System and method for producing products based upon demand

• US 10,558,201 B2
• Filed: 09/08/2017
• Issued: 02/11/2020
• Est. Priority Date: 09/09/2016
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Burkhard, Ryan Andrew, Moore, Nathan E, Fikes, Elizabeth Marie, Royce, Daniel Richard, Ballman, Kyle Christopher, Tysen, Julie Elizabeth
• Primary Examiner(s): Kasenge, Charles R
• Application Number:
  US15/698,677
• Publication Number:
  US 20180074478A1
• Time in Patent Office: 886 Days
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/4189 characterised by the transport system
• CPC Class Codes: G05B 2219/33064 Manufacturing planning and control agent and domain blackboards
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 50/04 Manufacturing
• 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 90/30 Computing systems specially adapted for manufacturing

Abstract

A system and method for producing products based upon demand are disclosed. In some cases, the products include containers and the contents therein. The containers are disposed on vehicles and are independently routable along a track system and are deliverable to at least one unit operation station. A control system: receives demand for finished products; determines a route for vehicles based upon the status of one or more unit operation stations; and causes a vehicle to progress along a determined route to create one or more of the demanded finished products. The system may be used to produce the same fluent products, different fluent products, and other types of products including assembled products.

Claims

1. A system for producing products based on demand data, said system comprising:

a plurality of vehicles for articles;

a track system comprising a track on which article-loaded vehicles are propellable;

a plurality of unit operation stations disposed along the track system and configured to cooperate to create at least one finished product;

wherein each article is disposed on a vehicle and the plurality of vehicles are independently routable along the track system to deliver at least some of the articles to at least one unit operation station;

a control system comprising one or more controller units which are in communication with said track system and said unit operation stations, and which control system;

receives demand for finished products to be made;

determines a route for a vehicle, where said route is determined based on a status of one or more unit operation stations; and

causes a vehicle to be propelled to progress along said determined route so as to create one or more of said demanded finished products and delivers said one or more finished products to an unloading station;

wherein the demanded finished products comprise a description of packages, wherein each package may comprise a unique set of finished products,

wherein the status of the one or more unit operation stations comprises information concerning the capacity utilization of the unit operation station and wherein the capacity can be based on a size of an infeed queue and information concerning progress of other vehicles along routes.

2. The system of claim 1 wherein the status of the one or more unit operation stations comprises a state of readiness of a unit operation station.

3. The system of claim 1 wherein the status of the one or more unit operation stations comprises one or more capabilities of the unit operation station.

4. The system of claim 3 wherein the capabilities comprise a plurality of operations that can be performed by the unit operation station.

5. The system of claim 1 wherein the status of the one or more unit operation stations comprises information concerning operations expected to be completed at one or more unit operation stations in the future.

6. The system of claim 5 wherein the information reflects progress of other vehicles along routes.

7. The system of claim 1 wherein the status of the one or more unit operation stations comprises information concerning the capacity of other unit operation stations.

8. The system of claim 1 wherein the status of the one or more unit operation stations comprises information concerning availability of raw materials to the unit operation station.

9. The system of claim 1 wherein the status of the one or more unit operation stations comprises information concerning expected maintenance activities involving the unit operation station.

10. The system of claim 1 wherein the control system establishes a sequence in which said demanded finished products will be created.

11. The system of claim 1 wherein the determined route is determined based on one or more constraints on arriving at one or more unit operation stations before one or more other vehicles or after one or more other vehicles.

12. The system of claim 1 wherein the determined route is determined based on status information of a vehicle, wherein such status information is selected from the following information:

container-holding interface type, maximum vehicle velocity, maximum vehicle acceleration, maximum container weight, and maximum container size.

13. The system of claim 1 wherein the description of a package further comprises information concerning the sequence of unloading of the finished products.

14. The system of claim 1 wherein the determined route is selected from a subset of all possible routes.

15. The system of claim 1 wherein the determined route is selected from a set of all possible routes that will result in creating a demanded finished product.

16. The system of claim 1 wherein the demand for finished products comprises demand for a first finished product and a second finished product, wherein the product to be produced is a fluent product within a container, and wherein the first finished product differs from the second finished product in one or more of:

container volume, container shape, container size, contained material volume or mass, contained material composition, decoration, label or label contents, closure type, closure color, closure composition, container composition, container color, or other finished product attribute.

17. The system of claim 1 wherein the determined route is selected by comparing potential routes where such comparison takes into account the utilization or capacity of one or more unit operation stations and the selected route is selected so as to best utilize the capacity of one or more unit operation stations.

18. The system of claim 1 wherein the step of determining a route for a vehicle comprises a recursive method.

19. The system of claim 1 wherein the control system is self-optimizing.

20. The system of claim 1 wherein the step of determining a route for the vehicle takes less than 1 second to complete.

21. The system of claim 1 wherein the step of determining a route for the vehicle considers partially finished products demanded from unit operation stations.

