Manufacturing information and troubleshooting system and method

• US 20040030435A1
• Filed: 11/18/2002
• Published: 02/12/2004
• Est. Priority Date: 08/07/2002
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Popp, Robert L., Popp, Nicholas A., Carbone, Henry L. II, Hein, John G., Bell, Jamie L., Chapple, Scott G., Dollevoet, Tim G., Quereshi, Shawn A., Morgan, Archie Dodds, Tremble, Erica C., Allen, Kyle S., Clark, Clinton David
• Granted Patent: US 6,904,330 B2
• Time in Patent Office: Days
• US Class Current: 700/110
• CPC Class Codes: A61F 13/15772 Control
• CPC Class Codes: B65H 2220/01 indicating an entity as a function of which control, adjustment or change is performed, i.e. input
• CPC Class Codes: B65H 2220/02 indicating an entity which is controlled, adjusted or changed by a control process, i.e. output
• CPC Class Codes: B65H 23/1882 and controlling longitudinal register of web
• CPC Class Codes: B65H 23/1886 Synchronising two or more webs
• CPC Class Codes: B65H 2511/11 Length
• CPC Class Codes: B65H 2511/24 Irregularities, e.g. in orientation or skewness
• CPC Class Codes: B65H 2511/51 Presence
• CPC Class Codes: B65H 2511/512 Marks, e.g. invisible to the human eye; Patterns
• CPC Class Codes: B65H 2511/515 Absence
• CPC Class Codes: B65H 2551/20 Display means; Information output means
• CPC Class Codes: B65H 2551/22 Numerical displays
• CPC Class Codes: B65H 2551/23 Analog displays
• CPC Class Codes: B65H 2553/41 Photoelectric detectors
• CPC Class Codes: B65H 2553/42 Cameras
• CPC Class Codes: B65H 2557/12 Network
• CPC Class Codes: B65H 2557/23 Recording or storing data
• CPC Class Codes: B65H 2557/24 Calculating methods; Mathematic models
• CPC Class Codes: B65H 2557/242 involving a particular data profile or curve
• CPC Class Codes: B65H 26/02 responsive to presence of irregularities in running webs
• CPC Class Codes: B65H 2701/1924 : Napkins or tissues, e.g. dressings, toweling, serviettes, kitchen paper and compresses
• CPC Class Codes: B65H 2801/57 : Diaper manufacture
• CPC Class Codes: B65H 39/14 : Associating sheets with webs
• CPC Class Codes: B65H 39/16 : Associating two or more webs
• CPC Class Codes: G05B 19/00 : Programme-control systems
• CPC Class Codes: G05B 19/042 : using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/40 : Open loop systems, e.g. using stepping motor
• CPC Class Codes: G05B 19/41865 : characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/41875 : characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31449 : Monitor workflow, to optimize business, industrial processes
• CPC Class Codes: G05B 2219/32203 : Effect of material constituents, components on product manufactured
• CPC Class Codes: G05B 23/024 : Quantitative history assessment, e.g. mathematical relationships between available data; Functions therefor; Principal component analysis [PCA]; Partial least square [PLS]; Statistical classifiers, e.g. Bayesian networks, linear regression or correlation analysis; Neural networks
• CPC Class Codes: G05B 23/0267 : Fault communication, e.g. human machine interface [HMI]
• CPC Class Codes: G06Q 10/06 : Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06395 : Quality analysis or management
• CPC Class Codes: G06Q 50/06 : Energy or water supply
• CPC Class Codes: G06T 2207/30124 : Fabrics; Textile; Paper
• CPC Class Codes: G06T 7/0004 : Industrial image inspection
• CPC Class Codes: Y02P 80/40 : Minimising material used in manufacturing processes
• CPC Class Codes: Y02P 90/80 : Management or planning

Abstract

Systems and methods for providing alarming indications and troubleshooting indications and actions in connection with a web converting manufacturing process such as that used for manufacturing disposable absorbent garments. Some of the disclosed embodiments include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

Claims

1. An automatic troubleshooting system, suitable for use in connection with a high speed web converting manufacturing process having at least one machine operating at a set point and producing a composite article from a sequential addition of component parts during a production run of composite articles, said system comprising:

a communication network;

a first inspection system automatically inspecting a first aspect of a composite article being produced during the production run, said first inspection system providing via the communication network a first inspection parameter indicative of a characteristic of the first aspect;

a second inspection system automatically inspecting a second aspect of said composite article, said second inspection system providing a second inspection parameter via the communication network indicative of a characteristic of the second aspect; and

a logic system obtaining via the communication network a plurality of the first inspection parameters, each corresponding to one of a plurality of composite articles produced during the production run, and obtaining a plurality of the second inspection parameters, each corresponding to one of said plurality of composite articles, said logic system determining a first mathematical characteristic associated with the obtained plurality of first inspection parameters and a second mathematical characteristic associated the obtained plurality of second inspection parameters, said logic system determining a corrective action in response to the first and second mathematical characteristics.

2. An automatic troubleshooting system as set forth in claim 1 wherein said first inspection system inspects the first aspect of substantially all composite articles produced during the production run, and said second inspection system inspects the second aspect of substantially all composite articles produced during the production run.

3. An automatic machine troubleshooting system as set forth in claim 1 wherein said first inspection system inspects the first aspect for a sample set comprising less than all of the composite articles produced during the production run, and said second inspection system inspects the second aspect of said sample set of composite articles.

4. An automatic machine troubleshooting system as set forth in claim 1 wherein the first inspection system comprises a first detection system, and the first inspected aspect of the composite article comprises a position of a component part of said article.

