Process control using multiple detections

• US 6,253,159 B1
• Filed: 02/08/1999
• Issued: 06/26/2001
• Est. Priority Date: 12/31/1998
• Status: Expired due to Term

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Arseneau, Gerald Bernard, Ungpiyakul, Tanakon, Bett, Thomas Arthur
• Primary Examiner(s): Shah, Kamini
• Assistant Examiner(s): MILLER, CRAIG S
• Application Number:
  US09/246,440
• Time in Patent Office: 869 Days
• Field of Search: 702/35, 702/36, 702/40, 702/85-88, 702/90, 702/104, 702/108, 702/116, 702/150, 702/155, 702/159, 702/158, 702/179-181, 702/189, 702/198, 702/199
• US Class Current: 702/85
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• 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

Methods of controlling manufacturing processes manufacturing, for example, absorbent articles. A target parameter to be measured is established, as are acceptable conditions of the target parameter. The target parameter is detected with first and second replications of determinations of the condition of the goods using multiple independent determinors, for example multiple sensors, or multiple replications using a common determinator, for example software instructions for analyzing a full digital vision image. Multiple determinations are taken at sites which are selected for their prospects for indicating acceptable conditions of the parameter. The method includes developing a measurement strategy, programming a computer to use appropriate analysis tools to evaluate the determination signals, transmitting the signals to the computer, and processing the signals according to an appropriate method. A given parameter can be inspected at respective duplicative sites, at spaced sites or multiple times at the same site. The parameter can be detected using three or more replications of the condition of the goods, optionally including processing signals from respective first and second parameters according to two or more different analytical methods. Averaging may or may not be an appropriate analytical method. The inspection system can compensate for various types of erroneous otherwise inappropriate signals and develop a corresponding response to respective process control devices. First and second replications can be taken at a common work station, or at spaced work stations. Preferably, the method measures parameters on every unit of goods fabricated or otherwise manipulated on the manufacturing line.

Claims

1. A method of measuring a parameter of goods during fabrication of such goods in a manufacturing operation, the method comprising:

(a) establishing a target parameter to be measured on the goods, and acceptable conditions of the target parameter;

(b) developing a measurement strategy for measuring the target parameter;

(c) detecting the target parameter with respective at least first and second separate and distinct replications of determinations of the condition of the established target parameter on a segment of a unit of the goods at a given stage of development of the target parameter on the goods, using at least one of multiple independent determinors or a common determinor taking multiple real time determinations of the established target parameter at corresponding multiple sites on the unit of goods which sites desirably indicate, in combination, a common acceptable condition of the target parameter, and thereby developing respective at least first and second separate and distinct replicate determination signals representative of the target parameter on the unit of goods;

(d) subsequent to developing the measurement strategy, programming a user-programmable computer to use an analysis method capable of assessing accuracy of determinor sensory input pertaining to the target parameters to evaluate the determination signals;

(e) transmitting the determination signals to the user-programmable computer for analysis; and

(f) processing the determination signals in the user-programmable computer so as to use the respective analysis method to analyze the determination signals so received for conformity to the established acceptable conditions.

2. A method as in claim 1, including detecting the target parameter with respective at least first and second separate and distinct replications of determinations for at least first and second parameters at respective duplicative sites on the unit of goods.

3. A method as in claim 2, including processing the determination signals so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

4. A method as in claim 1, including detecting the target parameter using respective at least first, second, and third separate and distinct replications of determinations of the condition of the unit of goods.

5. A method as in claim 4, processing of the determination signals comprising computing an average of the three signals.

6. A method as in claim 4 wherein, when the analysis detects an out-of-calibration condition in one of multiple independent determinors, automatically recalibrating the out-of-calibration determinor.

7. A method as in claim 4 wherein, when the analysis detects inappropriate input from one of multiple independent determinors, automatically adjusting the analysis to a basis of one less determinor.

8. A method as in claim 7, including automatically implementing back-up inspection of goods associated with the inappropriate input from the one determinor.

