The Stream of Variation (SoV) model and control chart are combined to study the fault diagnosis method of flexible materials R2R manufacturing system. Based on the analysis of the correlation between the fault source and product quality in the manufacturing process and also the statistical distribution rule of the processing quality characteristic vector and the fault source , SoV model under controlled or uncontrolled states and the mathematical model of the probability distribution of the statistic 2 , of the quality characteristic variable are deduced. And the calculation equation of the centerline, the upper limit, and the lower limit of the control chart are deduced. The experimental results show that, under controlled or uncontrolled condition, when the program runs to 500 steps, the Average Run Length (ARL) of the performance parameters tends to be stable; and when program reaches 1000 steps, the actual ARL value is almost the same as the theoretical value. The fault diagnosis experiment shows that, under the condition when the fault source is strongly correlated or the fault source correlation coefficient is the same, using the control chart established in this paper can simply and quickly determine the fault location in the system.

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