Maximization of yield for web-based articles

• US 7,187,995 B2
• Filed: 12/29/2004
• Issued: 03/06/2007
• Est. Priority Date: 12/31/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Skeps, Carl J., Masterman, James A., Floeder, Steven P., Berg, Brandon T.
• Primary Examiner(s): Masinick; Michael D.
• Application Number:
  US11/025,242
• Publication Number:
  US 20050141760A1
• Time in Patent Office: 797 Days
• Field of Search: 700/110, 700/122, 700/143, 382/141
• US Class Current: 700/122
• CPC Class Codes: G01N 2021/8854 Grading and classifying of flaws
• CPC Class Codes: G01N 21/89 in moving material, e.g. running paper or textiles G01N21/90, G01N21/91, G01N21/94 take precedence
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32036 Enter data, values for custom made articles
• CPC Class Codes: G05B 2219/32304 Minimize flow time, tact, shortest processing, machining time
• CPC Class Codes: G05B 2219/32318 Smallest value of product of imminent processing time with total processing time
• CPC Class Codes: G05B 2219/45234 Thin flat workpiece, sheet metal machining
• CPC Class Codes: G06T 2207/30124 Fabrics; Textile; Paper
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

Techniques are described for inspecting a web and controlling subsequent conversion of the web into one or more products. A system, for example, comprises an imaging device, an analysis computer and a conversion control system. The imaging device images the web to provide digital information. The analysis computer processes the digital information to identify regions on the web containing anomalies. The conversion control system subsequently analyzes the digital information to determine which anomalies represent actual defects for a plurality of different products. The conversion control system determines a value for at least one product selection parameter for each of the products, and selects one of the products for conversion of the web based on the respective determined value. Exemplary product selection parameters include web utilization, unit product produced, estimated revenue or profit, process time, machine capacity and demand for the different products.

Claims

1. A method comprising:

imaging a sequential portion of a web to provide digital information;

processing the digital information with at least one initial algorithm to identify regions on the web containing anomalies;

analyzing at least a portion of the digital information with a plurality of subsequent algorithms to determine which anomalies represent actual defects in the web for a plurality of different products;

determining a value of at least one product selection parameter for each of the products;

selecting at least one of the products based on the determined value for each of the products; and

converting the web into the selected product or products.

2. The method of claim 1, wherein determining a value comprises computing the respective determined value for each of the products based on the determined actual defects for the respective products.

3. The method of claim 1, wherein determining a value comprises computing a web utilization for each of the products based on the determined actual defects for the respective products.

4. The method of claim 1, wherein determining a value comprises:

computing an estimated number of components that would be produced for each of the products based on the determined actual defects for the respective products; and

computing an estimated total sales for each of the products based on the computed number of components.

5. The method of claim 1,

wherein determining a value comprises determining a process time for conversion of the web for the respective products, and

wherein selecting one of the products comprises selecting the product to minimize the process time for the web.

6. The method of claim 1,

wherein determining a value comprises determining a machine utilization for one or more converting sites, and

wherein selecting one of the products comprises selecting the product based on the determined machine utilization.

7. The method of claim 1, further comprising:

determining a value for a first product selection parameter for each of the products;

determining a value for a second product selection parameter for each of the products; and

selecting the product based on the determined first and second values for each of the products.

8. The method of claim 1, wherein determining a value comprises determining values for a plurality of product selection parameters, the method further comprising:

computing a weighted average of the values for each of the products; and

selecting the product based on the respective computed weighted averages.

9. The method of claim 1, wherein converting the web comprises:

generating a conversion plan for the web based on the determined actual defects and the selected product; and

wherein converting the web into the selected product or products comprises converting the web in accordance with the generated conversion plan.

10. The method of claim 1, wherein the at least one subsequent algorithm characterizes at least a portion of the web into quality classifications.

11. A system comprising:

an imaging device that images a sequential portion of a web to provide digital information;

an analysis computer that processes the digital information with an initial algorithm to identify regions on the web containing anomalies; and

a conversion control system that analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for a plurality of different products,

wherein the conversion control system determines a value of at least one product selection parameter for each of the products, and selects one of the products for conversion of the web based on the determined value for each of the products.

12. The system of claim 11, wherein the conversion control system generates a conversion plan for the web based on the determined actual defects and the selected product.

