GRAPHICAL USER INTERFACE SHOP FLOOR CONTROL SYSTEM

• US 20020054101A1
• Filed: 05/29/1998
• Published: 05/09/2002
• Est. Priority Date: 05/29/1998
• Status: Active Grant

• Current Assignee: Plex Systems Inc (Rockwell Automation, Inc.)
• Original Assignee: Plexus Systems, LLC (Rockwell Automation, Inc.)
• Inventors: BEATTY, ROBERT A.
• Granted Patent: US 6,396,516 B1
• Time in Patent Office: Days
• US Class Current: 715/764
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y10S 715/965 for process control and configuration

Abstract

A graphical user interface shop floor control system includes one or more of factory screens, shop floor screens, machine status screens, a material/parts container screens, machine login screens, new production screens, and machine maintenance screens. The factory screen graphically represents a factory. The shop floor screens represent different shop floors or other areas of the factory. These areas of the factory are represented by selectable icons, positioned within the factory screen at locations corresponding to the locations of the represented areas within the factory. Each shop floor screen depicts the general appearance of one of the areas of the factory and the factory elements of that area of the factory. Icons representing factory elements are positioned within the shop floor screens at locations corresponding to the locations of the represented factory elements within the corresponding shop floor. Icons representing machines and storage locations include graphics depicting the appearance of the represented machine or storage location. The shop floor screens include status buttons. Selecting a status button and a machine icon assigns the selected status to the machine represented by the selected machine icon, and color codes that icon. Containers of parts are associated with the various machines. Their movement around the shop floors is controlled by scanning bar code labels associated with the containers. Animations of the movement of the containers is displayed to indicate that the movement of the container has been recorded. Animations can also be provided for the machine icons based upon their status.

Claims

1. A control system that manages information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the control system comprising:

a plurality of computing devices interconnected into a network;

a database that stores the information about the manufacturing operation, the database stored on a first one of the plurality of computing devices, at least one of the plurality of computing devices located on the at least one shop floor; and

a graphical user interface displayable on each of the plurality of computing devices, the graphical user interface comprising at least one shop floor screen, each shop floor screen corresponding to one of the at least one shop floor of the manufacturing operation and graphically depicting the corresponding shop floor and the at least one factory element of the corresponding shop floor.

2. The control system of claim 1, wherein each shop floor screen comprises at least one selectable icon, each selectable icon representing one of the at least one factory element of the corresponding shop floor.

3. The control system of claim 2, wherein, for each shop floor screen, each selectable icon is positioned at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon.

4. The control system of claim 2, wherein each factory element is one of a machine, a storage location, a work center, an office, a material transport system, and a loading dock.

5. The control system of claim 2, wherein, for at least one of the at least one shop floor screen, at least one of the at least one selectable icon represents a machine located on the corresponding shop floor.

6. The control system of claim 2, wherein, for each selectable icon that represents a machine, that selectable icon includes at least one graphic depicting the machine represented by that selectable icon.

7. The control system of claim 6, wherein, for each of at least one of the selectable icons, the at least one graphic comprises a plurality of graphics that are sequentially displayable within that selectable icon.

8. The control system of claim 7, wherein, when the plurality of graphics are sequentially displayed, an animation of the machine represented by that selectable icon is displayed.

9. The control system of claim 5, wherein, for each shop floor screen that includes at least one selectable icon representing a machine, that shop floor screen further comprises a plurality of selectable status icons, each selectable status icon defining a status assignable to the at least one machine of the corresponding shop floor.

10. The control system of claim 9, wherein the plurality of selectable status icons comprise at least two of a production icon, a waiting-for-materials icon, a setup icon, a waiting-for-setup icon, a maintenance icon, a waiting-for-maintenance icon, an idle icon, a shut-down icon, a task list icon, a job trouble icon, and an excess setup icon.

11. The control system of claim 9, wherein, when a shop floor screen representing a shop floor of the manufacturing operation is displayed on one of the plurality of computing devices:

a status is assigned to a machine located on the shop floor represented by the displayed shop floor screen by selecting a selectable status icon and then selecting the selectable icon of the displayed shop floor screen representing that machine; and

the assigned status is communicated from the one of the computing devices to the database and the information about the manufacturing operation stored in the database is updated to reflect the status assigned to that machine.

12. The control system of claim 9, wherein, for each selectable icon that represents a machine, an appearance of that selectable icon is based on the status assigned to the machine represented by that selectable icon and stored in the database.

13. The control system of claim 12, wherein the appearance is a color encoding of the selectable icon.

14. The control system of claim 5, wherein the graphical user interface further comprises a machine status screen, status information stored in the database about a selected machine displayable on the machine status screen.

15. The control system of claim 14, wherein the machine status screen includes at least one of:

a status portion that displays status information stored in the database about the selected machine;

an employee portion that displays information stored in the database about employees associated with the selected machine;

a produced portion that displays information stored in the database about parts or material produced by the selected machine;

a material portion that displays information stored in the database about source material associated with the selected machine; and

a schedule portion that displays information stored in the database about jobs associated with the selected machine.

16. The control system of claim 15, wherein the status portion includes at least one of:

an assigned status portion that displays at least a status assigned to the selected machine; and

a status information portion that displays status information stored in the database about status assigned to the selected machine

17. The control system of claim 14, wherein, when a shop floor screen that includes at least one selectable icon that represents a machine is displayed on one of the plurality of computing devices, selecting one of the at least one selectable icon representing a machine causes the machine status screen to be displayed, the machine status screen displaying information stored in the database about the machine represented by the selected icon.

18. The control system of claim 14, wherein the machine status screen includes:

a flag setting portion for setting and removing a flag associated with the selected machine; and

a flag information input portion for inputting information about the selected machine, the input information to be associated with the flag when the flag is set.

19. The control system of claim 18, wherein, when the flag associated with the selected machine is set, an appearance of a machine icon representing the selected machine is altered.

20. The control system of claim 19, wherein the appearance of the machine icon is altered by altering a color of an alphanumeric code portion of the machine icon.

21. The control system of claim 18, wherein, when the flag setting portion indicates the flag associated with the selected machine is set, closing the machine status screen causes the information about the flag and the input information about the selected machine to be transmitted to the database.

22. The control system of claim 5, wherein the graphical user interface further comprises a new production screen, production information stored in the database about a selected machine displayable on the new production screen.

23. The control system of claim 22, wherein the new production screen includes at least one of:

a material portion that displays information stored in the database about source material associated with the selected machine; and

a new production portion that displays information stored in the database about new parts or material produced by the selected machine.

24. The control system of claim 23, wherein the material portion includes at least one of:

information about a part or material forming the source material;

information identifying the part or material;

information about a job number associated with the part or material;

information about an operation associated with the part or material;

information about a lot number of the source material;

information about a quantity of a remaining portion of the source material; and

information about a type of the source material.

25. The control system of claim 23, wherein the new production portion includes at least one of:

information about a part number of the new part or material produced;

information identifying the new part or material;

information about a job number associated with the new part or material;

information about an operation associated with the new part or material;

information about a lot number of the source material used to form the new part or material;

an input portion for inputting information about a quantity of the new part or material;

an input portion for inputting information about a type of the new part or material; and

an input portion for inputting note information about the new part or material.

26. The control system of claim 25, wherein, after the information about a quantity of the new part or material and the information about a type of the new part or material is input through the appropriate input portion, closing the new production screen causes this information to be transmitted to the database.

27. The control system of claim 25, wherein closing the new production screen and selecting another selectable icon corresponding to a new location for the new part or material causes the shop floor screen to display an animation representing movement of the new part or material from the machine represented by the selected icon to the factory element represented by the other selectable icon.

28. The control system of claim 25, wherein the new production screen includes a print icon, selecting the print icon causing a label to be printed for the new part or material, the label containing the information identifying the new part or material.

29. The control system of claim 22, wherein, when a shop floor screen that includes at least one selectable icon that represents a machine and a new production icon is displayed on one of the plurality of computing devices, selecting the new production icon and then one of the at least one selectable icon representing a machine causes the new production screen to be displayed, the new production screen displaying the production information stored in the database about the machine represented by the selected icon.

30. The control system of claim 5, wherein the graphical user interface further comprises a maintenance input screen, maintenance information about a selected machine capable of being input into the database using the maintenance input screen.

31. The control system of claim 30, wherein the maintenance input screen includes at least one of:

a maintenance type input portion that allows maintenance type information about the selected machine to be input;

a maintenance notes input portion that allows maintenance notes information about the selected machine to be input; and

a maintenance warning input portion that allows maintenance warning information about the selected machine to be input.

32. The control system of claim 30, wherein:

when a shop floor screen that includes at least one selectable icon that represents a machine and a maintenance input icon is displayed on one of the plurality of computing devices, selecting the maintenance input icon and then one of the at least one selectable icon representing a machine causes the maintenance input screen to be displayed; and

after the maintenance information about the selected machine is input, closing the maintenance input screen causes the input maintenance information to be transmitted to the database.

33. The control system of claim 5, wherein, for each selectable icon that represents a machine, that selectable icon includes an alphanumeric code that identifies the particular machine represented by that selectable icon.

34. The control system of claim 33, wherein the alphanumeric code further identifies a type of the machine represented by that selectable icon.

