System and method for facilities management
First Claim
1. A system for modeling a production plant, the system comprising:
- a processing unit; and
a memory portion in communication with the processing unit having information stored therein to configure the processing unit to;
receive model data for the production plant;
receive operational data for the production plant;
compare the operational plant data to the model plant data; and
generate a report at least daily containing the comparison between the operational plant data and the model plant data.
1 Assignment
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Accused Products
Abstract
Systems and methods for managing a facility such as a production facility, mill, plant, etc. are disclosed. One such system includes a system for modeling a production plant. The system includes a processing unit and a memory portion in communication with the processing unit having information stored to configure the processing unit to receive model data for the production plant, receive operational data for the production plant, compare the operational plant data to the model plant data, and generate a report at least daily containing the comparison between the operational plant data and the model plant data. One such method includes a method of managing a facility having at least one process, the at least one process having a plurality of steps. The method includes receiving model data relating to the plurality of steps of the at least one process, receiving actual data relating to the plurality of steps of the at least one process, and comparing the model data to the actual data.
22 Citations
45 Claims
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1. A system for modeling a production plant, the system comprising:
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a processing unit; and
a memory portion in communication with the processing unit having information stored therein to configure the processing unit to;
receive model data for the production plant;
receive operational data for the production plant;
compare the operational plant data to the model plant data; and
generate a report at least daily containing the comparison between the operational plant data and the model plant data.
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2. A method of managing a transfer of material within a plant, the method comprising:
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receiving model bin storage data;
receiving model flat storage data;
generating model data from the model bin storage data and the model flat storage data;
receiving actual transfer data; and
comparing the model data with the actual transfer data. - View Dependent Claims (3, 4, 5)
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6. A method of managing physical maintenance of a plant, the method comprising:
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receiving model maintenance data;
generating model data from the model maintenance data;
receiving actual maintenance data; and
comparing the model data with the actual maintenance data;
wherein the model maintenance data further comprises data relating to at least one of a mezzannine area, and a sweeping time based on empirical data. - View Dependent Claims (7)
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8. A method of managing personnel time for a recurring meeting in a plant, the method comprising:
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receiving model data relating to a number of employees for the recurring meeting;
receiving model data relating to a time per employee for the recurring meeting;
generating model data relating to a total number of hours required for the recurring meeting;
receiving actual data relating to a total number of hours for the recurring meeting; and
comparing the model data relating to the total number of hours required for the recurring meeting with the actual data relating to the total number of hours for the recurring meeting. - View Dependent Claims (9, 10)
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11. A method of managing a bag material receiving process in a plant, the method comprising:
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receiving model bag receiving data;
generating model data from the model bag receiving data;
receiving actual bag receiving data; and
comparing the model data with the actual bag receiving data;
wherein the model bag receiving data further comprises data relating to at least one of amount of bag material received with a forklift, and a capacity of the forklift. - View Dependent Claims (12)
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13. A method of managing a bulk material receiving process in a plant, the method comprising:
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receiving model dumping data;
generating model data from the model dumping data;
receiving actual dumping data; and
comparing the model data with the actual dumping data. - View Dependent Claims (14)
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15. A method of managing a mixing process in a plant, the method comprising:
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receiving model mixing data;
generating model data from the model mixing data;
receiving actual mixing data; and
comparing the model data with the actual mixing data;
wherein the model mixing data further comprises data relating to at least one of a best practice time for mixing, and a batches per hour. - View Dependent Claims (16)
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17. A method of managing a packing process in a plant, the method comprising:
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receiving model dry packing data;
receiving actual dry packing data;
comparing the model dry packing data with the actual dry packing data;
receiving model wet packing data;
receiving actual wet packing data; and
comparing the model wet packing data with the actual wet packing data. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of managing a shipping process in a plant, the method comprising:
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receiving model shipping data;
generating model data from the model shipping data;
receiving actual shipping data; and
comparing the model data with the actual shipping data;
wherein the model shipping data further comprises data relating to one of a set time for a rail car, a clean time for a rail car, a sample time for a rail car, a weigh time for a rail car, an operator rate for a rail car, a load rate for a rail car, a wet clean rate, a wet load rate, a wet average tons per item, and a resacking rate. - View Dependent Claims (28)
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29. A method of managing a pelleting process in a plant, the method comprising:
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receiving model pelleting data;
generating model data from the model pelleting data;
receiving actual pelleting data; and
comparing the model data with the actual pelleting data;
wherein the model pelleting data further comprises data relating to one of die friction, throughput of a pelleting machine, energy cost of the pelleting machine, and a time required to change a die of a pelleting machine. - View Dependent Claims (30)
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31. A method of managing a maintenance process in a plant, the method comprising:
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receiving model maintenance data;
generating model data from the model maintenance data;
receiving actual maintenance data; and
comparing the model data with the actual maintenance data;
wherein the model maintenance data further comprises data relating to one of a number of extruders, and a number of dryers. - View Dependent Claims (32)
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33. A method of managing an energy consumption process in a plant, the method comprising:
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receiving model energy consumption data;
generating model data from the model energy consumption data;
receiving actual energy consumption data; and
comparing the model data with the actual energy consumption data;
wherein the model energy consumption data further comprises data relating to one of an energy amount associated with an extruding process, an energy amount associated with an extrusion screen, an additional amount of steam, an additional BTU usage, and wet packing amps. - View Dependent Claims (34)
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35. A method of managing operations processes in a plant, the method comprising:
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receiving model operations processes data;
generating model data from the model operations processes data;
receiving actual operations processes data; and
comparing the model data with the actual operations processes data;
wherein the model operations processes data further comprises data relating to one of a cost associated with a security guard and a currency conversion. - View Dependent Claims (36)
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37. A method of managing contract labor in a plant, the method comprising:
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receiving model contract labor data;
receiving actual contract labor data; and
comparing the model contract labor data with the actual contract labor data;
wherein the model contract labor data and the actual contract labor data further comprise data relating to a cost associated with contracting one of interplant transfer, bag receiving, bulk receiving, mixing, packing, wet packing, bulk warehouse, bag warehouse, pelleting, grinding, second mixing, rolling, flaking, grain processing, block pressing, and extruding.
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38. A method of managing an extruding process in a plant, the method comprising:
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receiving model extruding data;
generating model data from the model extruding data;
receiving actual extruding data; and
comparing the model data with the actual extruding data;
wherein the model extruding data further comprise data relating to a cost associated with one of an energy cost associated with the extruding process and a labor cost associated with the extruding process. - View Dependent Claims (39)
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40. A method of managing a facility having at least one process, the at least one process having a plurality of steps, the method comprising:
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receiving model data relating to the plurality of steps of the at least one process;
receiving actual data relating to the plurality of steps of the at least one process; and
comparing the model data to the actual data. - View Dependent Claims (41, 42, 43)
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44. A method of providing consulting services, comprising:
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receiving, by a consulting servicer, operational data from a production plant;
generating model data for the production plant;
generating comparison data from the operational data and the model data, by the consulting servicer;
generating, by the consulting servicer, a report analyzing the operational data, the model data and the comparison data.
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45. A method of providing management reports for a production plant, comprising:
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receiving operational data at least partially automatically from machines in the production plant, by a data processing device;
generating model data for the production plant using a production plant modeling program running on the data processing device; and
generating a report based on the operational data and the model data.
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Specification