Method for creating master recipes

• US 6,834,370 B1
• Filed: 07/08/1999
• Issued: 12/21/2004
• Est. Priority Date: 07/08/1999
• Status: Expired due to Term

• Current Assignee: Osi Software, Inc. (Schneider Electric SE)
• Original Assignee: Osi Software, Inc. (Schneider Electric SE)
• Inventors: Hall, Ray, Xi, Xiaojin, Brandl, Dennis
• Primary Examiner(s): Hong, Stephen S.
• Application Number:
  US09/350,036
• Time in Patent Office: 1,993 Days
• Field of Search: 715/500, 715/530, 715/531, 700/96, 700/97, 700/121
• US Class Current: 715/201
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/34202 Reusable software, generic resource model library
• CPC Class Codes: G05B 2219/36225 Select and insert program from library, select case, variant
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe includes a plurality of recipe segments. The general recipe includes a plurality of process actions. Each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material. Each master recipe is for use with a specific set of equipment in a process cell. Each process action has one or more corresponding recipe segments that implement the process action on the set of equipment. The general recipe describes how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment. The method includes a first step of creating a list of recipe segments from the general recipe and the site information. The list of recipe segments includes each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell. The method includes a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.

Claims

1. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the general recipe comprising a plurality of process actions, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the method comprising:

creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in process cell; and

creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.

2. A method as recited in claim 1, wherein the method does not require human interaction.

3. A method as recited in claim 1, wherein each of the master recipes is for use with a single one of the process cells.

4. A method as recited in claim 1, wherein each of the master recipes comprises a data file.

5. A method as recited in claim 4, wherein the data file is inked with at least one OLE object.

6. A method as recited in claim 1, wherein the master recipe comprises a procedure flow chart.

7. A method as recited in claim 1, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each of the master recipes is for use with the batch control system to control the set of equipment in the process cell.

8. A method as recited in claim 7, wherein:

the batch control system further includes a batch server in communication with at least one process connected device, the at least one process connected device interfacing the set of equipment, the at least one process connected device is for controlling the set of equipment, and the batch server is for controlling the process connected devices; and

the master recipe is for use with the batch server to control the process connected devices to manufacture the at least one product.

9. A method as recited in claim 7, wherein the batch control system has a process control application residing on the batch control system, the process control application is for operating on the batch control system, and each master recipe is for execution by the process control application to control the set of equipment.

10. A method as recited in claim 1, wherein each master recipe includes a formula and equipment requirements.

11. A method as recited in claim 1, wherein each master recipe includes at least one unit operation.

12. A method as recited in claim 11, wherein each unit operation includes a procedure, a formula, and equipment requirements.

13. A method as recited in claim 1, wherein each master recipe includes at least one unit procedure.

14. A method as recited in claim 13, wherein each unit procedure includes a procedure, a formula, and equipment requirements.

15. A method as recited in claim 1, wherein:

the recipe segments are organized into at least one segment path in the master recipe, the at least one segment path interconnected in a production path to form the master recipe;

the process actions are organized into at least one process branch in the general recipe, the at least one process branch interconnected in a dependency path to form the general recipe, each process branch having one or more corresponding segment paths which can perform the process branch on the set of equipment; and

the second step includes

a) dividing the general recipe into the dependency path and a collection of the at least one process branches,

b) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch,

c) using the collection of segment path series, the dependency path, and the site information to create a set of production paths, and

d) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.

16. A method as recited in claim 15, wherein the at least one process branch comprises two or more process branches.

17. A method as recited in claim 16, wherein:

each process branch has a branch end, and

the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.

18. A method as recited in claim 15, wherein:

the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process branch; and

the at least one material comprises the at least one input material, the at least one product, or an intermediate material.