22. The system of claim 21 wherein the partially finished products demanded are assigned a time span.

23. The system of claim 21 wherein the partially finished products demanded are assigned a priority.

24. The system of claim 21 wherein the partially finished products demanded are assigned a quantity.

25. A system for producing products based on demand data, said system comprising:

a plurality of vehicles for articles;

a track system comprising a track on which article-loaded vehicles are propellable;

a plurality of unit operation stations disposed along the track system and configured to cooperate to create at least one finished product;

wherein each article is disposed on a vehicle and the plurality of vehicles are independently routable along the track system to deliver at least some of the articles to at least one unit operation station;

a control system comprising one or more controller units which are in communication with said track system and said unit operation stations, and which control system;

receives demand for finished products to be made;

determines a route for a vehicle, where said route is determined based on a status of one or more unit operation stations; and

causes a vehicle to be propelled to progress along said determined route so as to create one or more of said demanded finished products and delivers said one or more finished products to an unloading station;

wherein the demanded finished products comprise a description of packages, wherein each package may comprise a unique set of finished products and wherein the status of the one or more unit operation stations comprises information concerning availability of raw materials to the unit operation station.

26. The system of claim 25 wherein the status of the one or more unit operation stations comprises a state of readiness of a unit operation station.

27. The system of claim 25 wherein the status of the one or more unit operation stations comprises one or more capabilities of the unit operation station.

28. The system of claim 27 wherein the capabilities comprise a plurality of operations that can be performed by the unit operation station.

29. The system of claim 25 wherein the status of the one or more unit operation stations comprises information concerning operations expected to be completed at one or more unit operation stations in the future.

30. The system of claim 29 wherein the information reflects progress of other vehicles along routes.

31. The system of claim 25 wherein the status of the one or more unit operation stations comprises information concerning the capacity utilization of the unit operation station.

32. The system of claim 31 wherein the capacity can be based on a size of an infeed queue and information concerning progress of other vehicles along routes.

33. The system of claim 25 wherein the status of the one or more unit operation stations comprises information concerning the capacity of other unit operation stations.

34. The system of claim 25 wherein the status of the one or more unit operation stations comprises information concerning expected maintenance activities involving the unit operation station.

35. The system of claim 25 wherein the control system establishes a sequence in which said demanded finished products will be created.

36. The system of claim 25 wherein the determined route is determined based on one or more constraints on arriving at one or more unit operation stations before one or more other vehicles or after one or more other vehicles.

37. The system of claim 25 wherein the determined route is determined based on status information of a vehicle, wherein such status information is selected from the following information:

container-holding interface type, maximum vehicle velocity, maximum vehicle acceleration, maximum container weight, and maximum container size.

38. A system for producing products based on demand data, said system comprising:

a plurality of vehicles for articles;

a track system comprising a track on which article-loaded vehicles are propellable;

a plurality of unit operation stations disposed along the track system and configured to cooperate to create at least one finished product;

wherein each article is disposed on a vehicle and the plurality of vehicles are independently routable along the track system to deliver at least some of the articles to at least one unit operation station;

a control system comprising one or more controller units which are in communication with said track system and said unit operation stations, and which control system;

receives demand for finished products to be made;

determines a route for a vehicle, where said route is determined based on a status of one or more unit operation stations; and

causes a vehicle to be propelled to progress along said determined route so as to create one or more of said demanded finished products and delivers said one or more finished products to an unloading station;

wherein the demanded finished products comprise a description of packages, wherein each package may comprise a unique set of finished products, and wherein the status of the one or more unit operation stations comprises information concerning expected maintenance activities involving the unit operation station.

39. A system for producing products based on demand data, said system comprising:

a plurality of vehicles for articles;

a track system comprising a track on which article-loaded vehicles are propellable;

a plurality of unit operation stations disposed along the track system and configured to cooperate to create at least one finished product;

wherein each article is disposed on a vehicle and the plurality of vehicles are independently routable along the track system to deliver at least some of the articles to at least one unit operation station;

a control system comprising one or more controller units which are in communication with said track system and said unit operation stations, and which control system;

receives demand for finished products to be made;

determines a route for a vehicle, where said route is determined based on a status of one or more unit operation stations; and

causes a vehicle to be propelled to progress along said determined route so as to create one or more of said demanded finished products and delivers said one or more finished products to an unloading station;

wherein the demanded finished products comprise a description of packages, wherein each package may comprise a unique set of finished products, and wherein the determined route is determined based on status information of a vehicle, wherein such status information is selected from the following information;

container-holding interface type, maximum vehicle velocity, maximum vehicle acceleration, maximum container weight, and maximum container size.

40. The system of claim 39 wherein the status of the one or more unit operation stations comprises a state of readiness of a unit operation station.

41. The system of claim 39 wherein the status of the one or more unit operation stations comprises one or more capabilities of the unit operation station.

42. The system of claim 41 wherein the capabilities comprise a plurality of operations that can be performed by the unit operation station.

43. The system of claim 39 wherein the status of the one or more unit operation stations comprises information concerning operations expected to be completed at one or more unit operation stations in the future.

44. The system of claim 43 wherein the information reflects progress of other vehicles along routes.

45. The system of claim 39 wherein the status of the one or more unit operation stations comprises information concerning the capacity utilization of the unit operation station.

46. The system of claim 45 wherein the capacity can be based on a size of an infeed queue and information concerning progress of other vehicles along routes.

47. The system of claim 39 wherein the status of the one or more unit operation stations comprises information concerning the capacity of other unit operation stations.