SYSTEM AND METHOD FOR INSPECTING ARTICLES OF MANUFACTURE

• US 20050267704A1
• Filed: 06/01/2004
• Published: 12/01/2005
• Est. Priority Date: 06/01/2004
• Status: Active Grant

• Current Assignee: American Quality Assurance Corp.
• Original Assignee: American Quality Assurance Corp.
• Inventors: Huntley, Peter
• Granted Patent: US 7,006,937 B2
• Time in Patent Office: Days
• US Class Current: 702/83
• CPC Class Codes: G06Q 10/00 Administration; Management

Abstract

An inspection system for an article of manufacture and method of using the same, assists an inspector in the inspection of a wide variety of articles for conformance to a pre-selected set of requirements particularly when checking is done by means of human senses and the manual application of measuring devices. A computer server is utilized in conjunction with the inspector to impose constraints and discipline on the inspector'"'"'s actions. Such constraints include enforcing a standardized sequence for checking each of a pre-selected set of article requirements depending on the fabric article type, limiting the available responses by which the inspector can record the results of the observation, and enforcing a minimum lapsed time for inspection of certain article requirements. The inspector interfaces with the computer server via at least one remote inspection station each having computer monitor, keyboard, pointer and preferably a bar-code scanner capable of reading labels attached to the articles.

Claims

1. An inspection system for an article of manufacture comprising:

at least one computer operative to receive, store and process data, amend software settings, and loading and executing of at least one inspection procedure;

a first inspection station communicating electronically with the at least one computer, the first inspection station having an input device for entering an article identifier, a monitor screen for displaying a series of questions to be answered and inputted by an inspector in sequential order; and

a timer integrated into the at least one computer and triggered when a minimum time allocation is called for by a sub-routine of the at least one inspection procedure to prolong an observation by the inspector instructed by the sub-routine thus providing a thorough and complete inspection.

2. The inspection system set forth in claim 1 wherein the inspection station has a key board for entering of alpha-numeric data.

3. The inspection system set forth in claim 2 wherein the monitor screen has a touch-screen interface for making choices prompted by the at least one computer.

4. The inspection system set forth in claim 1 wherein the monitor screen has a touch-screen interface for making choices prompted by the at least one computer.

5. The inspection system set forth in claim 3 wherein the input device is a scanner which scans the workpiece identifier from a label attached to the article.

6. The inspection system set forth in claim 5 wherein the scanner is a charge-coupled device having an RS232 link.

7. The inspection system set forth in claim 5 wherein the scanner of the first inspection station is a point-of-sale type.

8. The inspection system set forth in claim 2 comprising:

a second inspection station;

a computer server of the at least one computer; and

a hub for linking the first and second inspection stations to the computer server.

9. The inspection system set forth in claim 8 comprising:

a first computer of the at least one computer being located at the first inspection station for receiving an uploaded inspection procedure of the at least one inspection procedures from the computer server, executing the inspection procedure and downloading of the inspection data to the computer server; and

a second computer of the at least one computer being located at the second inspection station for receiving an uploaded inspection procedure of the at least one inspection procedures from the computer server, executing the inspection procedure and downloading of the inspection data to the computer server.

10. The inspection system set forth in claim 1 wherein the first inspection station is one of a plurality of inspection stations communicating with the at least one computer.

11. The inspection system set forth in claim 2 wherein the first inspection station has a pointing device for entering inspection data to the monitor screen.

12. The inspection system set forth in claim 11 wherein the first inspection station has a microphone for recording verbal comments from the inspector.

13. The inspection system set forth in claim 1 wherein the article of manufacture is a fabric article.

14. The inspection system set forth in claim 9 wherein the article of manufacture is a fabric article.

15. A method of inspecting articles of manufacture comprising the steps of:

inputting an article identifier and class by an inspector into an inspection station communicating with a computer;

selecting automatically the correct inspection procedure having a plurality of sequential steps as a computer code for the identified article class;

displaying the most recent inspection report for the same identifier on a monitor screen of the inspection station if previously inspected;

initiating a timer and in regards to a specific sub-routine of the inspection procedure by the computer;

instructing the inspector to perform a particular observation to the article by the computer for the specific sub-routine;

expiring the timer by the computer;

entering observation data by the inspector into the inspection station for the specific sub-routine; and

comparing the observation to a specification stored by the computer.

16. The method of inspecting articles of manufacture set forth in claim 15 wherein the step of entering observation data by the inspector comprises the further steps of:

presenting pre-programmed comment choices on the monitor screen by the computer for the specific sub-routine;

selecting a choice by the inspector; and

storage of the choice by the computer.

17. The method of inspecting articles of manufacture set forth in claim 16 further comprising the steps of:

processing of the choice by the computer after comparing the observation;

determining by the computer if the observation data conforms to acceptance criteria;

flagging of the article by the computer for later rework if the observation data is not acceptable; and

initiation of the next sequential sub-routine of the procedure by the computer.

18. The method of inspecting articles of manufacture set forth in claim 17 further comprising the steps of:

reporting of data from the computer in regards to a flag designated for the specific sub-routine;

reworking of the article;

re-initiation of the inspection procedure;

re-inspection of the specific sub-routine that was flagged during the previous inspection; and

skipping by the computer of sequential sub-routines not flagged and previously inspected.

19. The method of inspecting articles of manufacture set forth in claim 16 further comprising the steps of:

processing of the choice by the computer after comparing the observation to specified acceptance criteria;

accepting the observation data as meeting the specification by the computer; and

initiating the timer for a next sequential sub-routine of the inspection procedure by the computer.

20. The method of inspecting articles of manufacture set forth in claim 16 further comprising the steps of:

processing of the choice by the computer after comparing the observation;

rejecting the article; and

terminating the inspection procedure by the computer.

21. The method of inspecting articles of manufacture set forth in claim 16 wherein the step of entering observation data by the inspector comprises the further steps of:

presenting a pre-programmed map of the article on the monitor screen by the computer prior to the step of storage of the choice;

utilizing a pointing device by the inspector to select a location on the map in regards to an observed defect; and

storage of the marked map by the computer.