Automated monitoring and control of contamination activity in a production area

• US 9,406,212 B2
• Filed: 01/28/2011
• Issued: 08/02/2016
• Est. Priority Date: 04/01/2010
• Status: Active Grant

• Current Assignee: Sealed Air Corporation (Sealed Air)
• Original Assignee: Sealed Air Corporation (Sealed Air)
• Inventors: De Luca, Nicholas, Sato, Koichi
• Primary Examiner(s): Lau, Hoi
• Application Number:
  US12/931,294
• Publication Number:
  US 20120150333A1
• Time in Patent Office: 2,013 Days
• Field of Search: 340/568.1, 340/10.1, 340/500, 340/540, 340/573.1, 340/686.1, 340/686.2, 340/686.6, 382/103, 382/115, 382/100, 382/182, 382/286, 382/291, 348/143, 348/77, 348/94
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06V 20/52 Surveillance or monitoring of activities, e.g. for recognising suspicious objects recognising microscopic objects G06V20/69
• CPC Class Codes: G06V 40/171 Local features and components; Facial parts eye characteristics G06V40/18; Occluding parts, e.g. glasses; Geometrical relationships
• CPC Class Codes: G06V 40/20 Movements or behaviour, e.g. gesture recognition recognition of facial expressions G06V40/16
• CPC Class Codes: G08B 13/1427 with transmitter-receiver for distance detection
• CPC Class Codes: G08B 21/12 responsive to undesired emission of substances, e.g. pollution alarms
• CPC Class Codes: G08B 21/22 responsive to presence or absence of persons
• CPC Class Codes: G08B 21/245 Reminder of hygiene compliance policies, e.g. of washing hands
• CPC Class Codes: G16H 40/20 for the management or administration of healthcare resources or facilities, e.g. managing hospital staff or surgery rooms
• CPC Class Codes: G16H 50/80 for detecting, monitoring or modelling epidemics or pandemics, e.g. flu

Abstract

An automated process for monitoring and controlling contamination activity in a production area comprises capturing image from the production area over a period of time, processing the image data with a computer to determine whether a contamination event has occurred in the production area, and activating a contamination control device in accordance with the processing of the image data. The contamination event can be a germ-releasing event from an individual in the production area, a pipe leaking fluid into the production area, etc. The automated monitoring and control may also determine whether an article of contamination control equipment (e.g., face mask, glove, etc) is properly positioned on the individual to prevent the contamination from entering the production area in a form that could contaminate product, equipment, or the production area itself. An automated system for monitoring and controlling contamination includes a computer, an imaging sensor in communication with the computer, and a computer-readable program code disposed on the computer.

Claims

1. An automated process for monitoring and controlling contamination activity in a production area, comprising:

(A) capturing image data from the production area over a period of time;

(B) processing the image data with a computer to determine whether a contamination event has occurred in the production area; and

(C) activating a contamination control device in accordance with the processing of the image data,

wherein the image data is processed using a stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with an absence of the contamination event or a pre-determined minimum image value correlating with a presence of the contamination event, and the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied.

2. The automated process according to claim 1, wherein the contamination event is a germ-releasing event or a germ-spreading event.

3. The automated process according to claim 1, wherein the image data is captured by scanning at least a portion of the production area with a camera.

4. The automated process according to claim 1, wherein at least one member selected from the production area, the individual, and the contamination control equipment has an RFID tag thereon.

5. The automated process according to claim 1, wherein activating the contamination control device comprises at least one member selected from the group consisting of:

(i) cutting off power to at least one machine in the production area, and (ii) interjecting a physical restraint or barrier between the individual and at least a portion of the production area, and (iii) sounding an alarm comprising at least one member selected from the group consisting of an audible alarm, a visual alarm, and a vibratory alarm, and (iv) generating and transmitting a report, with the transmission of the report comprising at least one member selected from the group consisting of transmission of an electronic report and transmission of a hard copy report.

6. The automated process for monitoring and controlling contamination activity in a production area according to claim 1, wherein the contamination event comprises at least one member selected from the group consisting of coughing, sneezing, sweating, spitting, bleeding, vomiting, belching, crying, excreting, spilling, breaking, dropping, touching, breathing on, a leaking pipe, a breaking pipe, a light bulb exploding, and a production equipment breaking and releasing parts or fragments.