9. A method as in claim 1 including detecting the target parameter using respective at least first, second, and third separate and distinct replications of determinations for at least first and second parameters at respective replication sites on the unit of goods.

10. A method as in claim 9, including processing the determination signals from the respective first and second parameters so as to use respective first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

11. A method as in claim 1, including detecting the target parameter using first and second separate and distinct sensors.

12. A method as in claim 1, including detecting the target parameter using first and second separate and distinct sensors selected from the group consisting of electric eye sensors, infrared sensors, motion sensors, temperature sensors, cameras, and light sensors.

13. A method as in claim 1, processing of the determination signals comprising determining the number of the signals, for the unit of goods, having common or nearly common signal duration.

14. A method as in claim 1, processing of the determination signals comprising computing a standard deviation based on the determination signals.

15. A method as in claim 1 wherein, when analysis of the determination signals comprises concluding that a given one of the determination signals is erroneous, the method includes modifying the signal combination to compensate for the erroneous signal.

16. A method as in claim 1, including comparing the signal combination to an existing database of signal combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

17. A method as in claim 16, including transmitting the response as a control signal to a process controller controlling the manufacturing operation.

18. A method as in claim 1, including comparing the signal combination to an existing database of signal combinations, including a historical probability of the occurrence of respective ones of the combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

19. A method as in claim 1, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the first and second replications are taken at a common such work station.

20. A method as in claim 1, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the second replication is taken at a work station downstream of the work station at which the first replication is taken.

21. A method as in claim 1, the manufacturing operation fabricating units of goods, the method further comprising so analyzing sequential ones of the units of goods.

22. A method of measuring a parameter of goods during fabrication of such goods in a manufacturing operation, the method comprising:

(a) establishing a target parameter to be measured on respective units of the goods, and acceptable conditions of the target parameter;

(b) developing a measurement strategy for measuring the target parameter;

(c) detecting, in real time, the target parameter in a unit of the goods at a given stage of development of the target parameter on the goods, with respective at least first and second separate and distinct sensors, and thereby developing respective at least first and second separate and distinct real time replicate determination signals representative of the target parameter in the unit of goods;

(d) subsequent to developing the measurement strategy, programming a user-programmable computer so as to utilize an analysis method computatively consistent with the measurement strategy to evaluate accuracy of the determination signals;

(e) transmitting the determination signals to the user-programmable computer so as to provide the computer with first and second separate and distinct determination signals; and

(f) analyzing the determination signals in combination, in the user-programmable computer, for conformity of the unit of goods to the established acceptable conditions, utilizing the respective analysis method.

23. A method as in claim 22, including detecting the target parameter with respective at least first and second separate and distinct sensors for at least first and second parameters at respective duplicative sites on the unit of goods.

24. A method as in claim 23, including processing the determination signals so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

25. A method as in claim 22, including detecting the target parameter in the unit of goods using respective at least first, second, and third separate and distinct sensors.

26. A method as in claim 25, processing of the determination signals comprising computing an average of the signals.

27. A method as in claim 25 wherein, when the analysis detects an out-of-calibration condition in one of the sensors, automatically recalibrating the out-of-calibration sensor.

28. A method as in claim 25 wherein, when the analysis detects inappropriate input from one of multiple independent sensors, automatically adjusting the analysis to a basis of one less sensor.

29. A method as in claim 28, including automatically implementing back-up inspection of goods associated with the inappropriate input from the one sensor.

30. A method as in claim 22 including detecting the target parameter in the unit of goods using respective at least first, second, and third separate and distinct sensors for at least first and second parameters at respective replication sites on the unit of goods.

31. A method as in claim 30, including processing the determination signals from the respective first and second parameters so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

32. A method as in claim 22, including detecting the target parameter using first and second separate and distinct sensors selected from the group consisting of electric eye sensors, infrared sensors, motion sensors, temperature sensors, cameras, and light sensors.

33. A method as in claim 22, processing of the determination signals comprising determining the number of the signals, for the unit of goods, having common or nearly common signal duration.

