Modular system for real-time evaluation and monitoring of a machining production-line overall performances calculated from each given workpiece, tool and machine

• US 10,101,735 B2
• Filed: 07/02/2013
• Issued: 10/16/2018
• Est. Priority Date: 07/10/2012
• Status: Active Grant

• Current Assignee: Matitiahu Tiano
• Original Assignee: Matitiahu Tiano
• Inventors: Tiano, Matitiahu
• Primary Examiner(s): Wai, Eric C
• Application Number:
  US14/412,590
• Publication Number:
  US 20150142154A1
• Time in Patent Office: 1,932 Days
• Field of Search: None
• CPC Class Codes: G05B 19/4065 Monitoring tool breakage, life or condition
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/32179 Quality control, monitor production tool with multiple sensors
• CPC Class Codes: G05B 2219/32366 Line performance evaluation
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/82 Energy audits or management systems therefor

Abstract

The present invention provides a modular system and method for real-time evaluation and monitoring of a machining production line overall performances, calculated from each given metal workpiece, consumable tool and machine. The present invention is configured for an iterative and incremental calculation and evaluation of the machining production-line overall performances, by incrementally evaluating individual workpiece'"'"'s performances, consumable tools'"'"'performances and machine'"'"'s performances, extracted from the data of a plurality of workpieces and machines. The present invention is further configured for comparing the workpiece'"'"'s performances to a similar workpiece'"'"'s best performance, extracted from the evaluation of a plurality of the data similar workpieces. The present invention is further configured for the identification of significant process faults and their cause. The present invention is further configured for the analysis of the applied engineering-plan effectiveness, using a defined engineering score.

Claims

1. A modular industrial-control based system [100] for real-time evaluation and monitoring of overall performances of a machining production-line, calculated from performances of at least one machined metal workpiece [110], at least one consumable tool [120] and at least one machine [130];

said system [100]comprising;

a. identification devices [140] of said machines, configured for performing one or more automated identifications and transmissions of first signals denoting said identifications of at least one selected item from a group consisting of;

said workpieces [110];

said workpieces'"'"' [110] at least one consumable tool [120];

said workpieces'"'"' [110] machine [130];

said workpieces'"'"' [110] production operations number; and

any combination thereof;

b. recording devices [150] of said machines, configured to record at least one data input and transmit second signals denoting said data inputs, concerning said machining production-line, selected from a group consisting of;

machining course of action time-indicators, velocities and working parameters of said workpieces [110];

idle time, such as loading or unloading of said workpieces [110];

exceptionally long waiting idle time;

said machine'"'"'s [130] fault time;

said consumable tools'"'"' [120] wear time and wear amount; and

any combination thereof;

c. a data-collection device [160], configured to collect at least one input data selected from a group consisting of;

said identifications by said identification device [140];

said data input recorded by said recording device [150];

said workpieces'"'"' [110] machining course of action;

said workpieces'"'"' [110] loading idle time;

said shaped workpieces'"'"' [110] resulted quality;

said machines'"'"' [130] fault cause;

exceptionally long waiting idle time cause;

said consumable tools'"'"' [120] wear characteristic features;

setup periods;

operator ID;

production batch number; and

any combination thereof;

d. a Computerized Processing Unit (CPU) [170], configured to receive said input data from said data-collection device [160] and calculate and evaluate, as a function of said input data, at least one performance selected from a group consisting of;

performances of said workpieces [110];

performances of said consumable tools [120];

performances of said machines [130]; and

any combination thereof;

e. a storage device [180], configured to receive from said CPU [170] and store at least one data entry selected from a group consisting of;

all data which is not process-dependent [185];

all process-dependent data [186] including;

said input data and all said calculated and evaluated information;

updated said workpieces'"'"' [110] performances;

updated said tools'"'"' [120] performances;

updated said machines'"'"' [130] performances; and

any combination thereof;

f. a user interface [190], configured for selecting a method of said calculation and selecting elements and combinations to display said calculated and evaluated performances; and

g. a display device [195], configured to display said calculated and evaluated performances;

wherein said CPU [170] is further configured for an iterative and incremental calculation and evaluation of said machining production-line overall performances, by incrementally evaluating said individual workpieces'"'"' [110] performances, said consumable tools'"'"' [120] performances and said machines'"'"' [130] performances, extracted from said input data of a plurality of said workpieces [110] and plurality of said machines [130];

said system [100] is further configured to display said overall performances on said display device;

said machining production-line overall performances comprise one or more key performance indicators (KPIs);

said KPIs selected from a group consisting of

i. a gross profit;

ii. an overall equipment efficiency (OEE);

iii. direct operations costs; and

iv. an engineering score defined by

2. The system [100] according to claim 1, wherein said CPU [170] is further configured to display, on said display device, a realistic goal of one or more of said performances for increasing production capacity, according to the evaluation of said best performances;

such that said system [100] is configured to increase said process'"'"'s energy efficiency and/or gross profit.

