WO2001050204A2 - Production line stability tool - Google Patents
Production line stability tool Download PDFInfo
- Publication number
- WO2001050204A2 WO2001050204A2 PCT/US2000/033400 US0033400W WO0150204A2 WO 2001050204 A2 WO2001050204 A2 WO 2001050204A2 US 0033400 W US0033400 W US 0033400W WO 0150204 A2 WO0150204 A2 WO 0150204A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- production
- threshold
- line
- display
- values
- Prior art date
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Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by quality surveillance of production
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32184—Compare time, quality, state of operators with threshold value
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/35—Nc in input of data, input till input file format
- G05B2219/35489—Discriminate, different colour, highlight between two states
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the present invention is related generally to monitoring and control systems. More particularly, the presen* invention is related to methods and systems for monitoring production lines in a manufacturing environment.
- U.S. Patent 5,768,119 to Havekost et al. discloses a process control system that includes an alarm priority adjustment.
- the disclosure is directed to systems which monitor and uniformly display diagnostic information for devices of multiple different types, such as valves and switches.
- Various users of the system can prioritize the alarm and event information that is displayed.
- a user can set a desired alarm priority, selecting more important alarms for more urgent display and assigning a lower display status to less important events.
- the user is associated with a display configuration for displaying alarm and event information that is pertinent to that particular user.
- U.S. Patent 5,351,195 to Sherman discloses a method for improving manufacturing processes in a factory. The method is performed by inputting an output capacity level for the factory, and a selected parameter for improvement; determining whether a maximum possible variation of the selected parameter would achieve the output capacity level; determining an achievable capacity output level when the maximum possible parameter variation does not allow for the desired output capacity level; determining an amount of improvement required to achieve the output capacity level when the maximum possible improvement meets or exceeds the output capacity level; and adjusting the processes of one or more factory workstations to implement the parameter improvements.
- U.S. Patent 4,802,094 to Nakamura et al. discloses a process monitoring apparatus for process management in production and assembly lines. More particularly, this patent discloses a method and apparatus for monitoring a process earned out along a line which branches and joins in a complicated manner, such as in the case where a plurality of parts or products of various kinds are moved in a line while they are joined together, or a lot of joined works is divided into sub-lots.
- the apparatus includes a first memory for holding facility-specific data for each of a plurality of facilities in a production line; a second memory for holding tracking conditions representing a detection of movement flow of works between facilities; third, fourth, and fifth memories holding management data, program triggering data for triggering a program to define contents of an operation represented by the management data, and process status data (including the movement detection signal), respectively; means for extracting the management data from the third memory and for determining which tracking conditions have been met; and a processor for executing a process corresponding to the contents of the first, second, and fourth memories.
- the present invention overcomes the above-noted problems, and achieves additional advantages, by providing for a method, system and program for monitoring one or more production lines and providing optically distinct indications of production line status to enable a person monitoring production lines to determine if any production lines are in a potentially unstable state.
- the method can be implemented by determining first and second threshold production values (e.g., upper and lower production limits) for each line: determining an actual production value from each of the one or more production lines; comparing the actual production values from each line with the first and second thresholds for each line; and for each line, providing a first output if the actual production value is below the first threshold, providing a second output if the actual production value is between the first and second thresholds, and providing a third output if the actual production value is above the second threshold.
- the outputs are preferably optically distinct outputs on a display screen to enable a viewer to quickly and easily determine if one or more of the production lines are in a potentially unstable state.
- FIG. 1 is a block diagram of an arrangement in which one or more embodiments of the present invention can be implemented
- FIG. 2 is a flow chart describing a method according to an embodiment of the present invention.
- FIGs. 3 and 4 are sample display screens displaying an output according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION
- FIG. 1 is a block diagram showing one arrangement in which an embodiment of the present invention can be implemented.
- the diagram includes a plurality of production lines 10 having associated sensors 12 which are communicatively connected to a computer system 14.
- the computer system 14 has one or more associated displays 16 for displaying information to one or more associated persons.
- the computer system 14 can be a computer network such as the Internet or an intranet (a secured network accessible only to particular persons).
