/
Lear_Project.py
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Lear_Project.py
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# Importing libraries
import os
import tkinter as tk
from tkinter import ttk
from ttkthemes import ThemedStyle
from tkinter import filedialog
import numpy as np
import pandas as pd
import matplotlib
import matplotlib.pyplot as plt
matplotlib.use('TkAgg')
from matplotlib.backends.backend_tkagg import (FigureCanvasTkAgg, NavigationToolbar2Tk)
from matplotlib.figure import Figure
from matplotlib.backends.backend_pdf import PdfPages
from PyPDF2 import PdfFileWriter, PdfFileReader
import io
from reportlab.pdfgen import canvas
from reportlab.lib.pagesizes import letter
plt.style.use('ggplot')
# reading the file containing data
# have to be modified based on the PC being used
path = "C:/Users/M SAI JASWANTH/OneDrive/Desktop/Jassu/Intern/Reference data"
report_1 = os.path.join(path, "hsl1 - 15 Report_20191015 070000~20191016 070000.csv")
report_2 = os.path.join(path, "HSL2 - 15 Report_20191015 070000~20191016 070000.csv")
df1 = pd.read_csv(report_1, low_memory=False)
df2 = pd.read_csv(report_2, low_memory=False)
df1['join']=" || "
df1['d_and_t']=df1['Date'].astype(str)+df1['join'].astype(str)+df1[' Time'].astype(str)
# Creating GUI for HSL-1
window_1 = tk.Tk()
window_1.title("Lear_Project - HSL 1")
window_1.geometry('700x800')
window_1.iconbitmap("D:\\Lear_Corporation_Logo.ico")
# Setting theme
s = ThemedStyle(window_1)
s.set_theme("breeze")
label = ttk.Label(window_1, text="Generation of Run-Chart")
label.config(font=("Helvetica", 14))
label.pack()
# dropdown menu
options = list(df1.columns)
options_start = list(df1['d_and_t'])
options_end = list(df1['d_and_t'])
var = tk.StringVar()
var.set(options[1])
var_s =tk.StringVar()
var.set(options_start[0])
var_e =tk.StringVar()
var.set(options_end[1])
class mclass:
def __init__(self, window_1):
global options, var, options_start, options_end, var_s, var_e
self.window_1 = window_1
frame = tk.Frame(self.window_1)
frame.pack()
parameter_label = tk.Label(frame, text="Choose a parameter:")
parameter_label.pack(side='left')
self.drop = ttk.Combobox(frame, width=65, textvariable=var)
self.drop['values'] = options
self.drop.pack(side='left', fill='x', expand=True, pady=10)
self.drop.current(1)
#Getting start and end times
frame_1 = tk.Frame(self.window_1)
frame_1.pack(padx=10, pady=10)
start_time_label = tk.Label(frame_1, text="Choose Start Time:")
start_time_label.pack(side='left', fill='x', expand=True)
self.start_time=ttk.Combobox(frame_1, width=20, textvariable=var_s)
self.start_time['values'] = options_start
self.start_time.pack(side='left', fill='x', expand=True, padx=10)
self.start_time.current(0)
end_time_label = tk.Label(frame_1, text="Choose End Time:")
end_time_label.pack(side='left', fill='x', expand=True, padx=10)
self.end_time=ttk.Combobox(frame_1, width=20, textvariable=var_e)
self.end_time['values'] = options_end
self.end_time.pack(side='left', fill='x', expand=True)
self.end_time.current(0)
# Functionality buttons
frame_2 = tk.Frame(self.window_1)
frame_2.pack(pady=10)
self.button_1 = ttk.Button(frame_2, text="Generate Run-Chart", command=self.plot)
self.button_1.pack(side='left', fill='x', expand=True, padx=0)
self.button_2 = ttk.Button(frame_2, text="Clear Plot", width=10, command=self.clr)
self.button_2.pack(side='left', fill='x', expand=True, padx=60)
self.button_3 = ttk.Button(frame_2, text="Export Report As PDF", command=self.save_file)
self.button_3.pack(anchor='nw', side='right', fill='x', expand=True, padx=0)
def plot (self):
global var, var_s, var_e, df1
column_index = df1.columns.get_loc(var.get())
row_start=int(df1[df1['d_and_t']==var_s.get()].iloc[0,0])-1
row_end=int(df1[df1['d_and_t']==var_e.get()].iloc[0,0])
parameter_1 = df1.iloc[row_start:row_end, column_index]
avg = parameter_1.mean()
std = parameter_1.std()
y_label = var.get()
df = df1.iloc[row_start:row_end].copy()
df['avg']=avg
number = df[' Time']
upper_1 = avg + std*1
upper_2 = avg + std*2
upper_3 = avg + std*3
lower_1 = avg - std*1
lower_2 = avg - std*2
lower_3 = avg - std*3
df['upper_1'] = upper_1
df['upper_2'] = upper_2
df['upper_3'] = upper_3
df['lower_1'] = lower_1
df['lower_2'] = lower_2
df['lower_3'] = lower_3
self.frame_top = tk.Frame(self.window_1)
self.frame_top.pack(fill='both', expand=True)
fig_1 = Figure(figsize=(10,6))
a = fig_1.add_subplot(111)
a.plot(number,parameter_1, color='b', marker='o')
a.plot(number, df['avg'], linestyle='solid', linewidth=3, color='g')
a.plot(number, df['upper_1'], linestyle='dashed', linewidth=3, color='r')
a.plot(number, df['upper_2'], linestyle='dashed', linewidth=3, color='r')
a.plot(number, df['upper_3'], linestyle='dashed', linewidth=3, color='r')
a.plot(number, df['lower_1'], linestyle='dashed', linewidth=3, color='r')
