Communication between machines and feed-forward control in event-based product manufacturing

• US 7,032,816 B2
• Filed: 11/27/2002
• Issued: 04/25/2006
• Est. Priority Date: 12/28/2001
• Status: Active Grant

• Current Assignee: Callahan Cellular LLC (Intellectual Ventures LLC)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Nygaard, Kurt Sigurd, Pokorny, Michael Roy, Reade, Walter Caswell, Markham, Charles Earl, Shaffer, Gregory Duncan, Barber, Douglas Gordon Barron, Tiffany, Flynn Matthew, Fuller, Paul D., Yosten, Roger Dale, Hise, John Harland, Ihde, Sheryl Annette, Lindsay, Jeffrey Dean, Matheus, Jon Ray
• Primary Examiner(s): LE, UYEN CHAU N
• Application Number:
  US10/306,794
• Publication Number:
  US 20030155415A1
• Time in Patent Office: 1,245 Days
• Field of Search: 235/376, 235/375, 235/435, 235/436, 235/462.01, 235/380, 705/11, 705/7, 705/26, 426/665, 426/383, 702/35, 702/36
• US Class Current: 235/376
• CPC Class Codes: G06Q 10/00 Administration; Management
• CPC Class Codes: G06Q 50/00 Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism healthcare informatics G16H

Abstract

Providing communication between machines and feed-forward control in event-based product manufacturing. Some of the disclosed embodiments include a system, method, and computer-readable media for communicating data relating to a material between machines during a process for feed-forward control. Also disclosed are an intelligent event-based manufacturing system including a process for converting a raw material to a product and a method of reducing the probability of waste, delay, or a quality defect in a process having process conditions for the manufacture of a product from a sequentially trackable raw material. The embodiments are operable in an intelligent manufacturing system including a process for converting raw materials to a product, a process control system including one or more sensors capable of generating an alarm in response to an event that results in one of waste, machine delay, or decrease product quality, a data logger associated with the process control system for obtaining event parameters associated with the event, a database on a server for recording event parameters obtained by the data logger, and a reporting system cooperatively associated with the database for reporting productivity parameters regarding the process derived at least in part from the event parameters.

Claims

1. A method of communicating event-based data relating to a material between machines during processing for feed-forward control in an event-based manufacturing system, the method comprising:

collecting material-specific event-based data in response to events occurring during manufacturing, said event-based data relating to a type and location of a defect in a material during a first process using or producing the material, said events being substantially randomly spaced in time, said event-based data comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process;

associating the collected, material-specific event-based data with an identifier identifying the material during the first process;

determining, from a label associated with the material, the identifier identifying the material;

obtaining material-specific event-based data associated with the determined identifier from a database populated with event-based data obtained from an event-based manufacturing system, wherein the determining and the obtaining occur during a second process occurring subsequent to the first process, wherein the second process produces a product from the material; and

governing the second process for the material by a feed-forward process control system responsive to the material-specific event-based data relating to the type and location of the defect to decrease the likelihood of at least one of a delay event, a waste event, or poor quality of the product during the second process.

2. The method of claim 1, further comprising implementing remedial action in response to the obtaining.

3. The method of claim 2, wherein a machine operates the second process, and wherein the implementing comprises adjusting at least one setting of the machine.

4. The method of claim 3, wherein the material is continuous, wherein the implementing comprises temporarily reducing a speed of the machine to prevent a break in the material.

5. The method of claim 2, wherein the implementing comprises splicing out a portion of the material having inadequate basis weight.

6. The method of claim 1, further comprising electronically conveying instructions to a human operator in response to the obtaining.

7. The method of claim 1, wherein the determining comprises receiving, from a scanning device, an identifier associated with the material.

8. The method of claim 1, wherein the determining comprises receiving, from a scanning device, a bar code associated with the material.

9. The method of claim 1, wherein the material is a raw material.

10. The method of claim 1, wherein the material is an intermediate product.

11. The method of claim 1, wherein obtaining comprises obtaining material-specific event-based data associated with the received identifier from a database populated with event-based data obtained from a plurality of manufacturers in an event-based manufacturing system.

12. The method of claim 1, wherein the obtaining occurs via a network.

13. The method of claim 1, wherein one or more computer-readable media have computer-executable instructions for performing the method of claim 1.

14. The method of claim 1, wherein the type of the defect comprises a hole or tear in the material, and the location of the defect comprises a distance into the material from an exposed outer end of the material.

15. The method of claim 1, wherein the type of the defect comprises a break in the material, and the location of the defect comprises position information relative to the material.

16. The method of claim 1, wherein the type of the defect comprises a splice in the material, and the location of the defect comprises a location of the splice in the material.

17. The method of claim 1, wherein the type of the defect comprises a color defect, and the location of the defect comprises a location of the color defect in the material.

18. The method of claim 1, wherein the material comprises a roll, wherein the type of the defect comprises an optically detected web defect in the roll, and the location of the defect comprises a position of the optically detected web defect in the roll.