13. The system of claim 12, further comprising:

a conversion server located within a converting sites and coupled to the conversion control system by a network,

wherein the conversion control system electronically communicates the conversion plan to the conversion server located with the converting sites.

14. The system of claim 13, wherein the conversion server displays the conversion plan for converting the web to the selected product.

15. The system of claim 13, wherein the conversion server controls configuration of a process line within the conversion in accordance with the conversion plan.

16. The system of claim 11, wherein the conversion control system computes the respective value for each of the products based on the determined actual defects for the respective products.

17. The system of claim 11, wherein the conversion control system computes one or more of an estimated utilization of the web for each of the products, an estimated number of components that would be produced for each of the products, an estimated total sales for each of the products, a process time for conversion of the web to each of the respective products or a machine utilization for one or more converting sites associates with the products.

18. The system of claim 11, wherein the conversion control system determining values for a plurality of product selection parameters, computes a weighted average of the values for each of the products;

and selects the product based on the respective computed weighted averages.

19. The system of claim 11, wherein the analysis computer process the digital information with the initial algorithm and extracts a portion of the digital information for each of the identified regions, and the conversion control system analyzes the extracted portions of the digital information to determine the actual defects for the plurality of different products.

20. The system of claim 11, wherein the conversion control system comprises:

a user interface module that presents a user interface to display the product selection parameter as one of a plurality of user-selectable product selection parameters;

a database storing data defining a set of conversion control rules; and

a conversion control engine that, for each products, applies the conversion control rules to determines values for the product selection parameters selected by a user, and selects the product based on the determined values.

21. A conversion control system comprising:

a database storing data defining a set of rules;

an interface to receive anomaly information from an analysis machine, wherein the anomaly information identifies regions of a web containing anomalies; and

a conversion control engine that applies the rules to the anomaly information to determine a value for at least one product selection parameter for each of a plurality of products,

wherein the conversion control engine selects one of the products for conversion of the web based on the determined values.

22. The conversion control system of claim 21, further comprising a plurality of defect processing modules that apply image processing algorithms to determine which anomalies represent actual defects in the web for the different products.

23. The conversion control system of claim 21, wherein the database stores product data that defines each of the products into which the web can be converted.

24. The conversion control system of claim 23,

wherein the product data stores data specifying an estimated revenue per unit for each of the products, an estimated income per unit for each of products, an estimated conversion time to convert a web roll to each product, a current level of industry demand for each of product, and

wherein the conversion engine utilizes the product data when applying the rules.

25. A computer-readable medium comprising instructions that cause a processor to:

store data defining a set of rules;

receive anomaly information from an analysis machine located within a manufacturing plant, wherein the anomaly information identify regions of a web containing anomalies;

apply the rules to the anomaly information to determine a value for at least one product selection parameter for each of a plurality of products; and

select one of the products for conversion of the web based on the determined values.

26. The computer-readable medium of claim 25, wherein the instruction cause the processor to compute one or more of an estimated utilization of the web for each of the products, an estimated number of components that would be produced for each of the products, an estimated total sales for each of the products, a process time for conversion of the web to each of the respective products or a machine utilization for one or more converting sites associates with the products.

27. The computer-readable medium of claim 25, wherein the instruction cause the processor to:

generate a conversion plan for the web based on the determined actual defects and the selected product;

communicate the conversion plan to a converting site for controlling conversion of the web; and

output shipment instructions for shipment of the web to the converting site for conversion.

28. A method comprising:

imaging a sequential portion of a web to provide digital information;

processing the digital information with at least one initial algorithm to identify regions on the web containing anomalies;

analyzing at least a portion of the digital information with a plurality of subsequent algorithms to determine which anomalies represent actual defects in the web for a plurality of different products;

selecting non-overlapping regions of the web for at least two of the products;

generating a composite defect map based on the selected non-overlapping regions;

generating a conversion plan based on the composite defect map; and

converting the web in accordance with the conversion plan.

29. A system comprising:

an imaging device that images a sequential portion of a web to provide digital information;

an analysis computer that processes the digital information with an initial algorithm to identify regions on the web containing anomalies; and

a conversion control system that analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for a plurality of different products and, based on the analysis, selects non-overlapping regions of the web for at least two of the products, and generates a composite defect map on the selected non-overlapping regions.

30. The method of claim 29, wherein the conversion control system additionally generates a conversion plan based on the composite defect map.

31. The method of claim 30, wherein the conversion control system additionally converts the web in accordance with the conversion plan.