- the sensors 12 can be selected and implemented to measure any relevant production line parameters, it is assumed for purposes of explanation that the sensors 12 monitor the total output of each production line. In the case of manufacturing chemicals, quantities are typically measured in kilograms.
- the sensors 12 sense the output of each line, and provide this data over an appropriate communications link (which may be a hard-wired communication link, wireless communication link, or any other appropriate communications link including an intranet or the internet) to the computer system 14, which processes the data and displays appropriate outputs on one or more of the displays 16.
- the computer system 14 can process the data according to the methods and programs disclosed below.
- the system of FIG. 1 can be implemented using automatic industrial monitoring (AIM) as is known in the art.
- AIM automatic industrial monitoring
- the system of FIG. 1 can be implemented using the General Electric Cimplicity® system, or other suitable techniques for sensing inputs and outputs, and performing the desired calculations and other processing.
- FIG. 2 a flow chart describing a method according to one embodiment of the present invention for monitoring output of one or more of the production lines in the example of FIG. 1.
- This method can be implemented by a suitable software program, which includes instructions for carrying out the various steps of the method, and which resides in a memory (not shown) associated with the computer system 14.
- the process starts in step 200, and proceeds to step 202, in which the computer system 14 determines whether the current time is equal to one or more predetermined default times.
- the predetermined default times would typically be at the end of a measuring interval (e.g., one hour, one day, or other relevant interval). If the current time is equal to a predetermined default time, the method proceeds to step 204, where all calculations are reset, and then the method returns to step 202.
- step 204 If the computer system 14 determines in step 204 that the current time is not a predetermined default time, then the computer system 14 retrieves first and second threshold values Ql and Q2 (which can be upper and lower line production limits, or other suitable criteria) from an associated memory. The method then proceeds to step 204
- step 208 where the computer system 14 determines (e.g., from the outputs of the sensors 12), whether the actual production of the line is smaller than the first threshold. If so, this indicates a undesirable or potentially unstable situation, and the computer system 14 causes one or more of the display screens 16 to provide a first display indication in step 208.
- one or more of the display screens 16 display in graphical form a plot of line output versus time; an exemplary plot will be described in more detail below.
- the first display indication in this example is causing the plot or portion thereof where the production line output is below the first threshold to be shown in a first optically distinct color (e.g., red).
- step 206 determines in step 206 that the actual production value is not below the first threshold
- step 208 the actual production value is compared to the second threshold. That is, the computer system 14 can determine whether the actual production value is between the first and second thresholds. If the actual production value of the line is between the first and second threshold values, the method proceeds to step 210, where the computer system 14 provides a second display indication.
- the second display indication can be causing the plot or portion thereof showing the actual production value to be between the first and second thresholds to be shown on the display screen 16 in a second optically distinct color (e.g., yellow).
- step 212 the computer system determines whether the actual production value is larger than the second threshold. If the actual production value is larger than the second threshold, indicating an undesirable and/or potentially unstable condition, the method proceeds to step 214, where the computer system 14 provides a third display indication on one or more of the displays 16.
- the third display indication can be provided by causing the plot or portion thereof showing the actual production value to be above the second threshold to be shown in a third optically distinct color (e.g., green).
- step 212 If the computer system 14 determines in step 212 that that actual production value is not larger than the second threshold value, an error has occurred, and the process returns to step 202.
- FIG. 3 is a summary display which identifies specific production lines of interest in a first column, the second threshold (e.g., the maximum desirable production value) in a second column, the first threshold (e.g., the minimum desirable production value) in a third column, an actual production value in a fourth column, and a difference value in a fifth column. Additional columns are provided to show a total quantity of reextrusion and rejected product per line in the relevant time period, and a total produced quantity, determined in this example as a sum of the actual production value and the total quantity of reextrusion and rejected product.
- the second threshold e.g., the maximum desirable production value
- the first threshold e.g., the minimum desirable production value
- Additional columns are provided to show a total quantity of reextrusion and rejected product per line in the relevant time period, and a total produced quantity, determined in this example as a sum of the actual production value and the total quantity of reextrusion and rejected product.
- this exemplary display includes links, which may be in hypertext markup language (HTML) or otherwise suitably implemented, to historical line data providing a graphical display of line output for the associated production line over time.