19. The method of claim 1, wherein the product comprises one or more of the following:

cosmetics, toiletries, health care products, absorbent articles, diapers, feminine care products, baby food, canned goods, tissue products, pharmaceutical products, automobiles, electronic goods, petrochemicals agricultural products, wood products, textiles, and plastics.

20. The method of claim 1, wherein the event-based data does not include metrology data.

21. A system for communicating event-based data relating to a material between machines during processing for feed-forward control, the system comprising:

at least one database storing event-based data, from a first process using or producing a material, said event-based data being collected in response to events occurring during the first process, the stored event-based data including a type and location of a quality attribute of the material, said events being substantially randomly spaced in time, the database having at least one identifier associated with the event-based data, said event-based data comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process;

a scanning device for reading a label including the identifier, the scanning device for use in conjunction with a second process; and

a feed-forward control system having computer-executable instructions which, when executed, receive the identifier from the scanning device and obtain the event-based data from the database during the second process, the second process occurring subsequent to the first process and being adjustable by the control system for the material responsive to the type and location of the quality attribute stored in the event-based data associated with the material from the database.

22. The system of claim 21, wherein the label comprises at least one of a bar code and a smart tag.

23. The system of claim 21, wherein the database stores manufacturing data associated with the manufacture of a product using the material.

24. The system of claim 21, wherein the first process comprises production of the material, and the second process comprises manufacture of a product using the produced material.

25. The system of claim 21, wherein the material is a raw material.

26. The system of claim 21, wherein the material is an intermediate product.

27. The system of claim 21, wherein the database stores a production history of the material, wherein the material is in roll form.

28. The system of claim 27, wherein the production history comprises a record of measured basis weight as a function of position in a roll.

29. The system of claim 27, wherein the production history comprises a record of optically detected web defects in the roll as a function of position in a roll.

30. The system of claim 21, wherein the quality attribute of the material comprises a defect of the material.

31. The system of claim 21, wherein the quality attribute of the material comprises production information associated with the first process and the material.

32. In a system for communicating event-based data relating to a material between machines, one or more computer-readable media having computer-executable components comprising:

an interface module for determining, from a label associated with a material, an identifier identifying the material; and

a control module for obtaining event-based data associated with the determined identifier from a database for feed-forward control in an event-based manufacturing system, wherein the event-based data is collected in response to events occurring during a first process using the material and includes a type and location of a quality attribute of the material, said events being substantially randomly spaced in time, wherein the event-based data comprises probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process, wherein the determining of the identifier of the material and the obtaining of the event-based data occur during a second process occurring subsequent to the first process, and wherein the control module adjusts the second process for the material as a function of the type and location of the quality attribute in the event-based data.

33. The computer-readable media of claim 32, wherein the interface module comprises a receiver for receiving, from a scanning device, a bar code associated with the material.

34. The computer-readable media or claim 32, wherein the control module comprises feed-forward process control for implementing remedial action in response to the obtained event-based data.

35. The computer-readable media of claim 34, wherein the second process comprises a machine, and wherein the remedial action comprises adjusting at least one setting of the machine.

36. The computer-readable media of claim 32, wherein the second process produces an absorbent article from the material.

37. The computer-readable media of claim 32, wherein the quality attribute comprises a defect of the material.

38. A method for communicating event-based data relating to a material between machines during processing for feed-forward control, the method comprising:

storing, in a device affixed to a material, material-specific event-based data relating to a type and location of a defect in the material in response to events occurring during a first process using or producing the material, said events being substantially randomly spaced in time, said event-based data comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process;

receiving, from the device affixed to the material, the stored event-based data during a second process occurring subsequent to the first process; and

implementing remedial action for the material for feed-forward control of the second process in response to the type and location of the defect in the received event-based data.

39. The method of claim 38, wherein the receiving comprises receiving the event-based data associated with the material from a smart tag affixed to the material.

40. The method of claim 38, wherein the receiving comprises receiving, from the device over a radio frequency, the event-based data associated with the material from a device affixed to the material.

41. The method of claim 38, wherein the material is a raw material.

42. The method of claim 38, wherein the material is an intermediate product.

43. The method of claim 38, wherein a machine operates the second process, and wherein the implementing comprises adjusting at least one setting of the machine.

44. The method of claim 43, wherein the implementing comprises temporarily reducing a speed of the machine to prevent a break in the material.

45. The method of claim 38, wherein the implementing comprises splicing out a portion of the material having inadequate basis weight.

46. The method of claim 38, further comprising electronically conveying instructions to a human operator in response to the receiving.

47. The method of claim 38, wherein one or more computer-readable media have computer-executable instructions for performing the method of claim 38.

48. A system for communicating event-based data relating to a material between machines during processing for feed-forward control, the system comprising:

at least one memory device storing event-based data collected in response to events occurring during a first process using the material, wherein the event-based data comprises a type and location of a quality attribute of the material, wherein the events are substantially randomly spaced in time, wherein the event-based data comprises probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process;

a scanning device for reading a label including the event-based data, the scanning device for use in conjunction with a second process occurring subsequent to the first process; and

a feed-forward control system having computer-executable instructions which, when executed during the second process, receive from the scanning device the event-based data associated with the first process and adjust the second process for the material as a function of the type and location of the quality attribute in the event-based data.

