Method and system for automatically isolating suspect items in a manufacturing or assembly environment

• US 20050113957A1
• Filed: 11/26/2003
• Published: 05/26/2005
• Est. Priority Date: 11/26/2003
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Pauli, John, Brower, William C., Gallu, Michael A., Maisonville, Richard
• Granted Patent: US 7,079,911 B2
• Time in Patent Office: Days
• US Class Current: 700/110
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/31286 Detect position of articles and equipment by receivers, identify objects by code
• CPC Class Codes: G05B 2219/31288 Archive collected data into history file
• CPC Class Codes: G05B 2219/31304 Identification of workpiece and data for control, inspection, safety, calibration
• CPC Class Codes: G05B 2219/31318 Data analysis, using different formats like table, chart
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A computer-implemented method and system includes capabilities for receiving suspect item definitions (e.g. item serial numbers, lot numbers, operation identifiers, date ranges, etc.) into a computer database, detecting item identifiers in a manufacturing or assembly process, and comparing the item identifiers with the suspect item definitions. If the detected item identifier falls within one of the suspect item definitions, the item is automatically isolated or otherwise rejected from manufacturing or assembly process. Other aspects of the invention include functionality for determining the location of suspect items. Locations may be inferred and off-site. Another aspect includes automatically modifying the manufacturing or assembly process to bypass one or more suspect manufacturing or assembly operations. A plurality of user interfaces are provided for defining, locating and managing suspect items. Suspect item definitions and location information may by broadcast or otherwise communicated to distributed locations (e.g. holding areas, warehouses, etc.).

Claims

1. A computer-implemented method for automatically isolating suspect items in a manufacturing environment, the method comprising:

inputting one or more suspect item definitions into a computer database;

automatically detecting an identifier for an item in a manufacturing or assembly process;

comparing the detected item identifier with the one or more suspect item definitions; and

if the detected item identifier falls within one or more of the suspect item definitions, automatically isolating the item in the manufacturing or assembly process.

2. The method of claim 1 additionally comprising displaying a location for the item.

3. The method of claim 2 wherein the location for the item is inferred.

4. The method of claim 1 wherein the step of isolating the item comprises physically removing the item from the manufacturing or assembly process.

5. The method of claim 1 additionally comprising automatically modifying the manufacturing or assembly process to bypass one or more suspect manufacturing or assembly operations.

6. The method of claim 1 wherein the suspect item definition includes one or more item serial numbers.

7. The method of claim 1 wherein the suspect item definition includes a manufacturing or assembly operation.

8. The method of claim 1 wherein the suspect item definition includes a time or date range.

9. The method of claim 1 wherein the suspect item definition includes an adapter plate identifier.

10. The method of claim 1 wherein the suspect item definition includes a sub-component identifier.

11. The method of claim 1 additionally comprising communicating one or more suspect item definitions to a remote location outside of the manufacturing or assembly process.

12. The method of claim 11 wherein the remote location is a remote manufacturing or assembly plant.

13. A computer system for automatically isolating suspect items in a manufacturing environment, the system comprising one or more computers operably programmed and configured to:

receive information including one or more suspect item definitions into a computer database;

receive information including an identifier for an item in a manufacturing or assembly process;

comparing the item identifier with the one or more suspect item definitions;

if the detected item identifier falls within one or more of the suspect item definitions, output a signal to a manufacturing or assembly station whereat the item is automatically isolated from manufacturing or assembly process.

14. The system of claim 13 wherein the one or more computers are additionally programmed and configured to display a location for the item.

15. The system of claim 13 wherein the one or more computers are additionally programmed and configured to infer the location of the item.

16. The system of claim 13 wherein the item is physically removed from the manufacturing or assembly process.

17. The system of claim 13 wherein the one or more computers are additionally programmed and configured to modify the manufacturing or assembly process to bypass one or more suspect manufacturing or assembly operations.

18. The system of claim 13 wherein the one or more computers are additionally programmed and configured to support a graphical user interface for inputting suspect item definitions.

19. The system of claim 13 wherein the one or more computers are additionally programmed and configured to support a graphical user interface for displaying the location of one or more suspect items falling within a suspect item definition.

20. The system of claim 13 wherein the one or more computers are additionally programmed and configured to communicate one or more suspect item definitions to a remote computer located outside of the manufacturing or assembly process.