A SYSTEM AND METHOD FOR MONITORING FACILITY DATA

• US 20050027656A1
• Filed: 02/11/2004
• Published: 02/03/2005
• Est. Priority Date: 02/11/2003
• Status: Abandoned Application

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.), Tyson Foods Incorporated
• Original Assignee: Tyson Foods Incorporated
• Inventors: Roach, John, Lepard, Charles V., Craddock, Michael James, Mullins, Jeffrey Keene, Whisel, David Wesley, Tobler, Peter Arthur, Parker, Johnathan Dale, Stillwell, Scott Douglas, Axxe, Aaron Earl, Griffith, William Wesley III, Whitfield, Kevin Leonard, Garringer, Joel, Lech, David Michael Sr., Mock, Harry W., Jaycox, Stacy W.
• Application Number:
  US10/708,146
• Publication Number:
  US 20050027656A1
• Time in Patent Office: Days
• US Class Current: 705/53
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

A system and method for monitoring facility data is disclosed. This includes at least one processor capable of receiving inputted data and generating alerts or alarms when scheduled activity does not occur, monitoring whether devices used in the facility are calibrated, determining what corrective actions are appropriate if defects occur, provide control over who and how users edit data, provide a pre-shipment review of products leaving a facility, determining disposition of at least one product, developing root causes for defects and scheduling tasks. There is an ability for a wide variety of individuals having access to exactly the same program with material added or blocked-out in terms of zones and data monitoring can be defined in terms of department, lines and processes with complete flexibility in configuration. There are both data collectors and data verifiers with the establishment of schedules and alarms tailored to each role.

Claims

1. A method for monitoring facility data utilizing a computer system comprising:

inputting information relating to at least one part from at least one input device into the computer system;

inputting information relating to at least one field from the at least one input device into the computer system; and

inputting measurement data from a plurality of measurement devices, wherein the inputted measurement data is at least partially correlated to the information related to the at least one part and the information related to the at least one field.

2. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting information relating to the at least one part includes inputting least one part type and inputting at least one specific part and the inputting information relating to the at least one field includes inputting at least one field type and inputting at least one specific field.

3. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprises inputting information relating to at least one facility into the computer system.

4. The method for monitoring facility data utilizing a computer system as set forth in claim 2, wherein the at least one part type is selected from the group consisting of types of components of products, types of subassemblies of products, types of fully assembled products, types of manufacturing machines, and types of processing machines.

5. The method for monitoring facility data utilizing a computer system as set forth in claim 2, wherein the at least one specific part includes information that is selected from the group consisting of at least one part name, at least one part type, at least one product code, at least one brand code, at least one regulatory category, at least one Hazard Analysis and Critical Control Point category and at least one product characteristic information.

6. The method for monitoring facility data utilizing a computer system as set forth in claim 2, wherein the at least one field group is selected from the group consisting of bone types, zero tolerance items, reprocessed zero tolerance items, salvaged zero tolerance items, fecal contamination locations, sanitation standard operating procedures (SSOP) ratings and work-in-progress temperatures

7. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting measurement data from a plurality of measurement devices includes inputting at least one type of unit of measurement.

8. The method for monitoring facility data utilizing a computer system as set forth in claim 7, wherein the at least one type of unit of measurement is selected from the group consisting of weight, count, temperature, percentage, string data, date, time, proportion, measurement, speed, pressure and length of time.

9. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting measurement data from a plurality of measurement devices includes inputting at least one specific unit of measurement.

10. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting measurement data from a plurality of measurement devices includes inputting at least one type of test.

11. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting measurement data from a plurality of measurement devices includes at least one specific test.

12. The method for monitoring facility data utilizing a computer system as set forth in claim 10, wherein the at least one type of test is selected from the group consisting of a temperature of a product at a particular point in processing, inspection for fecal contamination, weight of the product, percentage of trisodium phosphate solution, verification of critical limits, pre-shipment verification of product quality, thermometer calibration with comparison against NST certified standard weight and visual inspections regarding sanitation.

13. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein the inputting measurement data from a plurality of measurement devices includes inputting information selected from the group consisting of at least one type of measurement device, at least one manufacturer of a measurement device, at least one model of measurement device and at least one specific measurement device.

