Inventory control for web-based articles

• US 20050144094A1
• Filed: 12/29/2004
• Published: 06/30/2005
• Est. Priority Date: 12/31/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Skeps, Carl J., Masterman, James A., Floeder, Steven P., Berg, Brandon T., Roller, Wayne R.
• Granted Patent: US 7,120,515 B2
• Time in Patent Office: Days
• US Class Current: 705/27
• CPC Class Codes: G06T 11/00 2D [Two Dimensional] image generation
• CPC Class Codes: G06T 2207/20016 Hierarchical, coarse-to-fine, multiscale or multiresolution image processing; Pyramid transform
• CPC Class Codes: G06T 2207/30124 Fabrics; Textile; Paper
• CPC Class Codes: G06T 2207/30136 Metal
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

Techniques are described for inspecting a web and controlling subsequent conversion of the web into one or more products. A system, for example, includes an imaging device, an analysis computer and a conversion control system. The imaging device images a sequential portion of a web to provide digital information. The analysis computer processes the digital information with an initial algorithm to identify regions on the web containing anomalies. The conversion control system selects one of a plurality of converting sites to convert the web into a product, and analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

Claims

1. A method comprising:

imaging a sequential portion of a web to provide digital information;

processing the digital information with at least one initial algorithm to identify regions on the web containing anomalies;

selecting one of a plurality of converting sites to convert the web into a product;

analyzing at least a portion of the digital information with one or more subsequent algorithms to determine which anomalies represent actual defects in the web for the product; and

converting the web into the product at the selected converting site based on the determined actual defects.

2. The method of claim 1, wherein selecting one of a plurality of converting sites comprises:

identifying a set of products into which the web may be converted;

identifying a set of the converting sites that produce the identified set of products; and

selecting the converting site from the identified set of converting sites.

3. The method of claim 1, wherein selecting one of a plurality of converting sites comprises:

determining a value of at least one site selection parameter for each of the plurality of converting sites; and

selecting the converting site from the plurality of converting sites based on the determined value for each of the converting sites.

4. The method of claim 3, wherein the site selection parameters include one or more of an inventory level for the product at each of the plurality of converting sites, an order backlog for the product at each of the plurality of converting sites, a market demand for the product at each of the plurality of converting sites or a conversion time for the product at each of the plurality of converting sites.

5. The method of claim 1, wherein selecting one of a plurality of converting sites comprises:

determining a value for a first site selection parameter for each of the converting sites;

determining a value for a second site selection parameter for each of the converting sites; and

selecting the converting site from the plurality of converting sites based on the determined values for each of the converting sites.

6. The method of claim 1, wherein selecting one of a plurality of converting sites comprises:

computing respective weighted averages of a plurality of site selection parameters for each of the converting sites; and

selecting the converting site from the plurality of converting sites based on the respective computed weighted averages.

7. The method of claim 1, wherein converting the web comprises:

generating a conversion plan for the web based on the determined actual defects; and

converting the web at the selected converting site in accordance with the generated conversion plan.

8. The method of claim 1, wherein the at least one subsequent algorithm characterizes at least a portion of the web into quality classifications.

9. The method of claim 1, further comprising

presenting a user interface displaying a site selection parameter as one of a plurality of user-selectable site selection parameters;

and

receiving input selecting one or more of the user-selectable site selection parameters.

10. The method of claim 9, further comprising:

determining respective values for each of the selected site selection parameters for each of the plurality of converting sites; and

selecting one of the plurality of converting sites based on the determined values.

11. A system comprising:

an imaging device that images a sequential portion of a web to provide digital information;

an analysis computer that processes the digital information with an initial algorithm to identify regions on the web containing anomalies; and

a conversion control system that selects one of a plurality of converting sites to convert the web into a product and analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

12. The system of claim 11, wherein the conversion control system identifies a set of the converting sites that produce the product, and select the converting site from the identified set of converting sites.

13. The system of claim 11, wherein the conversion control system determines a value of at least one site selection parameter for each of the plurality of converting sites, and selects one of the converting sites for conversion of the web based on the determined value for each of the converting sites.

14. The system of claim 11, wherein the site selection parameters include one or more of an inventory level for the product at each of the plurality of converting sites, an order backlog for the product at each of the plurality of converting sites, a market demand for the product at each of the plurality of converting sites or a conversion time for the product at each of the plurality of converting sites.

15. The system of claim 11, wherein the conversion control system computes respective weighted averages of a plurality of site selection parameters for each of the plurality of converting sites, and selects the converting site from the plurality of converting sites based on the respective computed weighted averages.

16. The system of claim 11, wherein the analysis computer is located within a manufacturing plant that produces the web, and the conversion control system is coupled to the manufacturing plant by a network and is remotely located from the manufacturing plant.

17. The system of claim 11, wherein the conversion control system generates a conversion plan for the web based on the determined actual defects and the selected product.

18. The system of claim 17, further comprising:

a conversion server located within a converting site and coupled to the conversion control system by a network,

wherein the conversion control system electronically communicates the conversion plan to the conversion server located with the converting site.

19. The system of claim 18, wherein the conversion server displays the conversion plan for converting the web to the selected product.

20. The system of claim 11, wherein the analysis computer processes the digital information with the initial algorithm and extracts a portion of the digital information for each of the identified regions, and the conversion control system analyzes the extracted portions of the digital information to determine the actual defects for the products.

21. The system of claim 11, wherein the conversion control system comprises:

a user interface module that presents a user interface to display a site selection parameter as one of a plurality of user-selectable site selection parameters;

a database storing data defining a set of conversion control rules; and

a conversion control engine that, for each converting site, applies the conversion control rules to determine values for the site selection parameters selected by a user, and selects the converting site based on the determined values.

22. A conversion control system comprising:

a database storing data defining a set of rules;

an interface to receive anomaly information from an analysis machine, wherein the anomaly information identifies regions of a web containing anomalies; and

a conversion control engine that selects one of a plurality of converting sites to convert the web into a product,

wherein the conversion control engine analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

23. The conversion control system of claim 22,

wherein the converting site stores data specifying an inventory level at each of the converting sites, order information for the product at each of the converting sites, an estimated demand for the product for markets serviced by each of the converting sites and an estimated conversion time to convert the web to the product at each of the converting sites, and

wherein the conversion engine utilizes the converting site data when applying the rules.

24. A computer-readable medium comprising instructions that cause a processor to:

store data defining a set of rules;

receive anomaly information from an analysis machine located within a manufacturing plant, wherein the anomaly information identifies regions of a web containing anomalies; and

apply the rules to select one of a plurality of converting sites to convert the web into a product.

25. The computer-readable medium of claim 24, wherein the instructions cause the processor to determine a value of at least one site selection parameter for each of the plurality of converting sites, and select one of the converting sites for conversion of the web based on the determined value for each of the converting sites.

26. The computer-readable medium of claim 24, wherein the instructions cause the processor to compute one or more of an inventory level for the product at each of the plurality of converting sites, an order backlog for the product at each of the plurality of converting sites, a market demand for the product at each of the plurality of converting sites or a conversion time for the product at each of the plurality of converting sites.

27. The computer-readable medium of claim 24, wherein the instructions cause the processor to:

generate a conversion plan for the web based on the determined actual defects;

communicate the conversion plan to the selected converting site for controlling conversion of the web; and

output shipment instructions for shipment of the web to the selected converting site for conversion.