产生和累积会对产品质量产生耦合影响,使产品质量控制处于暗箱状态。将误差流理论与精度控制理论、工程数据处理方法相结合,构建对误差的传递、累积、湮灭进行描述和分析的误差流模型对于多工序制造复杂产品质量控制具有重要意义。因此,总结和归纳了误差流模型的构建方法及其应用研究,提出了多工序制造的误差流模型质量控制总体框架,从小数据驱动的时间序列数学解析模型和大数据驱动的复杂网络统计分析模型两个方面对多工序制造的误差流模型进行了分类综述。最后,展望了误差流模型在高端装备和复杂产品等未来多工序制造领域中的发展趋势。

全钢载重子午线轮胎胎圈露线的原因分析及解决措施

从产品设计和工艺控制方面分析全钢载重子午线轮胎胎圈露线的原因,并提出相应的解决措施。通过适当增大成型平面宽和鼓肩宽,适当减小钢丝圈内侧胎侧厚度和胎趾角度,严格控制胎侧成型定位、胎坯存放、硫化机机械手精度、钢丝圈缠绕工艺及存放等措施,有效地解决了全钢载重子午线轮胎胎圈露线问题,提高了轮胎的安全性能,降低了生产成本。

面向工业数字孪生的三层知识图谱结构设计方法

随着工业领域数字化和智能化的发展,企业正面临着提高生产效率、降低生产成本、优化生产过程以及实现实时监控等挑战。数字孪生技术作为一种有效的解决方案,受到了广泛关注。然而,工业建设数字孪生过程中存在数据获取与整合、模型构建与更新以及实时性与精度等难点。为解决这些问题,提出了一种基于数字孪生的知识图谱概念-实例-模块结构设计方法。数字孪生知识图谱模型采用概念-实例-模块三层架构,概念层通过知识图谱建立全面有机的知识网络;实例层进行数字化建模,实现理论参数的真实再现;知识模块层则将前两层知识进行融合,形成功能模块,以实现全面监测和控制。这一模型能够对工业加工知识进行更为准确、细致的建模和分析,帮助企业实现数字化建模、精确仿真模拟、预测分析、异常检测等高级应用功能。

电解水制高压氢气——技术挑战与研究进展

利用可再生能源电解水制氢替代化石燃料用于交通和工业领域是实现碳减排的重要技术路径,电解水制取高压氢气有利于简化氢能供应链工艺从而减少压缩机等设备投入,同时,利用电化学等温压缩减小综合能耗,对于降低可再生能源制氢综合成本具有重要意义。电解水制氢压力提高导致电解槽气密性和材料耐氢蚀要求提高,工作状态下更易发生氢氧互混导致氧中氢浓度增加以及电流效率下降,面临技术挑战。本文综述了质子交换膜电解水和碱性电解水两种技术路线在制取高压氢气方面的研究进展,开发高强度、低渗漏、高电导的隔膜材料以及适应隔膜溶胀形变的耐高压密封结构是差压式质子交换膜电解水实现高性能和高可靠性的关键,研发氢氧互混管理新工艺及过程控制技术是实现碱性电解水安全制取高压氢气的关键。

排单系统在印染数字化发展过程中的作用及意义

公司率先在行业内开展“全流程排单系统”平台建设,通过数字化优势和全生产参数系统传输,达到生产环节动态平衡,全流程生产可控、可视。3年时间大量投资建设,不断完善系统平台各项功能,提升生产管控能力,进而转变为可观经济收益。该平台建设项目示范并引领印染行业数字化、智能化、绿色化转型发展,同时数字化战略行动推动数字化人才梯队建设工作,面向数字时代,以人为本,更新思维方式与发展理念,变革组织架构与发展模式,建设高质量个性化学习发展体系,打造建设未来数字化工厂模型。