3. The system [100] according to claim 1, wherein said CPU [170] is further configured to display, on said display device, a realistic goal of one or more of said performances for reducing production costs, according to said best performances;

such that said system [100] is configured to increase said energy efficiency and/or gross profit.

4. The system [100] according to claim 1, wherein said CPU [170] is further adapted to identify a decline in said performances and classify the source of said decline by comparing said performances with best practice performances over different periods of time and sorting the performances by different said KPIs, and accordingly present maintenance recommendations, on said display device, such that said system [100] is configured for maintaining said energy efficiency and/or said gross profit of said process.

5. The system [100] according to claim 1, wherein said system [100] is further connected to said consumable tools'"'"' [120] electrical storage cabinet, for retrieving additional data regarding said consumable tools [120] and further wherein said identification system [140] is configured for the identification of at least one feature selected from a group consisting of:

said workpieces'"'"' [110];

identification, material, description, dimensions, cost and application;

said consumable tools'"'"' [120];

identification, material, description, dimensions, cost, manufacturer and expected life cycle;

said machines'"'"' [130];

identification, operational cost, model and manufacturer; and

any combination thereof.

6. The system [100] according to claim 1, wherein said recording device [150] is configured to record said machines'"'"' [130] “

working” and

“

non-working”

status and time schedule, according to said machines'"'"' [130] measured current consumption from said machines'"'"' [130] power supply.

7. The system [100] according to claim 1, wherein said CPU [170] is configured for the calculation and evaluation of said workpieces'"'"' [110] performances, extracted from at least one feature selected from a group consisting of:

said unshaped workpieces'"'"' [110] cost;

said shaped workpieces'"'"' [110] selling prices, according to its resulted quality;

said workpieces'"'"' [130] operational cost, for said machining time and idle time;

said consumable tools'"'"' [120] relative costs, each dived by the number of their machined workpieces [110] until wear-out;

said workpieces'"'"' [110] individual direct operations costs;

said workpieces'"'"' [110] individual gross profit; and

any combination thereof; and

at least one feature selected from a group consisting of;

said workpieces'"'"' [110] machining time;

said workpieces'"'"' [110] idle time;

said workpieces'"'"' [110] individual engineering score;

said workpieces'"'"' [110] cutting times;

said workpieces'"'"' [110] non cutting times;

said workpieces'"'"' [110] average spindle power;

said workpieces'"'"' [110] number of cuts;

said workpieces'"'"' [110] sub operations performances; and

any combination thereof.

8. A industrial-control based method for monitoring and evaluating overall performances of a machining production-line, calculated from each given machined metal workpiece [110], consumable tool [120] and machine [130], comprising the steps:

a. automatically identifying the characteristic features of;

said workpieces [110];

said workpieces'"'"' [110] at least one consumable tool [120];

said workpieces'"'"' [110] machine [130];

said workpieces'"'"' [110] production operations number; and

any combination thereof;

b. recording data concerning said machining production line, selected from a group consisting of;

machining course of action time indicators and velocities of said workpieces [110];

idle time, such as loading or unloading of said workpiece [110];

exceptionally long idle time;

said machines'"'"' [130] “

fault”

time;

said consumable tools'"'"' [120] wear time and tool'"'"'s wear amount; and

any combination thereof;

c. collecting input-data selected from a group consisting of;

said workpieces'"'"' [110] machining course of action;

said shaped workpiece'"'"'s [110] resulted quality;

said machines'"'"' [130] “

fault”

cause;

said exceptional idle time cause;

said consumable tools'"'"' [120] wear characteristic features;

said setup time;

said operator ID;

said production batch number; and

any combination thereof;

d. calculating and evaluating the performances of;

said workpieces [110];

said consumable tools [120];

said machines [130];

e. storing;

all data which is not process-dependent;

all process-dependent data including;

said input data, and all said calculated and evaluated information;

f. selecting a calculation and evaluation method;

g. updating said consumable tools'"'"' [120] performances and said machines'"'"' [130] performances;

h. selecting displayed elements and combinations;

i. displaying said evaluated performances; and

j. repeating said method for at least two workpieces [110];

wherein said step of calculating and evaluating comprises an iterative and incremental calculation and evaluation of said machining production-line overall performances, by incrementally evaluating said individual workpieces'"'"' [110] performances, said consumable tools'"'"' [120] performances and said machines'"'"' [130] performances, extracted from said input data of a plurality of said workpieces [110] and plurality of said machines [130];

said machining production-line overall performances comprise one or more key performance indicators (KPIs);

said KPIs selected from a group consisting of

i. a gross profit;

ii. an overall equipment efficiency (OEE);

iii. direct operations costs; and

iv. an engineering score defined by

9. The method according to claim 8, wherein said step of calculating and evaluating further comprises displaying a realistic goal of one or more of said performances, on said display device, for increasing the production capacity according to the evaluation of said best performances;

thereby said method is configured for increasing said process'"'"'s energy efficiency and/or gross profit.

