The document outlines a comprehensive verification process divided into three phases: Offline Simulation Verification, Online Low-Flow Pilot Verification, and Post-Full-Scale Deployment Continuous Verification, aimed at ensuring the reliability and efficiency of a Manufacturing Execution System (MES) for injection molding machines.
I. Offline Simulation Verification Phase (No Production Load)
1. Communication Link Connectivity Verification: Simulates data upload of RC calibration results to confirm that the MES system's data reception delay does not exceed 1 second, ensuring there is no packet loss or garbled characters.
2. Judgment Logic Boundary Value Verification: Conducts tests with three boundary data sets that deviate by 4.9%, 5%, and 5.1%. The system should accurately trigger a pass/fail judgment when the deviation is ≤5%.
3. Permission Lock Status Linkage Verification: Triggers the RC calibration task manually to confirm immediate locking of production permissions, and checks that permissions are automatically and promptly unlocked post data upload.
4. Abnormal Scenario Simulation Verification: Tests communication interruptions, data packet loss, and calibration limits to ensure the system retains permission lock status and avoids false device locking.
II. Online Low-Flow Pilot Verification Phase (Low-Load Production)
1. Single Machine Pilot Verification: Involves a non-critical injection molding machine executing the full cycle of triggering RC calibration, completing calibration, and unlocking permissions, validated over 10 consecutive trials with a 100% success rate.
2. Multi-Machine Concurrent Verification: Triggers calibration tasks on three machines simultaneously, verifying no congestion occurs within the MES task queue and that permissions are successfully unlocked without interference.
3. Production Stability Verification: Monitors production for 2 hours post-unlocking of permissions to validate stable functionality with RC parameters, maintaining temperature fluctuations within ±0.5℃ and ensuring zero defects.
4. Log Traceability Verification: Evaluates the MES operation log for completeness and traceability of timestamps, operators, and calibration data throughout the locking and unlocking processes.
III. Post-Full-Scale Deployment Continuous Verification Phase
1. 72-Hour Continuous Stability Verification: Runs the system for 72 hours post-deployment to ensure no erroneous locking or freezing in the automatic unlocking process.
2. Drift Scenario Entity Verification: Creates a drifting scenario to assess the system's capability in detecting excessive drift, locking permissions, and initiating calibration tasks accordingly.
3. Emergency Unlock Process Verification: Confirms emergency unlocking can be executed promptly using an administrator account without disrupting production schedules.
4. Monthly Regular Re-verification: Conducts monthly checks on 10% of machines to ensure boundary parameters remain stable and assess the system's logic over prolonged operation.
IV. Verification Effectiveness Criteria
The verification process aims for an automatic unlock success rate of at least 99.5%, ensuring no erroneous locks or missed unlocks occur. The response time for unlocking permissions must be ≤3 seconds, while all calibration data and operation logs must be 100% archived for process compliance and traceability.