19. A method as recited in claim 1, wherein the general recipe comprises a data file.

20. A method as recited in claim 19, wherein the data file is linked with at least one OLE object.

21. A method as recited in claim 1, wherein the general recipe is comprises a process dependency chart.

22. A method as recited in claim 1, wherein the general recipe comprises a process sequence table.

23. A method as recited in claim 1, wherein the general recipe comprises a sequence function chart.

24. A method as recited in claim 1, wherein each general recipe includes a formula and equipment requirements.

25. A method as recited in claim 1, wherein each general recipe includes at least one process operation.

26. A method as recited in claim 25, wherein each process operation includes a procedure, a formula, and equipment requirements.

27. A method as recited in claim 1, wherein each general recipe includes at least one process stage.

28. A method as recited in claim 27, wherein each process stage includes a procedure, a formula, and equipment requirements.

29. A method as recited in claim 1, wherein the site information comprises a data file.

30. A method as recited in claim 1, wherein the site information comprises material flow information, recipe segment information, and equipment information.

31. A method as recited in claim 30, wherein the material flow information comprises information describing how material can flow between the set of equipment in the process cell.

32. A method as recited in claim 30, wherein the recipe segment information includes:

a listing of all the recipe segments available to perform the process actions in the process cell; and

a summary of the process action that each available recipe segment performs.

33. A method as recited in claim 32, wherein:

the set of equipment comprises units; and

the recipe segment information further includes a listing of the unit associated with each recipe segment and a listing of the at least one input material associated with each recipe segment.

34. A method as recited in claim 30, wherein the recipe segment information comprises operational limits associated with the process action that each recipe segment performs in the process cell.

35. A method as recited in claim 30, wherein the equipment information comprises equipment limits.

36. A method as recited in claim 1, wherein:

the set of equipment comprises units, each unit may have a unit start recipe segment or a unit end recipe segment associated with the unit, and

the equipment information comprises a list of the unit start recipe segments and the unit end recipe segments associated with each unit.

37. A method as recited in claim 1, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.

38. A method as recited in claim 37, wherein the data file is linked with at least one OLE object.

39. A method as recited in claim 1, wherein each recipe segment comprises a recipe phase.

40. A method as recited in claim 1, wherein each recipe segment includes recipe segment parameters.

41. A method as recited in claim 1, wherein each recipe segment includes a procedure, a formula, and equipment requirements.

42. A method as recited in claim 1, wherein each of the process actions comprises a data file.

43. A method as recited in claim 1, wherein each of the process actions includes process action parameters.

44. A method as recited in claim 1, wherein the at least one input material and the at least one product are bulk materials.

45. A method as recited in claim 15, wherein:

the site information includes optimization information;

and the second step includes using the optimization information to select at least one optional production path from the set of production patls and creating the set of master recipes from the at least one optimal production path.

46. A method as recited in claim 45, wherein the selection information includes cycle time information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product in the least time.

47. A method as recited in claim 45, wherein the selection information includes equipment path information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product in the least numbers of equipment.

48. A method as recited in claim 45, wherein the selection information includes material transfer cost information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product with the least material transfer costs.

49. A method as recited in claim 1, wherein the set of equipment has an equipment layout and the general recipe is independent of equipment layout.

50. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the recipe segments organized into at least one segment path, the at least one segment path interconnected in a production path to form the master recipe, the general recipe comprising a plurality of process actions, the process actions organized into at least one process branch, the at least one process branch interconnected in a dependency path to form the general recipe, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, each process branch having one or more segment paths which perform the process branch on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the site information including recipe segment information, material flow information, and equipment information, the method including the steps of:

a) creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listers of corresponding recipe segments capable of performing that process action in the process cell;

b) dividing the general recipe into the dependency path and a collection of the at least one process branches;

c) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch;

d) using the collection of segment path series, the dependency path, and the site information to create a set of production paths; and

e) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.

51. A method as recited in claim 50, wherein the method does not require human intervention.

52. A method as recited in claim 50, wherein each master recipe is for use with a single process cell.

55. A method as recited in claim 50, wherein each master recipe comprises a procedure flow chart.

56. A method as recited in claim 50, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each master recipe is for use with the batch control system to control the set of equipment in the process cell.