10. The method according to claim 8, wherein said step of calculating and evaluating further comprises displaying a realistic goal of one or more of said performances, on said display device, for reducing production costs, according to said best performances;

thereby said method is configured for increasing said process'"'"'s energy efficiency and/or gross profit.

11. The method according to claim 8, wherein said step of calculating and evaluating further comprises identifying a decline in said performances and classifying the source of said decline by comparing said performances with best practice performances over different periods of time and sorting the performances by different said KPIs, and accordingly presenting maintenance recommendations, on said display device;

thereby said method is configured for maintaining said process'"'"'s energy efficiency and/or gross profit.

12. The method according to claim 8, wherein said method further comprises a step of retrieving additional data regarding said consumable tools [120], from said consumable tools'"'"' [120] electrical storage cabinet.

13. The method according to claim 8, wherein said step of identifying is configured for the identification of features selected from a group consisting of:

said workpieces'"'"' [110];

identification, material, description, dimensions, cost and application;

said consumable tools'"'"' [120];

identification, material, description, dimensions, cost, manufacturer and expected life cycle;

said machines'"'"' [130]-identification, -operational cost, -model and -manufacturer; and

any combination thereof.

14. The method according to claim 8, wherein said step of calculating and evaluating said workpiece'"'"'s [110] performances, comprises extracting features selected from a group consisting of:

said unshaped workpieces'"'"' [110] cost;

said shaped workpieces'"'"' [110] selling price, according to its resulted quality;

said machines'"'"' [130] operational cost, for said machining time and idle time;

said consumable tools'"'"' [120] relative costs, each dived by the number of their machined workpieces [110] until wear-out;

said workpieces'"'"' [110] individual direct operations costs;

said workpieces'"'"' [110] individual gross profit; and

any combination thereof; and

at least one feature selected from a group consisting of;

said workpieces'"'"' [110] machining time;

said workpieces'"'"' [110] idle time;

said workpieces'"'"' [110] individual engineering score;

said workpieces'"'"' [110] cutting times;

said workpieces'"'"' [110] non cutting times;

said workpieces'"'"' [110] average spindle power;

said workpieces'"'"' [110] number of cuts;

said workpieces'"'"' [110] sub operations performances; and

any combination thereof.

15. The method according to claim 14, wherein said sub operations performances include performance indicators selected from a group consisting of:

stock removal rate;

specific stock removal energy;

chip thickness ratio;

cutting performance indicators, extracted from the velocities and working parameters of each cutting action of said workpiece [110] and

any combination thereof.

16. The method according to claim 8, wherein said step of calculating and evaluating said consumable tools'"'"' [120] performances, comprises extracting features selected from a group consisting of:

said consumable tools'"'"' [120] cost;

said consumable tools'"'"' [120] wear-out characteristics such as;

life-cycle, failure cause;

said consumable tools'"'"' [120] number of machined workpieces [110] until wear-out; and

any combination thereof.

17. The method according to claim 8, wherein said step of calculating and evaluating performances of said machine [130], comprises extracting features selected from a group consisting of:

said machines'"'"' [130] operational cost;

said machines'"'"' [130] fault time;

said machines'"'"' [130] fault cause;

said machines'"'"' [130] working plan;

said machines'"'"' [130] exceptional long waiting idle time;

said machines'"'"' [130] exceptional long waiting idle time cause;

said machines'"'"' [130] setup time;

said machines'"'"' [130] neutral time;

said machines'"'"' [130] disconnection time; and

any combination thereof.

18. The method according to claim 8, wherein said step of calculating and evaluating comprises collecting a plurality of said individual workpieces'"'"' [110] performances and evaluating said machining production-line performances for a predetermined period of time selected from a group consisting of:

hour, day, week, month, quarter, year, shift period, operator working period, machine [130] working period, operation period and any combination thereof.

19. The method according to claim 18, wherein said step of calculating and evaluating comprises extracting said best performances, by comparing said plurality of workpieces'"'"' [110] performances over said per period of time, using a function selected from a group consisting of:

summarize, maximum, minimum, average, percentage and any combination thereof.

