System and method for integrating a business environment, a process control environment, and a laboratory environment

• US 6,141,647 A
• Filed: 04/15/1996
• Issued: 10/31/2000
• Est. Priority Date: 10/20/1995
• Status: Expired due to Term

• Current Assignee: The Dow Chemical Company (Dow, Inc.)
• Original Assignee: The Dow Chemical Company (Dow, Inc.)
• Inventors: Aerts, Ronny A. W., Meijer, Jean-Pierre, van Peteghem, Dirk O., Berkhof, Frank, Sandoval, Gerald A.
• Primary Examiner(s): Voeltz, Emanuel Todd
• Assistant Examiner(s): Alvarez, Raquel
• Application Number:
  US08/632,582
• Time in Patent Office: 1,660 Days
• Field of Search: 705/1, 705/28, 364/468.02, 364/468, 700/100, 700/103, 700/106, 700/109, 700/117, 700/222
• US Class Current: 705/28
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A system and method for integrating a business transaction processing system, a process control system, and a laboratory system provides a computer integrated manufacturing environment. The manufacturing execution system receives work orders from the business transaction processing system and obtains enrichment data to enhance the work orders. The manufacturing execution system uses the enrichment data and rules contained in a plant model database to generate setpoints based on the received work orders. A subset of the work order data is provided to the laboratory system to direct sample testing. The setpoints include detailed information required by the process control system to manufacture the product specified by the work order. The setpoints are transmitted to the process control system for manufacture of the required materials. The manufacturing execution system collects the manufacturing data resulting from the execution in response to the work order by the process control system and processes this manufacturing data to provide summary information on manufacturing processes and to provide inventory information data. The manufacturing execution system also collects the results of sample testing from the laboratory system and links the sample result data to the manufacturing process summary information, and combines these two data sources to determine the final quality status for a lot of manufactured product. This data is then transmitted to the business transaction processing system so that business records may be maintained.

Claims

1. A computer-based system for integrating a computerized business system, a computerized manufacturing system, and a laboratory information management system wherein the computerized business system creates a work order containing target data specifying a product to be manufactured, and the computerized manufacturing system requires a setpoint to manufacture the product, comprising:

a business systems interface configured to receive the work order from the computerized business system and to extract the target data from the received work order;

an event response processor coupled to said business system interface and configured to generate the setpoint by applying at least one rule to the target data, said at least one rule allowing computation of the setpoint to meet specific requirements of the computerized manufacturing system; and

a computerized laboratory systems interface configured to provide sample correspondence data derived from said work order to said laboratory information management system.

2. A computer-based system for integrating a computerized business system, a computerized manufacturing system, and a laboratory information management system, comprising:

receiving means for receiving a work order from the computerized business system, wherein said work order comprises target data specifying a product to be manufactured by the computerized manufacturing system;

computing means for applying at least one setpoint calculation rule to said target data to compute a setpoint required by the computerized manufacturing system to manufacture said specified product;

first sending means for sending said setpoint to the computerized manufacturing system,

examining means for examining quality indicators associated with said work order to determine whether quality testing is required for said specified product;

second sending means for sending to the laboratory information management system sample correspondence data, said sample correspondence data containing information sufficient to enable the laboratory information management system to perform sampling and quality testing of said specified product and to link the sample testing results to said work order;

first collecting means for collecting said sample testing results from the laboratory information management system;

second collecting means for collecting manufacturing process summary information from the computerized manufacturing system;

linking means for linking said sample testing results and said manufacturing process summary information to said work order to produce work order data; and

third sending means for sending said work order data to the computerized business system.

3. The computer-based system of claim 2, further comprising means for creating a field in a work order database for containing said sample testing results.

4. The computer-based system of claim 2, further comprising a computerized business system for generating said work order and receiving said work order data.

5. The computer-based system of claim 2, further comprising a computerized manufacturing system for receiving said setpoint and generating said manufacturing process summary information.

6. The computer-based system of claim 2, further comprising a laboratory information management system for receiving said sample correspondence data and generating said sample testing results.

7. The computer-based system of claim 6, further comprising a storage device having a database stored therein, said database having the structure depicted in FIG. 14.