35. The control system of claim 2, wherein, for at least one of the at least one shop floor screen, at least one of the at least one selectable icon represents a storage location of the corresponding shop floor.

36. The control system of claim 35, wherein, for each selectable icon that represents a storage location, that selectable icon includes a graphic depicting a parts or material stored in the storage location represented by that selectable icon.

37. The control system of claim 35, wherein the graphical user interface further comprises a storage location screen, status information stored in the database about at least one selected storage location displayable on the storage location screen.

38. The control system of claim 37, wherein the storage location screen includes at least one of:

a identification portion that displays identification information stored in the database about each of at least one subset of parts or material associated with the at least one selected storage location;

a material portion that displays information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location;

a quantity portion that displays quantity information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location;

a location portion that displays location information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location;

a operation portion that displays operation information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location;

a status portion that displays status information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location;

a type portion that displays type information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location; and

a note portion that displays note information stored in the database about each of the at least one subset of parts or material associated with the at least one selected storage location.

39. The control system of claim 38, wherein, when a subset of parts or material is stored in or associated with a container, the identification information for that subset of parts or material is a container number assigned to the container associated with or storing that subset of parts or material.

40. The control system of claim 38, wherein:

the storage location screen further includes a first option icon and a second option icon;

selection of the first option icon causes information only about current subsets of parts or material associated with the selected storage location to be displayed; and

selection of the second option icon causes information only about retired subsets of parts or material associated with the selected storage location to be displayed.

41. The control system of claim 38, wherein the storage location screen further includes an inventory icon and an inventory display portion, selecting the inventory icon causing an inventory of the displayed subsets of parts or material to be determined and displayed in the inventory display portion.

42. The control system of claim 38, wherein the storage location screen further includes a filter icon, selecting the filter icon allowing input of selection criteria, the subsets of parts or material displayed in the storage location screen being limited to those subsets of parts or material that meet the selection criteria.

43. The control system of claim 35, wherein, when a shop floor screen that includes at least one selectable icon that represents a storage location is displayed on one of the plurality of computing devices, selecting one of the at least one selectable icon representing a storage location causes the storage location screen to be displayed, the storage location screen displaying information stored in the database about the storage location represented by the selected icon.

44. The control system of claim 35, wherein, when a shop floor screen that includes at least one selectable icon that represents a large storage location is displayed on one of the plurality of computing devices, selecting one of the at least one selectable icon representing a large storage location causes a sublocation screen to be displayed, the sublocation screen displaying a plurality of selectable storage sublocation icons, each selectable storage sublocation icon representing a portion of the large storage location.

45. The control system of claim 44, wherein, when the sublocation screen is displayed on one of the plurality of computing devices, selecting one of the plurality of selectable storage sublocation icons causes the storage location screen for the selected portion of the large storage location to be displayed, the storage location screen displaying information stored in the database about the portion of the storage location represented by the selected sublocation icon.

46. The control system of claim 35, wherein, for each selectable icon that represents a storage location, that selectable icon includes an alphanumeric code that identifies the particular storage location represented by that selectable icon.

47. The control system of claim 46, wherein the alphanumeric code further identifies a type of parts or material generally stored in the storage location represented by that selectable icon.

48. The control system of claim 2, wherein, for at least one of the at least one shop floor screen, at least one of the at least one selectable icon represents a work center of the corresponding shop floor.

49. The control system of claim 48, wherein, for each selectable icon that represents a work center, that selectable icon includes an alphanumeric code that identifies the particular work center represented by that selectable icon.

50. The control system of claim 2, wherein each shop floor screen includes a login icon.

51. The control system of claim 50, wherein:

selecting the login icon causes an employee identification portion to be displayed in the shop floor screen; and

an employee is identified by inputting a corresponding employee identification number into the employee identification portion.

52. The control system of claim 51, wherein, after the employee is identified, selecting a selectable icon causes a login signal and the employee identification number to be transmitted to the database, a logged-in/logged out status of the identified employee for the machine represented by the selected icon being toggled in the database in response to the transmitted login signal and employee identification number.

53. The control system of claim 52, wherein selecting the login icon causes an appearance of at least one of the at least one machine icon of that shop floor screen to be altered based on the logged-in/logged-out status of the identified employed for the at least one machine icon of that shop floor screen.

54. The control system of claim 2, when one of the at least one shop floor screens is displayed and information is transmitted to the database about movement of parts or material from a first factory element to a second factory element of the displayed shop floor screen, an animation is displayed on the displayed shop floor screen representing the movement of the parts or material from the first factory element to the second factory element.

55. The control system of claim 54, wherein the animation comprises an icon of a human carrying a box moving from a first selectable icon representing the first factory element to a second selectable icon representing the second factory element.