7. The automated process for monitoring and controlling contamination activity in a production area according to claim 1, wherein the contamination event comprises an action outside the production area that cause the release of a contaminant into or within the production area, comprising at least one member selected from the group consisting of fire releasing particulates into the environment of the production area, vibration absorbed by the production area releasing particulates from a surface within the production area, a lightning strike into or near the production area causing a contaminate to be released into the production area, wind causing release of particulates from surfaces outside the production area into the production area.

8. An automated process for monitoring and controlling contamination activity in a production area, comprising:

(A) capturing image data from the production area over a period of time;

(B) processing the image data with a computer to determine whether a contamination event has occurred in the production area, wherein the processing of the image data further comprises processing the image data with a computer to determine;

(i) whether an individual is present within the production area,

(ii) whether the individual has engaged in the contamination event while in the production area,

(iii) whether an article of contamination control equipment is present in association with the individual during the contamination event, and

(iv) whether the article of contamination control equipment is properly positioned or properly configured during the contamination event; and

(C) activating a contamination control device in accordance with the processing of the image data,

wherein the image data is processed to find an image of at least a portion of the individual present in the production area while the individual is in motion, with the image data being processed using a stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with an absence of the contamination event by the individual and/or a pre-determined minimum image value correlating with the contamination control equipment being present and properly positioned while the individual is in the production area, with the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied, and the activation of the contamination control device providing a positive indication of an absence of the contamination event by the individual.

9. An automated process for monitoring and controlling contamination activity in a production area, comprising:

(A) capturing image data from the production area over a period of time;

(B) processing the image data with a computer to determine whether a contamination event has occurred in the production area, wherein the processing of the image data further comprises processing the image data with a computer to determine;

(i) whether an individual is present within the production area,

(ii) whether the individual has engaged in the contamination event while in the production area,

(iii) whether an article of contamination control equipment is present in association with the individual during the contamination event, and

(iv) whether the article of contamination control equipment is properly positioned or properly configured during the contamination event; and

(C) activating a contamination control device in accordance with the processing of the image data,

wherein the image data is processed to find an image of at least a portion of the individual present in the production area while the individual is in motion, with the image data being processed using a stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with the occurrence of the contamination event by the individual and a pre-determined minimum image value correlating with the contamination control equipment being absent or improperly positioned during the contamination event, with the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied, and the contamination control device being activated to provide a positive indication of the contamination event in the production area, due to a determination of both;

(i) the occurrence of the contamination event in the production area, and

(ii) the absence or improper positioning of the contamination control equipment during the contamination event.

10. The automated process according to claim 9, wherein the contamination event is a germ-releasing event and the contamination control equipment comprises at least one member selected from the group consisting of a glove, a face mask, a suit, a gown, and a hair net, and a product article comprising food.

11. The automated process according to claim 9, wherein the process further comprises:

processing the image data to determine the location in the production area of the individual when the contamination event occurs; and

processing the image data to identify at least one potentially contaminated product article and/or identify at least one potentially contaminated production article that is within a contamination zone produced by the contamination event.

12. The automated process according to claim 11, wherein the contamination control device comprises an automated report generator that processes the image data to generate a report including an identity of the at least one potentially contaminated product article and/or the at least one potentially contaminated production article within the contamination zone at the time of occurrence of the contamination event.

13. The automated process according to claim 11, wherein the potentially contaminated product article and/or potentially contaminated production article within the contamination zone is in motion during and/or after the contamination event, with the automated process further comprising processing the image data to track the location of the at least one potentially contaminated product article and/or potentially contaminated production article after the contamination event, so that identity and location of the potentially contaminated product article in the contamination zone and/or potentially contaminated production article in the contamination zone is known after the contamination event, with the tracking of the at least one potentially contaminated product article and/or potentially contaminated production article being carried out using the stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with the identity of the at least one potentially contaminated product article and/or the at least one potentially contaminated production article, and the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied.