20. The method according to claim 8, wherein said step of calculating and evaluating comprises evaluating business plans at least one selected from a group comprising of:

choosing said consumable tools'"'"' [120] suppliers, choosing said machines'"'"' [130] manufacturers, evaluating said applied engineering plans, evaluating workers'"'"' efficiency, evaluating machines'"'"'[130] efficiency, setting realistic goals to the different departments in the organization, implementing new innovative models with suppliers based on cost per part or improvements sharing, and evaluating the effectiveness of said machining production line, where evaluations are based on said comparison to best machining production-line overall performances further wherein said machine [130] is selected from a group consisting of;

metalworking machines, CNC machines, milling machines, turning machines, grinding machines, drilling machines, carving machines, EDM machines, laser machines, forging machines, water jet machines, deburring machines, chamfering machines, broaching machines and any combination thereof, further wherein said consumable tool [120] is a metalworking consumable cutting tool selected from a group consisting of;

machining tools, milling tools, turning tools, grinding tools, drilling tools, carving tools, forging dies, deburring tools, chamfering tools, electrodes, broaching tools, dressing tools; and

further wherein communications between said identification device [140], wherein said identification device [140] can identify and add an unfamiliar new said item;

said recording device [150];

said data-collection device [160], wherein said data collection device [160] can be notified of a planned said exceptional long waiting idle time;

said CPU [170];

said storage device [180];

said user interface [190], wherein said user interface [190] is further configured for manual input data; and

said display device [195] is selected from a group consisting of wired, wireless and any combination thereof.

21. A modular industrial-control based system [200] for real-time evaluation and monitoring of overall performances of a production-line, calculated from the performances of at least one part [210], at least one consumable material [220] and at least one machine[230];

said system [200] comprising;

a. an identification device [240], configured for performing one or more automated identifications and transmissions of first signals denoting said identifications of at least one item selected from a group consisting of;

said parts [210];

said parts'"'"' [210] consumable materials [220];

said parts'"'"' [210] machine [230];

said parts'"'"' [210] production operations number; and

any combination thereof;

b. a recording device [250], configured to record at least one recorded data, concerning said production-line, selected from a group consisting of;

processing course of action time-indicators, velocities and process parameters of said parts [210];

idle time, such as loading or unloading of said parts [210];

exceptionally long waiting idle time; and

said machines'"'"' [230] fault time;

said consumable materials'"'"' [220] wear time and wear characteristics; and

any combination thereof;

c. a data-collection device [260], configured to collect at least one input data selected from a group consisting of;

said identifications by said identification device [240];

said recorded data recorded by said recording device [250];

said parts'"'"' [210] processing course of action;

said parts'"'"' [210] loading idle time;

said produced parts'"'"' [210] resulted quality;

said machines'"'"' [230] fault cause;

exceptionally long waiting idle time cause;

said consumable materials'"'"' [220] wear characteristic features;

setup periods;

operator ID;

production batch number; and

any combination thereof;

d. a Computerized Processing Unit (CPU) [270], configured to receive said input data from said data-collection device [260] and calculate and evaluate, as a function of said input data, at least one performance selected from a group consisting of;

said parts'"'"' [210] performances;

said consumable materials'"'"' [220] performances;

said machines'"'"' [230] performances; and

any combination thereof;

e. a storage device [280], configured to receive from said CPU [270] store at least one entry selected from a group consisting of;

all data which is not process-dependent [285];

all process-dependent data [286] including;

said input data, and all said calculated and evaluated performances;

updated said parts'"'"' [210] performances;

updated said consumable materials'"'"' [220] performances;

updated said machines'"'"' [230] performances; and

any combination thereof;

f. a user interface [290], configured for selecting a method of said calculation and and selecting elements and combinations to display said calculated and evaluated performances; and

g. a display device [295], configured to display said calculated and evaluated performances;

wherein said CPU [270] is further configured for an iterative and incremental calculation and evaluation of said production-line overall performances, by incrementally evaluating said individual parts'"'"' [210] performances, said consumable materials'"'"' [220] performances and said machines'"'"' [230] performances, extracted from said input data of a plurality of said parts [210] and plurality of said machines [230];

said system [100] is further configured to display said overall performances on said display device;

said machining production-line overall performances comprise one or more key performance indicators (KPIs);

said KPIs selected from a group consisting of

i. a gross profit;

ii. an overall equipment efficiency (OEE);

iii. direct operations costs; and

iv. an engineering score defined by

22. The system [200] according to claim 21, wherein said recording device [250] is configured to further record said recorded data selected from a group consisting of:

a. said parts'"'"' [210] processing course of action time-indicators, velocities and process parameters;

b. said machines'"'"' [230] fault time;

c. said consumable materials'"'"' [220] wear time and wear characteristics; and

d. any combination thereof;

wherein said data-collection device [260] is configured to further collect said data input selected from a group consisting of;

e. said part'"'"'s [210] processing course of action time-indicators, velocities and process parameters;

f. said machine'"'"'s [230] fault time;

g. said consumable material [220] wear time and wear characteristics; and

h. any combination thereof.