34. A method as in claim 22, processing of the determination signals comprising computing a standard deviation based on the determination signals.

35. A method as in claim 22 wherein, when processing of the determination signals results in concluding that a given one of the determination signals is erroneous, the method includes modifying the signal combination to compensate for the erroneous signal.

36. A method as in claim 22, including comparing the signal combination to an existing database of signal combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

37. A method as in claim 36, including transmitting the response as a control signal to a process controller controlling the manufacturing operation.

38. A method as in claim 22, including comparing the signal combination to an existing database of signal combinations, including a historical probability of the occurrence of respective ones of the combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

39. A method as in claim 22, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the first and second replications are taken at a common such work station.

40. A method as in claim 22, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the second replication is taken at a work station downstream of the work station at which the first replication is taken.

41. A method as in claim 22, the manufacturing operation fabricating units of goods, the method further comprising so analyzing sequential ones of the units of goods.

42. A method of measuring a parameter of an absorbent article during fabrication of such absorbent article in a manufacturing operation manufacturing such absorbent articles, the method comprising:

(a) establishing a target parameter to be measured on respective units of the absorbent articles, and acceptable conditions of the target parameter;

(b) developing a measurement strategy for measuring the target parameter;

(c) detecting, in real time, the target parameter on a respective absorbent article at a given stage of development of the target parameter on the goods, with respective at least first and second separate and distinct sensors, and thereby developing respective at least first and second separate and distinct real time replicate determination signals representative of the target parameter on the respective absorbent articles;

(d) subsequent to developing the measurement strategy, programming a user-programmable computer so as to utilize an analysis method which enables user-programmable computer assessment of determination signals from determinors to evaluate accuracy of the determination signals;

(e) transmitting the determination signals to the user-programmable computer so as to provide the computer with first and second separate and distinct determination signals; and

(f) analyzing the determination signals in combination, in the user-programmable computer, for conformity of the respective absorbent article to the established acceptable conditions, utilizing the respective analysis method.

43. A method as in claim 42, including detecting the target parameter with respective at least first and second separate and distinct sensors for at least first and second parameters at respective duplicative sites on the respective absorbent article.

44. A method as in claim 43, including processing the determination signals so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

45. A method as in claim 42, including detecting the target parameter in the respective absorbent article using respective at least first, second, and third separate and distinct sensors.

46. A method as in claim 45, processing of the determination signals comprising computing an average of the signals.

47. A method as in claim 45 wherein, when the analysis detects an out-of-calibration condition in one of the sensors, automatically recalibrating the out-of-calibration sensor.

48. A method as in claim 45 wherein, when the analysis detects inappropriate input from one of multiple independent sensors, automatically adjusting the analysis to a basis of one less sensor.

49. A method as in claim 48, including automatically implementing back-up inspection of goods associated with the inappropriate input from the one sensor.

50. A method as in claim 42, including detecting the target parameter in the respective absorbent article using respective at least first, second, and third separate and distinct sensors for at least first and second parameters at respective replication sites on the respective absorbent article.

51. A method as in claim 50, including processing the determination signals from the respective first and second parameters so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

52. A method as in claim 42, including detecting the target parameter using first and second separate and distinct sensors selected from the group consisting of electric eye sensors, infrared sensors, motion sensors, temperature sensors, cameras, and light sensors.

53. A method as in claim 42, processing of the determination signals comprising determining the number of signals, for the respective absorbent article, having common or nearly common signal duration.

54. A method as in claim 42, processing of the determination signals comprising computing a standard deviation based on the determination signals.

55. A method as in claim 42 wherein, when the analysis of the determination signals results in concluding that a given one of the determination signals is erroneous, the method includes modifying the signal combination to compensate for the erroneous signal.

56. A method as in claim 42, including comparing the signal combination to an existing database of signal combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

57. A method as in claim 56, including transmitting the response as a control signal to a process controller controlling the manufacturing operation.