58. A method as recited in claim 50, wherein each master recipe includes at least one unit procedure.

59. A method as recited in claim 50, wherein the at least one process branch comprises two or more process branches.

60. A method as recited in claim 59, wherein:

each process branch has a branch end, and

the dependency path includes at least one material join, the at least one material join connecting at least two branch ends 61.

61. A method as recited in claim 50, wherein:

the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another p process branch; and

the at least one material comprises the at least one input material, the at least one product, or an intermediate material.

62. A method as recited in claim 50, wherein the general recipe comprises a data file.

63. A method as recited in claim 50, wherein the data file is linked with at least one OLE object.

64. A method as recited in claim 50, wherein the general recipe comprises a process dependency chart.

65. A method as recited in claim 50, wherein the general recipe comprises a process sequence table.

66. A method as recited in claim 50, wherein the general recipe comprises a sequence function chart.

67. A method as recited in claim 50, wherein each general recipe includes at least one process operation.

68. A method as recited in claim 50, wherein each general recipe includes at least one process stage.

69. A method as recited in claim 50, wherein the site information comprises a data file.

70. A method as recited in claim 50, wherein the recipe segment information includes:

a listing of all the recipe segments available to perform the process actions in the process cell; and

a summary of the process action that each available recipe segment performs.

71. A method as recited in claim 50, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.

72. A method as recited in claim 71, wherein the data file is inked with at least one OLE object.

73. A method as recited in claim 50, wherein each recipe segment comprises a recipe phase.

74. A method as recited in claim 50, wherein each process action comprises a data file.

75. A method as recited in claim 50, wherein:

the site information includes optimization formation; and

the method includes using the optimization information to select at least one optimal production path from the set of production paths and creating the set of master recipes,from the at least one optimal production path.

53. A method as recited in lain 50, wherein each master recipe comprises a data file.

54. A method as recited in claim 53, wherein the data file is linked with at least one OLE object.

57. A method as recited in clam 50, wherein each master recipe includes at least one unit operation.

76. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the recipe segments organized into at least one segment path, the at least one segment path interconnected in a production path to form the master recipe, the general recipe comprising a plurality of process actions, the process actions organized into at least one process branch, the at least one process branch interconnected in a dependency path to form the general recipe, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, each process branch having one or more segment paths which perform the process branch on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the site information including recipe segment information, material flow information and equipment information, the method including the steps of

a) creating a list of recipe segments from the general recipe and the recipe segment information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in the process cell;

b) dividing the general recipe into the dependency path and a collection of the at least one process branches;

c) using the list of recipe segments and the material flow information to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment pat series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch;

d) using the collection of segment path series, the dependency path, and the material flow information to create a set of production paths; and

e) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.

77. A method as recited in claim 76, wherein the method does not require human intervention.

78. A method as recited in claim 76, wherein each master recipe is for use with a single process cell.

79. A method as recited in claim 76, wherein each master recipe comprises a data file.

80. A method as recited in claim 79, wherein the data file is linked with at least one OLE object.

81. A method as recited in claim 76, wherein each master recipe comprises a procedure flow chart.

82. A method as recited in claim 76, wherein the process cell includes a batch control system interfacing the set of equipment, the bath control system is for controlling the operation of the set of equipment, and each master recipe Is for use with the batch control system to control the set of equipment in the process cell.

83. A method as recited in claim 76, wherein each master recipe includes at least one unit operation.

84. A method as recited in claim 76, wherein each master recipe includes at least one unit procedure.

85. A method as recited in claim 76, wherein the at least one process branch comprises two or more process branches.

86. A method as recited in claim 85, wherein:

each process branch has a branch end, and

the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.

87. A method as recited in claim 76, wherein:

the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process branch; and

the at least one material comprises the at least one input material, the at least one product, or an intermediate material.