14. The method for monitoring facility data utilizing a computer system as set forth in claim 13, wherein the inputting information relating to at least one type of measurement device is selected from the group consisting of at least one name of a measurement device type, at least one indication as to whether a measurement device type is portable, at least one unit of measurement for a measurement device type, at least one name of a manufacturer of a measurement device, contact information for a manufacturer of a measurement device, at least one indication as to whether a manufacturer of a measurement device is active, at least one name of a measurement device model, at least one manufacturer of a measurement device model, at least one type of measurement device model, at least one indication as to whether a measurement device model requires calibration, at least one indication as to whether a model of measurement device model requires two-point calibration, at least one indication as to whether at least one model of measurement device is active, at least one name of a specific measurement device, at least one type for a specific measurement device, at least one serial number for a specific manufacturing device, at least one indication of whether a specific measurement device is a reference device, at least one calibration procedure for a specific measurement device, at least one indication as to whether a serial port is utilized for a specific measurement device and at least one indication as to whether or not a specific measurement device is active.

15. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprising entering and viewing the measurement data utilizing at least one workstation.

16. The method for monitoring facility data utilizing a computer system as set forth in claim 15, wherein the at least one workstation is selected from the group consisting of pocket processors, industrial computers, programmable logic controllers and personal computers.

17. The method for monitoring facility data utilizing a computer system as set forth in claim 15, wherein the computer system includes at least one main server that is able to transmit data with the at least one workstation through a group consisting of wireless communication, direct hardwired connection, local area networks, wireless communication, internet and wide area network.

18. The method for monitoring facility data utilizing a computer system as set forth in claim 15, wherein the at least one workstation includes associated information from the group consisting of at least one name of a workstation type, at least one indication as to whether a workstation type is portable, at least one name of a workstation manufacturer, contact information for a workstation manufacturer, at least one indication as to whether a workstation manufacturer is active, at least one name of a workstation model, at least one name of a workstation model manufacturer, at least one type of workstation and at least one indication as to whether a workstation model is active, at least one name of a specific workstation, at least one type of a specific workstation, at least one serial number for a specific workstation, and at least one indication as to whether a specific workstation is active.

19. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprising evaluating the inputted measurement data from a plurality of measurement devices with the computer system in accordance with at least one predetermined test and providing a notification when the at least one predetermined test fails.

20. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprising evaluating the inputted measurement data from a plurality of measurement devices with the computer system in accordance with at least one predetermined test and providing an assignable causes when the at least one predetermined test fails.

21. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprising evaluating the inputted measurement data from a plurality of measurement devices with the computer system in accordance with at least one predetermined test and providing a recommended remedial action when the at least one predetermined test fails.

22. The method for monitoring facility data utilizing a computer system as set forth in claim 19, wherein the at least one predetermined test includes aspects selected from the group consisting of at least one predetermined target, a selection of a predetermined number of decimals from the predetermined target, an indication of whether there is zero tolerance regarding the predetermined target, a selection of an upper alert limit for the predetermined target, a selection of a lower alert limit for the predetermined target, a selection of an upper alarm limit for the predetermined target, a selection of an lower alarm limit for the predetermined target, a selection of an upper guard limit for the predetermined target, a selection of an lower guard limit for the predetermined target, a selectable maximum percentage of an upper limit, a selectable value for the maximum upper limit, an input for an alarm string, a corrective action procedure for the at least one predetermined test, an activation date for the at least one predetermined test, an activation time for the at least one predetermined test, a deactivation date for the at least one predetermined test and a deactivation time for the at least one predetermined test.

23. The method for monitoring facility data utilizing a computer system as set forth in claim 1, further comprising generating reports with the computer system.

24. The method for monitoring facility data utilizing a computer system as set forth in claim 23, wherein the generating reports with the computer system includes reports selected from the group consisting of at least one calibration report, at least one alert report, at least one alarm report, at least one corrective action report, at least one data edit report, at least one data verification report, at least one hold tag report, at least one preshipment review report, at least one report log report, at least one root cause report and at least one workstation schedule report.

25. The method for monitoring facility data utilizing a computer system as set forth in claim 23, further providing an electronic signature from at least one user for reports selected from the group of reports consisting of the at least one alarm report, the at least one data edit report, the at least one data verification report, and the at least one pre-shipment review report.

26. The method for monitoring facility data utilizing a computer system as set forth in claim 15, further comprising identifying at least one first user that provides the entering of the measurement data utilizing at least one workstation.

27. The method for monitoring facility data utilizing a computer system as set forth in claim 26, wherein the identifying at least one first user that provides the entering of the measurement data utilizing at least one workstation includes inputting a userid and a personal identification number to create an electronic signature.