58. A method as in claim 42, including comparing the signal combination to an existing database of signal combinations, including a historical probability of the occurrence of respective ones of the combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

59. A method as in claim 42, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the first and second replications are taken at a common such work station.

60. A method as in claim 42, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the second replication is taken at a work station downstream of the work station at which the first replication is taken.

61. A method as in claim 42, the manufacturing operation fabricating absorbent articles units, the method further comprising so analyzing sequential ones of the absorbent articles.

62. A method of measuring a parameter of an absorbent article during fabrication of such absorbent article in a manufacturing operation manufacturing such absorbent articles, the method comprising:

(a) establishing a target parameter to be measured on respective units of the absorbent articles, and acceptable conditions of the target parameter;

(b) detecting, in real time, the target parameter on a respective absorbent article at a given stage of development of the target parameter on the goods, with respective at least first and second separate and distinct sensors, and thereby developing respective at least first and second separate and distinct real time replicate determination signals representative of the target parameter on the respective absorbent article;

(c) transmitting the determination signals to a controller so as to provide the controller with first and second separate and distinct determination signals; and

(d) analyzing the determination signals in combination, in the controller, for conformity of the respective absorbent article to the established acceptable conditions, utilizing an analysis method other than averaging the respective determination signals, wherein such analysis method is capable of assessing accuracy of determinor sensory input pertaining to the target parameters.

63. A method as in claim 62, including detecting the target parameter with respective at least first and second separate and distinct sensors for at least first and second parameters at respective duplicative sites on the respective absorbent article.

64. A method as in claim 63, including processing the determination signals so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

65. A method as in claim 62, including detecting the target parameter in the respective absorbent article using respective at least first, second, and third separate and distinct sensors.

66. A method as in claim 65 wherein, when the analysis detects an out-of-calibration condition in one of the sensors, automatically recalibrating the out-of-calibration sensor.

67. A method as in claim 65 wherein, when the analysis detects inappropriate input from one of multiple independent sensors, automatically adjusting the analysis to a basis of one less sensor.

68. A method as in claim 67, including automatically implementing back-up inspection of goods associated with the inappropriate input from the one sensor.

69. A method as in claim 62, including detecting the target parameter in the respective absorbent article using respective at least first, second, and third separate and distinct sensors for at least first and second parameters at respective replication sites on the respective absorbent article.

70. A method as in claim 69, including processing the determination signals from the respective first and second parameters so as to use first and second different analytical methods to analyze the determination signals representative of the respective first and second parameters.

71. A method as in claim 62, including detecting the target parameter using first and second separate and distinct sensors selected from the group consisting of electric eye sensors, infrared sensors, motion sensors, temperature sensors, cameras, and light sensors.

72. A method as in claim 62, processing of the determination signals comprising determining the number of the signals, for the respective absorbent article, having common or nearly common signal durations.

73. A method as in claim 62, processing of the determination signals comprising computing a standard deviation based on the determination signals.

74. A method as in claim 62 wherein, when the analysis of the determination signals results in concluding that a given one of the determination signals is erroneous, the method includes modifying the signal combination to compensate for the erroneous signal.

75. A method as in claim 62, including comparing the signal combination to an existing database of signal combinations, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

76. A method as in claim 75, including transmitting the response as a control signal to a process controller controlling the manufacturing operation.

77. A method as in claim 62, including comparing the signal combination to an existing database of signal combinations, including a historical probability of the occurrence of respective ones of the combinations in such absorbent articles, and based on the comparison, developing a conclusion as to cause of anomaly in the signal combination, and developing a corresponding response to the signal combination.

78. A method as in claim 62, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the first and second replications are taken at a common such work station.

79. A method as in claim 62, the manufacturing operation comprising a manufacturing line having a plurality of work stations, and wherein the second replication is taken at a work station downstream of the work station at which the first replication is taken.

80. A method as in claim 62, the manufacturing operation fabricating units of goods, the method further comprising so analyzing sequential ones of the units of the goods.