Generating a reliability analysis by identifying casual relationships between events in an event-based manufacturing system

• US 7,221,987 B2
• Filed: 06/15/2004
• Issued: 05/22/2007
• Est. Priority Date: 06/15/2004
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Reade, Walter Caswell, Bett, Thomas Arthur, Irwin, Michelle Renee, Ungpiyakul, Tanakon, Cannady, Jeremy Brian, Bedenbaugh, Babe
• Primary Examiner(s): KOSOWSKI, ALEXANDER J
• Application Number:
  US10/868,137
• Publication Number:
  US 20050278052A1
• Time in Patent Office: 1,071 Days
• Field of Search: 700/51, 700/122, 700108-110, 700127-129, 700/174
• US Class Current: 700/108
• CPC Class Codes: G05B 2219/31485 Verify and update all related data in relational database
• CPC Class Codes: G05B 23/0229 knowledge based, e.g. expert systems; genetic algorithms
• CPC Class Codes: G05B 23/0267 Fault communication, e.g. human machine interface [HMI]
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

Analyzing an event chronology record to permit identification of periods of a production sequence that correspond to a high probability of failure. Systems and methods include receiving an event chronology for a particular machine in the production sequence and for a particular time interval. A reliability analysis system accesses process flow information to determine whether a particular event in the event chronology is related to a subsequent adverse event within a predefined event window.

Claims

1. A method for analyzing reliability of a manufacturing system, said method comprising:

receiving an event chronology having a plurality of chronologically ordered event records, said event chronology being associated with a manufacturing system, said manufacturing system including a plurality of machines operating in sequence, each of the plurality of machines operating in sequence being identified by a machine section value, each of the plurality of chronologically ordered event records having a machine section value associated therewith;

identifying an adverse event record in the received event chronology;

determining a relationship between the adverse event record associated with one of the plurality of machines and at least one previous event record in the event chronology, said at least one previous event record being associated with the one machine or another machine from the plurality of machines, said other machine operating previous to the one machine in the sequence, said determining including comparing the machine section value of the identified adverse event record and the machine section value of the previous event record; and

incrementing a value representative of a correlation between the identified adverse event record and the previous event record as a function of the determined relationship.

2. The method of claim 1, wherein determining the relationship comprises accessing a memory area storing process flow information, said process flow information identifying relationships between machine sections.

3. The method of claim 2, further comprising storing the process flow information in the memory area.

4. The method of claim 1, wherein the event chronology is associated with a particular converting line and further comprising acting on the incremented value by modifying the particular converting line based on the determined relationship.

5. The method of claim 1, further comprising extracting machine subsection data from one or more data tables as a function of a particular machine section value.

6. The method of claim 1, further comprising exporting the event chronology and the incremented value to an analytical environment for further processing.

7. The method of claim 1, wherein the received event chronology comprises waste data, delay data, and material usage data collected from an event-based manufacturing system.

8. The method of claim 1, wherein the received event chronology comprises data related to the manufacture of an absorbent article.

9. The method of claim 1, wherein the incremented value is associated with one or more of the following:

the machine section value of the identified adverse event record, and the machine section value of the previous event record.

10. The method of claim 1, wherein determining the relationship comprises determining whether the identified adverse event record and the previous event record are within a predefined event window.

11. The method of claim 1, wherein one or more computer storage media have computer-executable instructions for performing the method recited in claim 1.

12. One or more computer storage media having computer-executable components for analyzing reliability of a manufacturing process, said components comprising:

an interface component for receiving an event chronology having a plurality of chronologically ordered event records, said event chronology being associated with a manufacturing system, said manufacturing system including a plurality of machines operating in sequence, each of the plurality of machines operating in sequence being identified by a machine section value, each of the plurality of chronologically ordered event records having a machine section value associated therewith;

a process flow component for identifying a causal relationship between the event records in the event chronology received by the interface component by;

identifying an adverse event record in the event chronology, said identified adverse event record being associated with one of the plurality of machines in the sequence; and

determining if the machine section value of the identified adverse event record and the machine section value of at least one previous event record in the event chronology are related, said at least one previous event record being associated with the one machine or another machine from the plurality of machines, said other machine operating previous to the one machine in the sequence; and

a display component for displaying the identified causal relationship to a user.

13. The computer storage media of claim 12, wherein the process flow component further increments a value representative of a correlation between the identified adverse event record and the previous event record responsive to the identified causal relationship.

14. The computer storage media of claim 13, wherein the incremented value is associated with one or more of the following:

the machine section value of the identified adverse event record, and the machine section value of the previous event record.

15. The computer storage media of claim 12, further comprising a chronology component for extracting delay data and raw material usage data from one or more data tables as a function of a time interval value and a target location value and merging the extracted delay data and raw material usage data into the event chronology.

16. The computer storage media of claim 12, further comprising a subsection component for extracting subsection data from one or more data tables as a function of a particular machine section value.

17. The computer storage media of claim 12, wherein the received event chronology comprises waste data, delay data, and material usage data collected from an event-based manufacturing system.