8. A computer-based method for integrating a computerized business system, a computerized manufacturing system, and a laboratory information management system, comprising the steps of:

(a) receiving a work order from the computerized business system, wherein said work order comprises target data specifying a product to be manufactured by the computerized manufacturing system;

(b) applying at least one setpoint calculation rule to said target data to compute a setpoint required by the computerized manufacturing system to manufacture said specified product;

(c) sending said setpoint to the computerized manufacturing system;

(d) examining quality indicators associated with said work order to determine whether quality testing is required for said specified product;

(e) if said specified product is to be quality tested, sending to the laboratory information management system sample correspondence data, said sample correspondence data containing information sufficient to enable the laboratory information management system to perform sampling and quality testing of said specified product and to link the sample testing results to said work order;

(f) collecting said sample testing results from the laboratory information management system;

(g) collecting manufacturing process summary information from the computerized manufacturing system;

(h) linking said sample testing results and said manufacturing process summary information to said work order to produce work order data; and

(i) sending said work order data to the computerized business system.

9. The computer-based method of claim 8, further comprising the step of:

(j) creating a field in a work order database for containing said sample testing results.

10. A computer-based system for determining a quality status for a product manufactured by a process, comprising:

first receiving means for receiving from a laboratory information management system an SQC status for the product, wherein said SQC status is a measure of the conformity of the product to the specification for the product;

second receiving means for receiving from a computerized manufacturing system an SPC status for the product, wherein said SPC status is a measure of the conformity of the process to the specification for the process; and

determining means for determining the quality status for the product, wherein said determination is based on said SQC status and said SPC status.

11. The system of claim 10, further comprising examining means for examining quality indicators associated with a work order for the product to determine whether quality testing is required for the product.

12. The system of claim 10, further comprising first sending means for sending, to said computerized manufacturing system, manufacturing data associated with said work order.

13. The computer-based system of claim 12, further comprising a computerized manufacturing system for receiving said manufacturing data and generating said SPC status.

14. The system of claim 10, further comprising second sending means for sending, to said laboratory information management system, sample correspondence data, said sample correspondence data containing information sufficient to enable said laboratory information management system to perform sampling and quality testing of the product and to associate the sample testing results with said work order.

15. The computer-based system of claim 14, further comprising a laboratory information management system for receiving said sample correspondence data and generating said SQC status.

16. The computer-based system of claim 15, further comprising a storage device having a database stored therein, said database having the structure depicted in FIG. 14.

17. The system of claim 10, further comprising third sending means for sending, to said laboratory information management system, said SPC status, wherein said laboratory information management system determines whether to perform sampling and quality testing of the product based on said SPC status.

18. The system of claim 10, further comprising first associating means for associating said SQC status with said work order.

19. The system of claim 10 further comprising second associating means for associating said SPC status with said work order.

20. The computer-based system of claim 10, further comprising creating means for creating a field in a work order database for containing said SQC status.

21. A computer-based method for determining a quality status for a product manufactured by a process, comprising the steps of:

(a) receiving from a laboratory information management system an SQC status for the product, wherein said SQC status is a measure of the conformity of the product to the specification for the product;

(b) receiving from a computerized manufacturing system an SPC status for the product, wherein said SPC status is a measure of the conformity of the process to the specification for the process; and

(c) determining the quality status for the product, wherein said determination is based on said SQC status and said SPC status.

22. The computer-based method of claim 21, further comprising creating the step of:

(d) examining quality indicators associated with a work order for a product to be manufactured by a process to determine whether quality testing is required for said product.

23. The computer-based method of claim 21, further comprising creating the step of:

(e) sending, to the computerized manufacturing system, manufacturing data associated with said work order.

24. The computer-based method of claim 21, further comprising creating the step of:

(f) sending, to the laboratory information management system, sample correspondence data, said sample correspondence data containing information sufficient to enable the laboratory information management system to perform sampling and quality testing of said product and to associate the sample testing results with said work order.

25. The computer-based method of claim 21, further comprising creating the step of:

(g) associating said SQC status with said work order.

26. The computer-based method of claim 21, further comprising creating the step of:

(h) associating said SPC status with said work order.

27. The computer-based method of claim 22, further comprising creating the step of:

(i) creating a field in a work order database for containing said SQC status.