28. The method for monitoring facility data utilizing a computer system as set forth in claim 26, further comprising observing verification of the entered measurement data by the at least one first user with at least one second user.

29. The method for monitoring facility data utilizing a computer system as set forth in claim 28, further comprising identifying the identity of the at least one second user by inputting a userid and a personal identification number to create an electronic signature.

30. The method for monitoring facility data utilizing a computer system as set forth in claim 19, wherein the failure of the at least one predetermined test generates an alarm.

31. The method for monitoring facility data utilizing a computer system as set forth in claim 19, further including generating at least one statistical process control chart utilizing the inputted measurement data.

32. The method for monitoring facility data utilizing a computer system as set forth in claim 1, wherein selective aspects of the computer system can be selectively blocked from view for a user depending on a predetermined security role determined for that user.

33. A method for monitoring facility data utilizing a computer system comprising:

inputting information relating to at least one part into the computer system;

inputting information relating to at least one field into the computer system;

inputting measurement data from a plurality of measurement devices;

entering and viewing measurement data utilizing at least one workstation; and

evaluating the inputted measurement data from a plurality of measurement devices with the computer system in accordance with at least one predetermined test and providing a notification when the at least one predetermined test fails.

34. A computer system for monitoring facility data comprising:

at least one input device for receiving information relating to at least one part and receiving information relating to at least one field; and

a plurality of measurement devices for receiving measurement data, wherein the inputted measurement data is at least partially correlated to the information related to the at least one part and the information related to the at least one field.

35. The computer system for monitoring facility data as set forth in claim 34, wherein the information relating to the at least one part includes at least one part type and at least one specific part and the information relating to the at least one field includes at least one field type and at least one specific field.

36. The computer system for monitoring facility data as set forth in claim 35, wherein the at least one part type is selected from the group consisting of types of components of products, types of subassemblies of products, types of fully assembled products, types of manufacturing machines and types of processing machines, wherein the at least one specific part includes information that is selected from the group consisting of at least one part name, at least one part type, at least one product code, at least one brand code, at least one regulatory category, at least one Hazard Analysis and Critical Control Point category and at least one product characteristic information and wherein the at least one field group is selected from the group consisting of bone types, zero tolerance items, reprocessed zero tolerance items, salvaged zero tolerance items, fecal contamination locations, sanitation standard operating procedures (SSOP) ratings and work-in-progress temperatures.

37. The computer system for monitoring facility data as set forth in claim 34, wherein the inputted measurement data that is correlated to the information related to the at least one part and the information that is related to the at least one field includes information selected from the group consisting of at least one type of unit of measurement, at least one specific unit of measurement, at least one type of test, at least one specific test, at least one type of measurement device, at least one manufacturer of a measurement device, at least one model of measurement device and at least one specific measurement device.

38. The computer system for monitoring facility data as set forth in claim 34, further comprising at least one workstation for entering and viewing the measurement data.

39. The computer system for monitoring facility data as set forth in claim 38, wherein the at least one workstation is selected from the group consisting of pocket processors, industrial computers, programmable logic controllers and personal computers.

40. The computer system for monitoring facility data as set forth in claim 34, further comprising at least one main server that is able to transmit data with the at least one workstation through a group consisting of wireless communication, direct hardwired connection, local area networks, wireless communication, internet and wide area network.

41. The computer system for monitoring facility data as set forth in claim 34, wherein the inputted measurement data is evaluated with the computer system with at least one predetermined test and a notification is provided if the at least one predetermined test fails.

42. The computer system for monitoring facility data as set forth in claim 34, wherein the computer system generates at least one report.

43. The computer system for monitoring facility data as set forth in claim 42, wherein the at least one report is selected from the group consisting of at least one calibration report, at least one alert report, at least one alarm report, at least one corrective action report, at least one data edit report, at least one data verification report, at least one hold tag report, at least one pre-shipment review report, at least one report log report, at least one root cause report and at least one workstation schedule report.

44. The computer system for monitoring facility data as set forth in claim 34, wherein the at least one workstation requires identification of at least one first user that provides the entering of the measurement data with an electronic signature.

45. The computer system for monitoring facility data as set forth in claim 34, wherein the at least one workstation requires identification of at least one second user that observes the entered measurement data by the at least one first user with an electronic signature.

46. The computer system for monitoring facility data as set forth in claim 34, wherein the computer system generates an alarm upon failure at least one predetermined test.

47. The computer system for monitoring facility data as set forth in claim 34, wherein the computer system generates a response from the group consisting of a recommended remedial action and an assignable cause.