14. The automated process according to claim 9, wherein the activating of the contamination control device comprises activating at least one member selected from group consisting of:

(i) an alarm to notify the individual that the article of contamination control equipment is not present or is not properly positioned;

(ii) an automated report generator that processes the image data to generate a report including information pertaining to the article of contamination control equipment not being present or not being properly positioned during the contamination event; and

(iii) equipment to decontaminate, move, reposition, shield, or discard the at least one potentially contaminated product article and/or the at least one potentially contaminated production article within the contamination zone at the time of the contamination event.

15. The automated process according to claim 14, wherein the automated report generator processes the image data to generate a report that includes an image of the individual in the production area while the threshold image value is satisfied for the threshold time period, and a notation of a time at which the image was captured.

16. An automated system for monitoring and controlling contamination in a production area, the system comprising:

(A) a computer;

(B) an image sensor in communication with the computer, the image sensor being configured and arranged to capture image data of at least a portion of the production area; and

(C) computer-readable program code disposed on the computer, the computer-readable program code comprising;

(i) a first executable portion for processing the image data to produce an image of at least the portion of the production area captured by the image sensor,

(ii) a second executable portion for processing image data and determining if a contamination event occurs within the portion of the production area captured by the image sensor,

(iii) a third executable portion for activating a contamination control device in accordance with the processing of the image data, and

(iv) a stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with an absence of the contamination event or a pre-determined minimum image value correlating with a presence of the contamination event, and the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied.

17. The automated system according to claim 16, wherein the computer-readable program code further comprises an executable portion for processing the image data and determining whether an article of contamination control equipment is present and properly positioned or properly configured in the image data captured by the image sensor.

18. The automated system according to claim 16, wherein the computer-readable program code further comprises an executable portion for processing the image data to find an image of an individual in the image data captured by the image sensor.

19. The automated system according to claim 18, wherein the computer-readable program code comprises an executable portion for determining whether the individual has engaged in the contamination event while in the production area.

20. The automated system according to claim 19, wherein the computer-readable program code further comprises an executable portion for processing the image data and determining whether an article of contamination control equipment is present and properly positioned on the individual in the production area.

21. The automated system according to claim 16, wherein the computer-readable program code further comprises an executable portion for processing the image data to identify at least one potentially contaminated product article and/or identify at least one potentially product article that is within a contamination zone produced by the contamination event.

22. The automated system according to claim 21, wherein the computer-readable program code further comprises an executable portion for tracking the at least one potentially contaminated product article that is within the contamination zone produced by the contamination event.

23. The automated system according to claim 21, wherein the computer-readable program code further comprises an executable portion for marking the at least one potentially contaminated product article that is within the contamination zone produced by the contamination event.

24. The automated system according to claim 16, wherein the image sensor is a first image sensor in communication with the computer and the system further comprises a second image sensor in communication with the computer, and the first image sensor capturing image data from a first portion of the production area and the second image sensor capturing image data from a second portion of the production area, with both the first and second image sensors being in communication with the computer, with the computer-readable program code processing image data from both the first image sensor and the second image sensor.

25. The automated system according to claim 16, wherein the image sensor is a scanning imaging sensor configured and arranged to scan the production area.

26. The automated system according to claim 16, further comprising a data entry device in communication with the computer.

27. The automated system according to claim 16, further comprising a printer in communication with the computer, the printer being capable of printing a report of a determination of whether the contamination event has or has not occurred.

28. The automated system according to claim 16, wherein the computer-readable program code further comprises an executable portion for processing the image data to find an image of an individual in the image data captured by the image sensor, and an executable portion for determining whether the individual has engaged in the contamination event while in the production area, and an executable portion for determining whether contamination control equipment is properly positioned on the individual in the production area, and an executable portion for processing the image data to identify at least one potentially contaminated product article within a contamination zone produced by the contamination event, and wherein the computer-readable program code further comprises a stabilization algorithm to determine whether the image data satisfies a threshold image value for a threshold time period, with the threshold image value being a pre-determined minimum image value correlating with a presence of the contamination event, and the threshold time period being a pre-determined minimum time period that the threshold image value is satisfied.