a.plot(number, df['lower_2'], linestyle='dashed', linewidth=3, color='r')
a.plot(number, df['lower_3'], linestyle='dashed', linewidth=3, color='r')
a.set_xlabel('Time', fontsize=14)
a.set_ylabel('{}'.format(y_label), fontsize=14)
a.set_title('X-Bar Run Chart', fontsize=16)
for label in a.get_xticklabels():
label.set_rotation(90)
self.canvas = FigureCanvasTkAgg(fig_1, master=self.frame_top)
self.canvas.get_tk_widget().pack(fill='both', expand=True)
self.canvas.draw()
toolbar = NavigationToolbar2Tk(self.canvas, self.frame_top)
toolbar.update()
self.results()
def results(self):
global var, var_s, var_e
column_index = df1.columns.get_loc(var.get())
row_start=int(df1[df1['d_and_t']==var_s.get()].iloc[0,0])
row_end=int(df1[df1['d_and_t']==var_e.get()].iloc[0,0])
parameter_1 = df1.iloc[row_start:row_end+1, column_index]
avg = parameter_1.mean()
std = parameter_1.std()
target = avg
tolerance = std
# defining the zones and limits
upper_1 = avg + std*1
upper_2 = avg + std*2
upper_3 = avg + std*3
lower_1 = avg - std*1
lower_2 = avg - std*2
lower_3 = avg - std*3
# checking for special cause variations
self.errors=set()
self.errors.clear
differentials_to_target = parameter_1 - target
differentials_to_avg = parameter_1 - avg
first_differences = np.ediff1d(parameter_1)
#tolerances
if np.max(np.absolute(differentials_to_target)) > tolerance:
self.errors.add("Dimensions are out of tolerance")
#beyond limit
absolute_differentials = np.absolute(differentials_to_avg)
if np.max(absolute_differentials) > upper_3:
self.errors.add("Outliers Exist")
#outer region or Zone A
for index, i in enumerate(absolute_differentials):
if index < 2:
continue
count = np.count_nonzero(absolute_differentials[index-2:index+1] > (std*2))
if count >= 2:
self.errors.add("Outer Zone Clusters")
#middle regions or Zone B
for index, i in enumerate(absolute_differentials):
if index < 4:
continue
count = np.count_nonzero(absolute_differentials[index-4:index+1] > (std*1))
if count >= 4:
self.errors.add("Middle Zone Clusters")
#inner region or Zone C
for index, i in enumerate(absolute_differentials):
if index < 6:
continue
count = np.count_nonzero(differentials_to_avg[index-6:index+1] > 0)
if count >= 7:
self.errors.add("Inner Zone Clusters")
count = np.count_nonzero(differentials_to_avg[index-6:index+1] < 0)
if count >= 7:
self.errors.add("Inner Zone Clusters")
#trends
for index, i in enumerate(first_differences):
if index < 6:
continue
count = np.count_nonzero(first_differences[index-5:index+1] > 0)
if count >= 7:
self.errors.add("Trending Data is Present")
count = np.count_nonzero(first_differences[index-5:index+1] < 0)
if count >= 7:
self.errors.add("Trending Data is Present")
#mixture
for index, i in enumerate(absolute_differentials):
if index < 8:
continue
count = np.count_nonzero(absolute_differentials[index-8:index+1] > upper_3)
if count == 0:
self.errors.add("No Mixture")
else:
self.errors.add("Mixture")
#stratification
for index, i in enumerate(absolute_differentials):
if index < 15:
continue
count = np.count_nonzero(absolute_differentials[index-15:index+1] > upper_1)
if count == 0:
self.errors.add("No Stratification")
#over control
def sign_change(x,y):
if x > 0 and y > 0:
return 0
elif x < 0 and y < 0:
return 0
else:
return 1
changes = []
for index, i in enumerate(first_differences):
if index == 0:
continue
change = sign_change(first_differences[index],first_differences[index-1])
changes.append(change)
for index, i in enumerate(changes):
if index < 14:
continue
if np.array(changes[index-14:index+1]).sum() >= 15:
self.errors.add("Over Control")
self.frame_bottom_1 = tk.Frame(window_1)
self.frame_bottom_1.pack(fill='x')
tk.Label(self.frame_bottom_1, text="Errors:").pack(side='left', fill='x')
entry1=ttk.Entry(self.frame_bottom_1,width=100,font=('Helvetica', 10))
entry1.pack(side='left', fill='x', expand=True)
entry1.insert(0,repr(self.errors))
self.cause()
def cause(self):
# Possible causes
self.causes = set()
for ele in self.errors:
if ele == "Dimensions are out of tolerance":
self.causes.add("Process not proper, leading to dimensional variation")
elif ele == "Outliers Exist" or ele == "Outer Zone Clusters":
self.causes.add("New person doing the job, Wrong setup, Measurement error, Process step skipped, Process step not completed, Power failure, Equipment breakdown")
elif ele == "Middle Zone Clusters" or ele == "Inner Zone Clusters":
self.causes.add("Raw material change, Change in work instruction, Different measurement device/calibration, Different shift, Person gains greater skills in doing the job, Change in maintenance program, Change in setup procedure")
elif ele == "Trending data is present":
self.causes.add("Tooling wear or Temperature effects (cooling, heating)")
elif ele == "Mixture" or ele == "Stratification":
self.causes.add("More than one process present (e.g. shifts, machines, raw material.)")