5. An automatic troubleshooting system as set forth in claim 4 wherein the second inspection system comprises a second detection system positioned downstream from the first detection system on the production line, and the second inspected aspect of the composite article comprises the position of the component part of said article.

6. An automatic troubleshooting system as set forth in claim 5 wherein the second detection system comprises a machine vision system positioned to inspect completed composite articles.

7. An automatic troubleshooting system as set forth in claim 4 wherein the second inspection system comprises a second detection system positioned adjacent the first detection system on the production line, and the second inspected aspect of the composite article comprises the position of the component part of said article.

8. An automatic troubleshooting system as set forth in claim 1 further comprising a machine control system for controlling the machine in response to the set point, and wherein the logic system selectively provides a set point control signal for use by the machine control system for adjusting the set point, said logic system providing the set point control signal as a function of the determined corrective action.

9. An automatic troubleshooting system as set forth in claim 1 further comprising:

a machine control system for controlling the at least one machine parameter in response to the set point;

an operator display for displaying the determined corrective action; and

wherein the determined corrective action comprises an indication of a change to the set point for use by an operator of the machine.

10. An automatic troubleshooting system as set forth in claim 1 wherein the logic system determines a first corrective action in response to the first mathematical characteristic and a second corrective action in response to the second mathematical characteristic, said logic system applying a logic filter to identify a priority as between the first and second corrective actions.

11. An automatic troubleshooting system as set forth in claim 1 wherein the composite article comprises a disposable absorbent article.

12. A method of automatically troubleshooting a machine, suitable for use in connection with a high speed web converting manufacturing process having at least one machine operating at a set point and producing a composite product from a sequential addition of component parts during a production run of composite products, said method comprising:

inspecting a first aspect of a composite product constructed using the high speed web converting process and being produced during the production run;

providing a first inspection parameter being indicative of a characteristic of said first aspect of said composite product;

inspecting a second aspect of the composite product being produced during the production run;

providing a second inspection parameter being indicative of said second aspect of said composite product;

obtaining a plurality of the first inspection parameters, each one of the obtained plurality of first inspection parameters corresponding to one of a plurality of composite products produced during the production run;

determining a first mathematical characteristic associated with said obtained plurality of the first inspection parameters;

obtaining a plurality of the second inspection parameters, each one of the obtained plurality of second inspection parameters corresponding to one of a plurality of composite products produced during the production run;

determining a second mathematical characteristic associated with said obtained plurality of the second inspection parameters; and

determining a corrective action associated with the at least one machine in response to the determined first and second mathematical characteristics.

13. A method as set forth in claim 12 wherein inspecting the first aspect of a composite product being produced during the production run comprises inspecting a sample set comprising less than all composite products produced during the production run, and wherein inspecting the second aspect comprises inspecting said sample set.

14. A method as set forth in claim 13 further comprising selecting the sample set to correspond to a sampling plan.

15. A method as set forth in claim 12 wherein inspecting the first aspect of the composite product being produced during the production run comprises detecting a position of a component part of the composite product.

16. A method as set forth in claim 15 wherein inspecting the second aspect of the composite product being produced during the production run comprises inspecting the composite product with a machine vision inspection system positioned to detect the position of the component part.

17. A method as set forth in claim 12 further comprising selectively adjusting the set point of the at least one machine as a function of the determined corrective action.

18. A method as set forth in claim 12 further comprising displaying to an operator the determined corrective action.

19. A method as set forth in claim 18 wherein displaying to the operator the determined corrective action comprises displaying a recommended amount of adjustment to be applied to the set point of the machine.

20. A method for providing a troubleshooting response for a manufacturing process, said method being suitable for use in connection with a web converting manufacturing process producing a composite product from a sequential addition of component parts during a production run of composite products, said method comprising:

automatically inspecting at a first aspect of a composite product being produced during the production run to determine a component attribute of said first aspect;

automatically determining a machine setting of a machine associated with the web converting process at the first time;

identifying a relationship between the component attribute of the first aspect and the machine setting; and

identifying a troubleshooting action based on the identified relationship between the component attribute of the first aspect and the machine setting.

21. A method as set forth in claim 20 further comprising storing the determined component attribute in a database and wherein identifying the relationship between the component attribute of the first aspect and the machine setting comprises a non-real time identification process.

22. A method as set forth in claim 20 wherein identifying the relationship between the component attribute of the first aspect and the machine setting comprises a substantially real time identification process.

23. A method as set forth in claim 20 further comprising automatically determining another machine setting of the machine associated with the web converting process and identifying a relationship between the component attribute of the first aspect and the other determined machine setting.

24. A method as set forth in claim 20 further comprising automatically determining a machine setting of another machine associated with the web converting process and identifying a relationship between the component attribute of the first aspect and the machine setting of the other machine.

25. A method as set forth in claim 20 further comprising automatically inspecting a second aspect of the composite product to determine a component attribute of the second aspect and identifying a relationship between the component attribute of the second aspect and the machine setting.

26. A method as set forth in claim 20 further comprising:

automatically inspecting a second aspect of the composite product to determine a component attribute of the second aspect;

automatically determining another machine setting of the machine associated with the web converting process; and

identifying a relationship between the component attribute of the second aspect and the other determined machine setting.

27. A method as set forth in claim 20 further comprising:

automatically inspecting a second aspect of the composite product to determine a component attribute of the second aspect;

automatically determining a machine setting of another machine associated with the web converting process; and

identifying a relationship between the component attribute of the second aspect and the machine setting of the other machine.

28. A method as set forth in claim 20 wherein identifying the troubleshooting action comprises displaying a troubleshooting action on an operator display.

29. A method as set forth in claim 20 wherein the machine setting comprises an automatically adjustable set point and wherein identifying the troubleshooting action comprises adjusting the set point.