Graphical user interface shop floor control system

• US 6,523,045 B1
• Filed: 05/29/1998
• Issued: 02/18/2003
• Est. Priority Date: 05/29/1998
• Status: Expired due to Term

• Current Assignee: Plex Systems Inc (Rockwell Automation, Inc.)
• Original Assignee: Plexus Systems, LLC (Rockwell Automation, Inc.)
• Inventors: Beatty, Robert A.
• Primary Examiner(s): ROBINSON, GRETA LEE
• Application Number:
  US09/086,950
• Time in Patent Office: 1,726 Days
• Field of Search: 707/102, 707/104, 707/200, 707/10, 707/1, 707/104.1, 345/351, 345/440, 345/339, 345/348, 345/352, 345/835, 345/736, 345/967, 700/95, 700/96, 700/83, 700/196, 700/108
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202
• CPC Class Codes: Y10S 707/99943 Generating database or data structure, e.g. via user interface
• CPC Class Codes: Y10S 707/99945 Object-oriented database structure processing
• CPC Class Codes: Y10S 707/99948 Application of database or data structure, e.g. distributed, multimedia, or image

Abstract

A method for managing information about a manufacturing operation uses factory screens, shop floor screens and/or the like of a shop floor control graphical user interface. The factory screen graphically represents a factory. The shop floor screens represent different shop floors or other areas of the factory. These areas of the factory are represented by selectable icons, positioned within the factory screen at locations corresponding to the locations of the represented areas within the factory. Each shop floor screen depicts the general appearance of one of the areas of the factory and the factory elements of that area of the factory. Icons representing factory elements are positioned within the shop floor screens at locations corresponding to the locations of the represented factory elements within the corresponding shop floor. Icons representing machines and storage locations include graphics depicting the appearance of the represented machine or storage location.

Claims

1. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon,

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon, and

displaying, for each of at least one selectable machine icon, an alphanumeric code adjacent that selectable machine icon, wherein the alphanumeric code identifies both a type of the machine represented by that selectable machine icon and the particular machine represented by that selectable machine icon, and

providing each selectable machine icon with at least one graphic depicting the machine represented by that selectable machine icon, comprising, for each of at least one of the selectable machine icons, sequentially displaying a plurality of graphics depicting the represented machine within that selectable machine icon; and

selectively displaying one of the at least one shop floor screen.

2. The method of claim 1, wherein the plurality of graphics animate the machine represented by that selectable icon.

3. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon,

displaying, for each of at least one selectable machine icon, an alphanumeric code adjacent that selectable machine icon, wherein the alphanumeric code identifies both a type of the machine represented by that selectable machine icon and the particular machine represented by that selectable machine icon, and

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen; and

wherein inputting the information about the manufacturing operation through the graphical user interface comprises, for each shop floor screen that includes at least one selectable machine icon representing a machine of the corresponding shop floor, assigning a status to at least one of the at least one machine represented by a selectable machine icon of that shop floor screen;

wherein graphically depicting the at least one machine of that shop floor on the corresponding shop floor screen comprises altering an appearance of that selectable icon based on the status assigned to the machine represented by that selectable icon;

wherein altering the appearance comprises color encoding of the selectable icon.

4. The method of claim 3, wherein displaying the information about the manufacturing operation on the graphical user interface comprises providing the shop floor screen with a plurality of selectable status icons, each selectable status icon defining a status assignable to the at least one machine.

5. The method of claim 4, wherein the plurality of selectable status icons comprise at least two of a production icon, a waiting-for-materials icon, a setup icon, a waiting-for-setup icon, a maintenance icon, a waiting-for-maintenance icon, an idle icon, a shut-down icon, a task list icon, a job trouble icon, and an excess setup icon.

6. The method of claim 3, wherein assigning a status to a machine comprises:

displaying one of the at least one shop floor screens;

selecting a selectable status icon of the shop floor screen;

selecting a selectable icon of the displayed shop floor screen representing the machine;

communicating the assigned status to the database; and

updating the information about the manufacturing operation stored in the database to reflect the status assigned to the machine.

7. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon, and

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen; and

displaying status information stored in the database about a desired machine on a machine status screen;

wherein displaying status information stored in the database about the desired machine comprises;

setting and removing a flag associated with the desired machine;

inputting information about the desired machine; and

associating the input information with the desired machine when the flat is set;

wherein, when the flag associated with the desired machine is set, displaying status information stored in the database about the desired machine further comprises altering an appearance of a corresponding selectable machine icon representing the desired machine;

wherein altering the appearance of the machine icon comprises altering a color of an alphanumeric code portion of the corresponding selectable machine icon.

8. The method of claim 7, wherein displaying status information stored in the database about the desired machine on the machine status screen comprises at least one of:

displaying status information stored in the database about the desired machine;

displaying information stored in the database about employees associated with the desired machine;

displaying information stored in the database about parts or material produced by the desired machine;

displaying information stored in the database about source material associated with the desired machine; and

displaying information stored in the database about jobs associated with the desired machine.

9. The method of claim 8, wherein displaying status information stored in the database about the desired machine comprises at least one of:

displaying at least a status assigned to the desired machine; and

displaying status information stored in the database about the status assigned to the desired machine.

10. The method of claim 7, wherein, when the flag associated with the selected machine is set, inputting status information about the desired machine comprises:

closing the machine status screen; and

in response, transmitting information about the flag and the input information about the machine to the database.

11. The method of claim 7, wherein displaying the status information stored in the database about the desired machine comprises:

displaying a shop floor screen that includes a selectable icon that represents the desired machine;

selecting the selectable icon representing the desired machine; and

in response, displaying the machine status screen, the machine status screen displaying the status information stored in the database about the machine represented by the selected icon.

12. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in a database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon, and

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen; and

displaying production information stored in the database about a desired machine on a new production screen,

wherein displaying the production information stored in the database about the desired machine on the new production screen comprises at least one of;

displaying information stored in the database about source material associated with the desired machine; and

displaying information stored in the database about new parts or material produced by the desired machine.

13. The method of claim 12, wherein displaying information stored in the database about source material associated with the desired machine comprises at least one of:

displaying information about a part or material forming the source material;

displaying information identifying the part or material;

displaying information about a job number associated with the part or material;

displaying information about an operation associated with the part or material;

displaying information about a lot number of the source material;

displaying information about a quantity of a remaining portion of the source material; and

displaying information about a type of the source material.

14. The method of claim 12, wherein displaying and inputting information stored in the database about new parts or material produced by the desired machine comprises at least one of:

displaying information about a part number of the new part or material produced;

displaying information identifying the new part or material;

displaying information about a job number associated with the new part or material;

displaying information about an operation associated with the new part or material; and

displaying information about a lot number of the source material used to form the new part or material.

15. The method of claim 12, wherein inputting information about the manufacturing operation through the new production screen comprises at least one of:

inputting information about a quantity of the new part or material;

inputting information about a type of the new part or material; and

inputting note information about the new part or material.

16. The method of claim 15, wherein, when at least one of information about the quantity of the new part or material and information about the type of the new part or material is input, inputting the information through the new production screen further comprises:

closing the new production screen; and

in response, transmitting this information to the database.

17. The method of claim 16, wherein, in response to closing the new production screen, displaying and inputting information stored in the database about new parts or material produced by the desired machine further comprises:

selecting another selectable icon corresponding to a new location for the new part or material; and

in response displaying an animation representing movement of the new part or material from the selected icon representing the desired machine to he other selectable icon representing the new location.

18. The method of claim 12, further comprising printing a label for the new part or material, the label containing the information identifying the new part or material.

19. The method of claim 12, wherein displaying the production information stored in the database about the desired machine comprises:

displaying a shop floor screen that includes a new production icon and a selectable icon that represents the desired machine;

selecting the new production icon;

selecting the selectable icon representing the desired machine; and

in response, displaying the new production screen, the new production screen displaying the production information stored in the database about the machine represented by the selected icon.

20. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon,

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon, and

displaying, for each of at least one selectable machine icon, an alphanumeric code that identifies both a type of the machine represented by that selectable machine icon and the particular machine represented by that selectable machine icon; and

selectively displaying one of the at least one shop floor screen; and

wherein inputting information about the manufacturing operation using the graphical user interface comprises inputting maintenance information about a desired machine to the database using a maintenance information input screen.

21. The method of claim 20, wherein inputting the maintenance information about the desired machine using the maintenance information input screen comprises at least one of:

inputting maintenance type information about the selected machine;

inputting maintenance notes information about the selected machine; and

inputting maintenance warning information about the selected machine.

22. The method of claim 20, wherein inputting the maintenance information using the maintenance information input screen comprises:

displaying a shop floor screen that includes a maintenance information icon and a selectable icon that represents the desired machine;

selecting the maintenance information icon;

selecting the selectable icon representing the desired machine; and

in response, displaying the maintenance information input screen.

23. The method of claim 22, wherein, when maintenance information about the desired machine is input, inputting the information using the maintenance information input screen further comprises:

closing the maintenance information input screen; and

in response, transmitting the maintenance information to the database.

24. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one machine located on the corresponding shop floor with a corresponding selectable machine icon,

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon, and

displaying, for each of at least one selectable machine icon, an alphanumeric code adjacent that selectable machine icon, wherein the alphanumeric code identifies both a type of the machine represented by that selectable machine icon and the particular machine represented by that selectable machine icon; and

selectively displaying one of the at least one shop floor screen.

25. The method of claim 24, wherein each factory element is one of a machine, a storage location, a work center, an office, a material transport system, and a loading dock.

26. The method of claim 24, wherein, for at least one of the at least one shop floor screen, graphically depicting that shop floor and the at least one factory element of that shop floor on the corresponding shop floor screen comprises representing a work center of the corresponding shop floor with a corresponding selectable work center icon.

27. The method of claim 26, wherein graphically depicting that shop floor and the at least one factory element of that shop floor on the corresponding shop floor screen further comprises, for each selectable work center icon representing a work center, displaying an alphanumeric code adjacent that selectable work center icon, the alphanumeric code identifying the particular work center represented by that selectable work center icon.

28. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, comprising, for at least one of the at least one shop floor screen, representing each of at least one storage location of the corresponding shop floor with a corresponding selectable storage location icon, and

positioning each selectable storage location icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the storage location represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen;

wherein graphically depicting that shop floor and the at least one factory element of that shop floor on the corresponding shop floor screen further comprises, for each selectable storage location icon representing a storage location, displaying an alphanumeric code adjacent that selectable storage location icon, the alphanumeric code identifying the particular storage location represented by that selectable storage location icon.

29. The method of claim 28, wherein graphically depicting the at least one storage location of that shop floor on the corresponding shop floor screen comprises providing each selectable storage location icon with at least one graphic depicting parts or material stored in the storage location represented by that selectable storage location icon.

30. The method of claim 28, wherein displaying the information about the manufacturing operation on the graphical user interface comprises displaying information stored in the database about at least one desired storage location on a storage location screen.

31. The method of claim 30, wherein displaying the information stored in the database about at least one desired storage location on the storage location screen comprises at least one of:

displaying identification information stored in the database about each of at least one subset of parts or material associated with the at least one desired storage location;

displaying information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location;

displaying quantity information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location;

displaying location information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location;

displaying operation information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location;

displaying status information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location;

displaying type information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location; and

displaying note information stored in the database about each of the at least one subset of parts or material associated with the at least one desired storage location.

32. The method of claim 31, wherein, when a subset of parts or material is stored in or associated with a container, the identification information for that subset of parts or material is a container number assigned to the container associated with or storing that subset of parts or material.

33. The method of claim 31, wherein displaying the information stored in the database about at least one desired storage location on the storage location screen further comprises displaying a first option icon and a second option icon, wherein

selecting the first option icon causes information only about current subsets of parts or material associated with the at least one desired storage location to be displayed;

and

selecting the second option icon causes information only about retired subsets of parts or material associated with the at least one desired storage location to be displayed.

34. The method of claim 31, wherein displaying the information stored in the database about at least one desired storage location on the storage location screen further comprises determining and displaying an inventory of the displayed subsets of parts or material.