49. The system of claim 48, wherein the memory device comprises a smart tag affixed to the material.

50. The system of claim 48, wherein the memory device broadcasts the event-based data via a radio frequency.

51. The system of claim 48, wherein the first process comprises production of the material, and the second process comprises manufacture of a product using the produced material.

52. The system of claim 48, wherein the material is a raw material.

53. The system of claim 48, wherein the material is an intermediate product.

54. The system of claim 48, wherein the memory device stores a production history of the material.

55. The system of claim 54, wherein the production history comprises a record of measured basis weight as a function of position on a roll.

56. The system of claim 54, wherein the production history comprises a record of optically detected web defects in the roll as a function of position in a roll.

57. In a system for communicating event-based data relating to a material between machines, one or more computer-readable media having computer-executable components comprising a feed-forward control module for receiving, from a device affixed to a material, event-based data relating to a type and location of a defect in the material, said event-based data being collected in response to events occurring during a first process using the material, said events being substantially randomly spaced in time, said event-based data comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process, wherein the receiving of the event-based data associated with the first process occurs during a second process occurring subsequent to the first process, wherein the feed-forward control module governs the second process for the material in response to the type and location of the defect in the received event-based data.

58. The computer-readable media of claim 57, wherein the control module comprises feed-forward process control for implementing remedial action in response to the received event-based data.

59. The computer-readable media of claim 58, wherein a machine operates the second process, and wherein the remedial action comprises adjusting at least one setting of the machine.

60. An intelligent event-based manufacturing system comprising:

a first process for converting a raw material to a product;

a feed-forward process control system comprising, one or more sensors for generating an alarm in response to an event that results in one of waste, machine delay, or decreased product quality;

a data logger associated with the feed-forward process control system for obtaining an event parameter associated with the event;

a database on a server for recording the event parameter obtained by the data logger;

a second process using the product, said second process being governed by the feed-forward process control system responsive to the event parameter recorded in the database, said feed-forward process control system being further responsive to probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based data for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based data for a component used in the first process, and product quality as a function of raw material data for a component used in the first process; and

a reporting system cooperatively associated with the database for reporting a productivity parameter regarding the first process derived at least in part from the event parameter.

61. A method of reducing the probability of at least one of waste, delay, or a quality defect in a process having process conditions for the manufacture of a product from a sequentially trackable raw material, the raw material being associated with event-based manufacturing information obtained responsive to events occurring during production of the raw material, said events being substantially randomly spaced in time, the method comprising:

identifying a problematic portion of the raw material during a first process for feed-forward control of a second process occurring subsequent to the first process of the raw material by analyzing the event-based manufacturing information, the problematic portion being associated with an increased probability of at least one of waste, delay, or a quality defect during the second process, said event-based manufacturing information comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based manufacturing information for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based manufacturing information f or a component used in the first process, and product quality as a function of raw material data for a component used in the first process; and

temporarily adjusting the process conditions of the second process responsive to the identified problematic portion in the raw material such that the second process has the adjusted process conditions for at least a portion of the time when the problematic portion of the raw material is used in the second process.

62. The method of claim 61, wherein the sequentially trackable raw material comprises a roll good, a web, or a material in a fixed sequence.

63. The method of claim 61, wherein the event-based manufacturing information includes a property value, wherein identifying comprises identifying a portion of the raw material having a property value associated with an increased probability of at least one of waste, delay, or a quality defect during the process.

64. The method of claim 61, wherein identifying comprises identifying a problematic portion of the raw material via the event-based manufacturing information.

65. A method of reducing the probability of at least one of waste, delay, or a quality defect in a process, the method comprising:

accessing event-based manufacturing information for a sequentially trackable raw material, said event-based manufacturing information being stored in response to events occurring during production of the raw material during a first process, said events being substantially randomly spaced in time, said event-based manufacturing information comprising probabilistic data obtained by correlations of one or more of past machine performance as a function of the event-based manufacturing information for a component used in the first process, past machine performance as a function of raw material data for a component used in the first process, product quality as a function of the event-based manufacturing information for a component used in the first process, and product quality as a function of raw material data for a component used in the first process;

identifying, from the accessed event-based manufacturing information, a portion of the raw material having an increased probability of at least one of waste, delay, or a quality defect;

determining a location in the raw material of the identified portion of the raw material; and

temporarily adjusting process conditions of a second process at the determined location in the raw material for at least a portion of the time when the problematic portion of the raw material is used in the second process for feed-forward control of the second process to reduce the probability of at least one of waste, delay, or a quality defect of the second process, said second process resulting in the manufacture of a product from the raw material.

66. The method of claim 65, wherein the sequentially trackable raw material comprises a roll good, a web, or a material in a fixed sequence.

67. The method of claim 65, wherein the event-based manufacturing information includes a property value, wherein identifying comprises identifying a portion of the raw material having a property value associated with an increased probability of at least one of waste, delay, or a quality defect.

68. The method of claim 65, wherein identifying comprises identifying, via the event-based manufacturing information, a portion of the raw material having an increased probability of at least one of waste, delay, or a quality defect.