應用物聯網實踐智能工廠生產線即時品質監控-以電線電纜製造為例

全球化經濟隨網路科技與市場環境變遷，產銷模式快速變化，企業面臨的是一個高度競爭與快速變遷的環境，為有效縮減與整體市場間之隔閡，欲藉由導入工業4.0、物聯網、雲端、虛實整合、大數據、智慧生產..等科技，來達成資訊共享，即時決策，供需配合無間，讓產品的價格最大化、成本最小化，提高整體營運生產效益。必須不斷的改變才能順應環境的變動，跟上新時代潮流。追求卓越，適時調整營運策略，掌握市場需求創新求變，與時俱進力求革新和創新，才能在瞬息萬變的環境中維持競爭優勢，才能持續生存，永續經營。導入工業4.0，以精實管理基礎來進化。以TPS 具體的觀念，展開實施生產線的改善，有效的整理及整頓現場缺失，徹底消除浪費，從事務管理到資訊管理，進行企業改善創新。本論文以傳統電纜廠為研究，在「生產力4.0」的精神架構下，透過自我瞭解精實管理程度，因應工業4.0的浪潮前進。研究著重在即時的品質監控，利用感測器於生產中在線即時檢測出品質為標的。藉由感測器、檢驗儀蒐集製程品質數據，以螢幕看板與行動化資訊系統為基礎，建置更有效率、即時、正確的品質監控系統。並將數據傳遞至雲端進行分析與共享，讓操作人員、管理者能夠即時同步獲得機台狀況，可即時進行必要的因應監控決策。資訊網頁讓使用者，利用行動裝置隨時隨地隨手可得產品的品質即時資訊。運用物聯網(The Internet of Things，IoT)技術，期望達到提升自動化、省力化、智能化的目標。研究以既有的精實管理架構下，在設備生產線上，運用產品品質檢測設施在既有或新增的火花試驗機、雷射外徑測試儀、凹凸檢測儀、厚度測試儀、外觀檢測儀、印字檢測儀、印米檢測儀..等，即時的檢測品質狀態。研究結果物聯網聯結品質檢測設施，可達全面品質檢查，數據自動記錄存查分析。檢測設施運用PID閉迴路控制，對厚度/長度值運算調節，自動循環回饋，厚度/長度變異範圍縮小，CPK得到升級。螢幕看板與行動化資訊系統，工程師/ 生產主管利用資訊網頁顯查詢，可即時同步得到實際生產的產品狀態資訊。品質資料結合MES系統，可列印出產品軸ID品質標籤。厚度設施啟動除可提升厚度品質穩定外，也可減少絕緣用料量4% 降低材料的耗用，節省成本的效果。啟用連續印米長度量測系統除品質穩定避免困擾外，可減少損耗0.14%，成本也有助益。

關鍵字

工業4.0 ；物聯網；電纜

並列摘要

With the changes in network technology and market environment, the global economy changes rapidly in production and sales models. Companies are faced with a highly competitive and fast-changing environment. In order to effectively reduce the gap with the overall market, they want to introduce Industry 4.0, Internet of Things, Cloud, virtual and real integration, big data, smart production... and other technologies to achieve information sharing, real-time decision-making, seamless supply and demand coordination, maximize product prices, minimize costs, and improve overall operating and production efficiency. Constant change is necessary to adapt to changes in the environment and keep up with the trend of the new era. Pursuit of excellence, timely adjustment of operating strategies, grasp of market demand, innovation and change, and advancing with the times, strive for innovation and innovation, in order to maintain a competitive advantage in a rapidly changing environment, and to survive and sustain operations. Introduce Industry 4.0 and evolve based on lean management. Based on the specific concept of TPS, we will implement the improvement of the production line, effectively sort out and rectify the on-site defects, completely eliminate waste, and carry out enterprise improvement and innovation from business management to information management. This thesis takes the traditional cable factory as the research, under the spiritual framework of "Productivity 4.0", through self-understanding of the level of lean management, in response to the wave of Industry 4.0. The research focuses on real-time quality monitoring, using sensors to detect the quality as the target in real-time online during production. Collect process quality data by sensors and testers, and build a more efficient, real-time and correct quality monitoring system based on screen billboards and mobile information systems. And transfer the data to the cloud for analysis and sharing, so that operators and managers can obtain the status of the machine in real time and make necessary response monitoring decisions in real time. The information page allows users to use their mobile devices to obtain real-time information about product quality anytime, anywhere. Using the Internet of Things (IoT) technology, we hope to achieve the goal of improving automation, labor saving, and intelligence. Under the existing lean management structure, the research uses product quality inspection facilities on the existing or newly-added spark tester, laser outer diameter tester, bump tester, thickness tester, and appearance tester on the equipment doi:10.6840/cycu202100217 III production line. , Printing Tester, Printed length Tester... etc., real-time inspection quality status. Research results The Internet of Things is connected with quality inspection facilities, which can achieve comprehensive quality inspection and automatic data recording, storage and analysis. The testing facility uses PID closed loop control, calculates and adjusts the thickness/length value, and automatically loops feedback. The thickness/length variation range is reduced, and the CPK is upgraded. With screen billboard and mobile information system, engineers/production supervisors can use the information webpage to display inquiries and obtain real-time product status information in real-time synchronization. The quality data combined with the MES system can print out the product drum ID quality label. In addition to improving the thickness quality and stability, the start-up of the thickness facility can also reduce the amount of insulation material used by 4%, reducing material consumption and saving costs. In addition to stable quality and avoiding troubles, the use of the continuous printing length measurement system can reduce the loss by 0.14%, and the cost is also helpful.