35. The method of claim 31, wherein displaying the information stored in the database about at least one desired storage location on the storage location screen further comprises:

inputting at least one selection criterion; and

displaying in the storage location screen only those subsets of parts or material that meet the at least one selection criterion.

36. The method of claim 30, wherein displaying the information stored in the database about the at least one desired storage location comprises:

displaying a shop floor screen that includes at least one selectable storage location icon that represents the at least one desired storage location;

selecting one of the at least one selectable storage location icon; and

in response, displaying the storage location screen, the storage location screen displaying information stored in the database about the storage location represented by the selected storage location icon.

37. The method of claim 30, wherein displaying the information stored in the database about at least one desired storage location comprises:

displaying a shop floor screen that includes at least one selectable storage location icon that represents the at least one desired storage location, one of the at least one desired storage location being a large storage location having a plurality of distinct location portions;

selecting the selectable storage location icon representing the large storage location; and

in response, displaying a sublocation screen comprising a plurality of selectable storage sublocation icons, each selectable storage sublocation icon representing one of the plurality of distinct portions of the large storage location.

38. The method of claim 37, further comprising:

selecting one of the plurality of sublocation icons; and

in response, displaying the storage location screen, the storage location screen displaying information stored in the database about the portion of the large storage location represented by the selected sublocation icon.

39. The method of claim 28, wherein the alphanumeric code further identifies a type of parts or material generally stored in the storage location represented by that selectable icon.

40. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface, comprising logging an employee into at least one of the at least one factory element of that shop floor, wherein the logging tracks the employee as being associated with the at least one factory element of that shop floor;

wherein displaying the information about the manufacturing operation in the database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon, and

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen;

wherein logging the employee into at least one of the at least one factory element of that shop floor further comprises altering an appearance of the selected icon based on the logged-in/logged out status of the identified employee for the machine represented by the selected icon.

41. The method of claim 40, wherein logging the employee into at least one of the at least one factory element of that shop floor comprises displaying a login icon on the at least one shop floor screen.

42. The method of claim 41, logging the employee into at least one of the at least one factory element of that shop floor comprises:

selecting the login icon

in response, displaying an employee identification portion in the shop floor screen; and

identifying an employee by inputting a corresponding employee identification number into the employee identification portion.

43. The method of claim 42, wherein logging the employee into at least one of the at least one factory element of that shop floor further comprises, after the employee is identified:

selecting a selectable icon;

in response, transmitting a login signal and the employee identification number to the database,

toggling a logged-in/logged out status of the identified employee for the machine represented by the selected icon being toggled in the database in response to the transmitted login signal and employee identification number.

44. A method for managing information about a manufacturing operation, the manufacturing operation comprising at least one shop floor, each shop floor including at least one factory element, the method comprising:

storing the information about the manufacturing operation in a database;

displaying the information about the manufacturing operation stored in the database on a graphical user interface; and

inputting the information about the manufacturing operation through the graphical user interface;

wherein displaying the information about the manufacturing operation in a database on the graphical user interface comprises;

graphically depicting each at least one shop floor and the at least one factory element of that shop floor on a corresponding shop floor screen, comprising, for each at least one shop floor;

representing each of the at least one factory element of that shop floor with a selectable icon and an alphanumeric code, which identifies both a type of the element represented by the selectable icon and the particular element represented by the selectable icon, and

positioning each selectable icon at a location within that shop floor screen corresponding to a location of the corresponding shop floor occupied by the factory element represented by that selectable icon; and

selectively displaying one of the at least one shop floor screen; and

wherein displaying the information about the manufacturing operation stored in the database comprises, when one of the at least one shop floor screens is displayed and information is transmitted to the database about movement of parts or material from a first factory element to a second factory element of the displayed shop floor screen, displaying an animation on the displayed shop floor screen representing the movement of the parts or material from the first factory element to the second factory element.

45. The method of claim 44, wherein the animation comprises an icon of a human carrying a box moving from a first selectable icon representing the first factory element to a second selectable icon representing the second factory element.