- the production line identification for each line in the first column of FIG. 3 can advantageously be displayed in optically distinct colors consistent with the current stability or other status of each production line.
- FIG. 4 shows a second exemplary display, which can be presented on the display 16 in response to a system user clicking on one of the links in the exemplary display of FIG. 3.
- the second exemplary display of FIG. 4 includes a graph plotting the actual production value over time for one or more particular production lines. It will be appreciated that the plots, or relevant portions thereof, can be displayed in different optically distinct colors to quickly and easily indicate to a system user the stability or other status of the production line.
- L23_DIFERE$MV (L23_KGPROD$MV - L23_TOTALR$MV) - L23_Q3$MV
- L23_KGGOOD$MV L23_KGPROD$MV - L23_TOTALR$MV
- Such source code or other suitable source code can be stored and implemented in the computer system 14 of FIG. 1.
- the principles of the present invention can easily be applied to monitoring values other than production quantities. For example, quality values such as item size, color, or other relevant qualitative values can be monitored. Further, it may be desirable to monitor the production lines based on more than two threshold values. For example, it may be desirable to measure production item size or weight, and to classify the produced items in one of many categories. Items so classified can be directed to locations corresponding to their category. Other modifications will also be apparent to those of ordinary skill in the art.
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- General Factory Administration (AREA)
- Management, Administration, Business Operations System, And Electronic Commerce (AREA)
- Multi-Process Working Machines And Systems (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU29071/01A AU2907101A (en) | 1999-12-30 | 2000-12-08 | Production line stability tool |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17372699P | 1999-12-30 | 1999-12-30 | |
US60/173,726 | 1999-12-30 | ||
US49803300A | 2000-02-04 | 2000-02-04 | |
US09/498,033 | 2000-02-04 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2001050204A2 true WO2001050204A2 (en) | 2001-07-12 |
WO2001050204A3 WO2001050204A3 (en) | 2002-03-21 |
Family
ID=26869475
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/033400 WO2001050204A2 (en) | 1999-12-30 | 2000-12-08 | Production line stability tool |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU2907101A (en) |
WO (1) | WO2001050204A2 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4802094A (en) * | 1985-07-10 | 1989-01-31 | Hitachi, Ltd. | Process monitoring apparatus for process management in production and assembly lines |
US5351195A (en) * | 1989-07-24 | 1994-09-27 | The George Group | Method for improving manufacturing processes |
US5440478A (en) * | 1994-02-22 | 1995-08-08 | Mercer Forge Company | Process control method for improving manufacturing operations |
US5495417A (en) * | 1990-08-14 | 1996-02-27 | Kabushiki Kaisha Toshiba | System for automatically producing different semiconductor products in different quantities through a plurality of processes along a production line |
-
2000
- 2000-12-08 WO PCT/US2000/033400 patent/WO2001050204A2/en active Application Filing
- 2000-12-08 AU AU29071/01A patent/AU2907101A/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4802094A (en) * | 1985-07-10 | 1989-01-31 | Hitachi, Ltd. | Process monitoring apparatus for process management in production and assembly lines |
US5351195A (en) * | 1989-07-24 | 1994-09-27 | The George Group | Method for improving manufacturing processes |
US5495417A (en) * | 1990-08-14 | 1996-02-27 | Kabushiki Kaisha Toshiba | System for automatically producing different semiconductor products in different quantities through a plurality of processes along a production line |
US5440478A (en) * | 1994-02-22 | 1995-08-08 | Mercer Forge Company | Process control method for improving manufacturing operations |
Non-Patent Citations (1)
Title |
---|
WIENDAHL H P: "PRODUCTION PLANNING AND CONTROL-THE TOOL TO ENSURE LOGISTICAL QUALITY" ROBOTICS AND COMPUTER INTEGRATED MANUFACTURING,GB,ELSEVIER SCIENCE PUBLISHERS BV., BARKING, vol. 10, no. 1 / 02, 1 February 1993 (1993-02-01), pages 99-107, XP000336236 ISSN: 0736-5845 * |
Also Published As
Publication number | Publication date |
---|---|
WO2001050204A3 (en) | 2002-03-21 |
AU2907101A (en) | 2001-07-16 |
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