elif ele == "Over Control":
self.causes.add("Tampering by operator or Alternating raw materials")
self.frame_bottom_2 = tk.Frame(window_1)
self.frame_bottom_2.pack(fill='x')
tk.Label(self.frame_bottom_2, text="Possible\nCauses:").pack(side='left', fill='x')
entry1=tk.Text(self.frame_bottom_2, height=3, width=5,font=('Helvetica', 10), bg='white', borderwidth=3)
entry1.pack(side='left', fill='x', expand=True, pady=4)
lst = repr(self.causes).split("',")
for ele in lst:
entry1.insert(tk.END, str(ele)+"\n")
def save_file(self):
# create a new PDF with Reportlab
can = canvas.Canvas("Report.pdf", pagesize=letter)
# exporting plot as PDF
global var, var_s, var_e, df1
column_index = df1.columns.get_loc(var.get())
row_start=int(df1[df1['d_and_t']==var_s.get()].iloc[0,0])-1
row_end=int(df1[df1['d_and_t']==var_e.get()].iloc[0,0])
parameter_1 = df1.iloc[row_start:row_end, column_index]
avg = parameter_1.mean()
std = parameter_1.std()
y_label = var.get()
df = df1.iloc[row_start:row_end].copy()
df['avg']=avg
number = df[' Time']
upper_1 = avg + std*1
upper_2 = avg + std*2
upper_3 = avg + std*3
lower_1 = avg - std*1
lower_2 = avg - std*2
lower_3 = avg - std*3
df['upper_1'] = upper_1
df['upper_2'] = upper_2
df['upper_3'] = upper_3
df['lower_1'] = lower_1
df['lower_2'] = lower_2
df['lower_3'] = lower_3
#with PdfPages('C:\\Users\\M SAI JASWANTH\\Report.pdf') as export_pdf:
plt.plot(number,parameter_1, color='b', marker='o')
plt.plot(number, df['avg'], linestyle='solid', linewidth=3, color='g')
plt.plot(number, df['upper_1'], linestyle='dashed', linewidth=3, color='r')
plt.plot(number, df['upper_2'], linestyle='dashed', linewidth=3, color='r')
plt.plot(number, df['upper_3'], linestyle='dashed', linewidth=3, color='r')
plt.plot(number, df['lower_1'], linestyle='dashed', linewidth=3, color='r')
plt.plot(number, df['lower_2'], linestyle='dashed', linewidth=3, color='r')
plt.plot(number, df['lower_3'], linestyle='dashed', linewidth=3, color='r')
plt.xlabel('Time', fontsize=10)
plt.ylabel('{}'.format(y_label), fontsize=10)
plt.title('X-Bar Run Chart', fontsize=12)
plt.xticks(rotation=90)
plt.grid(True)
plt.savefig('plot.png')
plt.close()
# errors and causes to PDF
can.drawImage("Lear_Logo.png", 10, 710, width=200,height=75, mask=None )
can.drawImage("plot.png", 15, 300, width=600,height=400, mask=None )
can.drawString(65, 250, "Errors:")
can.drawString(65,230, repr(self.errors))
can.drawString(65, 180, "Possible Causes:")
lst = repr(self.causes).split("',")
y = 140
for i in range(len(lst)):
ele = str(lst[i])
print(ele)
if len(str(ele))>90:
can.drawString(65, y+15, ele[:90])
can.drawString(65, y, ele[90:180])
can.drawString(65, y-15, ele[180:270])
can.drawString(65, y-30, ele[270:])
else:
can.drawString(65, y-15, ele)
y-=15
can.save()
def clr(self):
self.frame_top.destroy()
self.frame_bottom_1.destroy()
self.frame_bottom_2.destroy()
start= mclass (window_1)
window_1.mainloop()