18. The computer storage media of claim 12, wherein the received event chronology comprises data related to the manufacture of an absorbent article.

19. The computer storage media of claim 12, further comprising a subsection component for extracting, as a function of a particular machine section value, subsection data from the event chronology received by the interface component.

20. The computer storage media of claim 12, wherein the process flow component identifies the causal relationship further by determining whether the identified adverse event record and the previous event record are within a predefined event window.

21. A system for analyzing the reliability of a manufacturing process having one or more machine sections, said system comprising:

an event chronology having a plurality of chronologically ordered event records, each of the plurality of chronologically ordered event records having a machine section value associated therewith, said event chronology being associated with a manufacturing system, said manufacturing system including a plurality of machines operating in sequence, each of the plurality of machines operating in sequence being identified by a machine section value;

a memory area for storing process flow information identifying at least one relationship between machine section values; and

a processor configured to execute computer-executable instructions for identifying a causal relationship between at least two of the event records in the event chronology, said at least two of the event records being associated with machines in sequence in the manufacturing system, said identifying including accessing the process flow information stored in the memory area and comparing the accessed process flow information with the machine section values corresponding to the machines associated with the at least two of the event records.

22. The system of claim 21, further comprising a user interface for displaying the identified causal relationship to a user.

23. The system of claim 21, wherein the processor is further configured to execute computer-executable instructions for identifying the causal relationship by identifying an adverse event record in the event chronology and determining if the machine section value of the identified adverse event record and the machine section value of a previous event record in the event chronology are related per the process flow information stored in the memory area.

24. The system of claim 23, wherein the processor is further configured to execute computer-executable instructions for identifying the causal relationship by determining whether the identified adverse event record and the previous event record are within a predefined event window.

25. The system of claim 21, wherein the event chronology is associated with the manufacturing system including the plurality of machines operating in sequence on a web of absorbent material to create an absorbent article.

26. The system of claim 21, further comprising:

a chronology tool for building the event chronology from data collected from an event-based manufacturing system; and

a reliability analysis tool for producing a report from the event chronology built by the chronology tool, said report including the event chronology, said report further including a plurality of dimensions, said dimensions including a measure of reliability during machine start, a measure of reliability of a running operation, and a measure of reliability per asset in the production sequence and per time frame.

27. The system of claim 26, wherein the reliability analysis tool further produces a subsection report for a machine section, said subsection report representing a cross-tabulation of a plurality of stop events to identify one or more delay subsections for the machine section, wherein the reliability analysis tool further produces a material converting report for a machine section, said material converting report representing a cross-tabulation of a plurality of stop events for the machine section to identify one or more material identifiers related to the plurality of stop events, and wherein the reliability analysis tool further produces a material converting report for a subset of machine sections, said material converting report representing a cross-tabulation of a plurality of stop events for the subset of machine sections to identify one or more material identifiers related to the plurality of stop events.

28. The system of claim 21, further comprising a user interface having a display and providing a report and a data set used to generate the report, said user interface comprising:

a start-up reliability portion for displaying on the display a tabulation of start-up failure events for a target machine during a time interval; and

an efficiency portion for displaying on the display splice efficiency data for the target machine during the time interval.

29. The system of claim 28, wherein the user interface further comprises a classification portion for displaying classification information on the display, said classification information specifying the target machine and the time interval, a summary portion for displaying on the display a data set summary for the target machine during the time interval, and a delay event portion for displaying on the display a plurality of delay events for the target machine during the time interval categorized by process location.

30. The system of claim 28, wherein the user interface further comprises:

a first field for displaying classification information on the display, said classification information specifying a target machine and a time interval;

a second field for displaying on the display a data set summary for the target machine during the time interval;

a third field for displaying on the display a plurality of delay events for the target machine during the time interval categorized by process location;

a fourth field for displaying on the display a tabulation of start-up failure events for the target machine during the time interval; and

a fifth field for displaying on the display splice efficiency data for the target machine during the time interval.

31. The system of claim 30, wherein the second field further displays one or more of the following for the target machine during the time interval:

a count of process events organized into delay and material consumption categories, and a converting event reliability ratio measuring converting reliability as a count of consumption events divided by a count of delay events to indicate overall system health and efficiency, and wherein the fourth field further displays a count of repeat failures for the target machine during the time interval to provide a measure of difficulty during process re-start.

32. The system of claim 30, wherein the fifth field further displays one or more of the following for the target machine during the time interval:

a splice count per machine section, a process failure count per machine section, and a computed efficiency ratio of the splice count and the process failure count, or wherein the fifth field represents splice efficiency across a 1500 cut process event window, or wherein the fifth field displays the splice efficiency data having an event window length, said event window length being from about 0 cuts to about 3000 cuts.

33. The system of claim 30, wherein the data set comprises waste, delay, and material usage data collected from an event-based manufacturing system for the target machine during the time interval, and wherein the second field displays the data set summary relating to data collected by an event-based manufacturing system, or wherein the second field displays the data set summary relating to data pertaining to the manufacture of an absorbent article.