88. A method as recited in claim 76, wherein the general recipe comprises a data file.

89. A method as recited in claim 88, wherein the data file is linked with at least one OLE object.

90. A method as recited in claim 76, wherein the general recipe comprises a process dependency chart.

92. A method as recited in claim 76, wherein the general recipe comprises a sequence function chart.

93. A method as recited in claim 76, wherein each general recipe includes at least one process operation.

94. A method as recited in claim 76, wherein each general recipe includes at least one process stage.

95. A method as recited in claim 76, wherein the site information comprises a data file.

96. A method as recited in claim 76, wherein the recipe segment information includes:

a listing of all the recipe segments available to perform the process actions in the process cell; and

a summary of the process action that each available recipe segment performs.

97. A method as recited in claim 76, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.

98. A method as recited in claim 97, wherein the data file is linked with at least one OLE object.

99. A method as recited in claim 76, wherein each recipe segment comprises a recipe phase.

100. A method as recited in claim 76, wherein each of the process actions comprises a data file.

101. A method as recited in claim 76, wherein:

the site information includes optimization information; and

the method includes using the optimization information to select at least one optimal production path from the set of production paths and creating the set of master recipes from the at least one optimal production path.

91. A method as recited in clam 76, wherein the general recipe comprises a process sequence table.

102. A method for automatically seating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe phases, the general recipe comprising a plurality of process actions, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material by using recipe segments, the recipe segments comprising at least one recipe phase, each process action being performed by one recipe segment, each master recipe for use with a specific set of equipment in a process cell, each process action having one or more corresponding recipe segments that implement the process action on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the method comprising:

a first step of creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in the process cell; and

a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.

103. A method as recited in claim 102, wherein the method does not require human intervention.

104. A method as recited i claim 102, wherein each master recipe is for use with a single process cell.

105. A method as recited in claim 102, wherein each master recipe comprises a data file.

106. A method as recited in claim 105, wherein the data file is linked with at least one OLE object.

107. A method as recited in claim 102, wherein each master recipe comprises a procedure flow chart.

108. A method as recited in claim 102, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each master recipe is for use with the batch control system to control the set of equipment in the process cell.

109. A method as recited in claim 102, wherein each master recipe includes at least one unit operation.

110. A method as recited in claim 102, wherein each master recipe includes at least one unit procedure.

111. A method as recited in claim 102, wherein:

the recipe segments are organized into at least one segment path in the master recipe, the at least one segment path interconnected in a production path to form the master recipe,

the process actions organized into at least one process branch in the general recipe, the at least one process branch interconnected in a dependency path to form the general recipe, each process branch having one or more corresponding segment paths which can perform the process branch on the set of equipment, and

the second step includes

a) dividing the general recipe into the dependency path and a collection of the at least one process branches,

b) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch,

c) using the collection of segment path series, the dependency path, and the site information to create a set of 5 production paths, and

d) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.

112. A method as recited in claim 111, wherein the at least one process branch comprises two or more process branches.

113. A method as recited in claim 112, wherein:

each process branch has a branch end, and

the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.

114. A method as recited in claim 102, wherein:

the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process brand; and

the at least one material comprises the at least one input material, the at least one product, or an intermediate material.

115. A method as recited in claim 102, wherein the general recipe comprises a data file.

116. A method as recited in claim 115, wherein the data file is linked with at least one OLE object.

117. A method as recited in claim 102, wherein the general recipe comprises a process dependency chart.

118. A method as recited in claim 102, wherein the general recipe comprises a process sequence table.

119. A method as recited in claim 102, wherein the general recipe comprises a sequence function chart.

121. A method as recited in claim 102, wherein each general recipe includes at least one process stage.

122. A method as recited in claim 102, wherein the site information comprises a data file.

123. A method as recited in claim 102, wherein the recipe segment information includes:

a listing of all the recipe segments available to perform the process actions in the process cell; and

a sublunary of the process action that each available recipe segment performs.

124. A method as reacted in claim 102, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.

125. A method as recited in claim 124, wherein the data file is linked with at least one OLE object.

126. A method as recited in claim 102, wherein each process action comprises a data file.

127. A method as recited in claim 102, wherein:

the site information includes optimization information; and

the second step included using the optimization information to select at least one optimal production from the set of production paths and creating the set of master recipes from the at least one optimal production path.

120. A method as recited in clam 102, wherein each general recipe includes at least one process operation.