Method and apparatus for predicting errors in a manufacturing process
First Claim
1. A method for adjusting a process for manufacturing products from blanks, said method operating in real-time to avoid defects in said products during said manufacturing process, said method comprising the steps of:
- (a) forming a digital image of each of said products;
(b) comparing each said image to an ideal predetermined image to derive difference measurements between said ideal predetermined image and each formed image, said comparison taking place at a plurality of selected locations on each of said formed images;
(c) determining if said difference measurements exceed predetermined parameters indicative of a flawed product;
(d) sampling difference measurements from a predetermined number of products to form a graph with respect to time versus said difference measurements, said sampled difference measurements falling within a predetermined range indicative of questionable difference measurements;
(e) applying statistical analysis to said graph to develop a trend indicative of future flaws in future products; and
(f) adjusting said process responsive to said trend to avoid said predicted future flaws in said future products.
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Accused Products
Abstract
An inspection system for a variety of products, and in particular flat-folded corrugated boxes uses real-time statistical processing control. This control allows graphs to be derived from which to develop trends indicative of future flaws in the products. These flaws are automatically corrected once a trend has been established. Glue marks on flat-folded corrugated boxes are identified and measured by means of pixel count, thereby providing very accurate depiction of the amount of glue on a box so that accurate comparison to a standard configuration can be made.
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Citations
25 Claims
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1. A method for adjusting a process for manufacturing products from blanks, said method operating in real-time to avoid defects in said products during said manufacturing process, said method comprising the steps of:
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(a) forming a digital image of each of said products; (b) comparing each said image to an ideal predetermined image to derive difference measurements between said ideal predetermined image and each formed image, said comparison taking place at a plurality of selected locations on each of said formed images; (c) determining if said difference measurements exceed predetermined parameters indicative of a flawed product; (d) sampling difference measurements from a predetermined number of products to form a graph with respect to time versus said difference measurements, said sampled difference measurements falling within a predetermined range indicative of questionable difference measurements; (e) applying statistical analysis to said graph to develop a trend indicative of future flaws in future products; and (f) adjusting said process responsive to said trend to avoid said predicted future flaws in said future products. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. An apparatus for controlling a process for manufacturing products from blanks, said apparatus operating in real-time to avoid defects in said products during said manufacturing process, said apparatus comprising:
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(a) a digital imager; (b) means comparing each said image to an ideal predetermined image to derive difference measurements between said ideal predetermined image and each formed image, said means for comparing operating at derived difference measurements at a plurality of selected locations on each of said formed images; (c) means for determining if said difference measurements exceed predetermined parameters indicative of a flawed product; (d) means for sampling difference measurements from a predetermined number of products to form a graph with respect to time versus said differences measurements, said means for sampling difference measurements operating to select difference measurements within a predetermined range indicative of questionable difference measurements; (e) means for applying statistical analysis to said graph to develop a trend indicative of future flaws in future products; and (f) means for adjusting said blanks responsive to said trend to avoid said predicted future flaws in said future products. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification