Systems and methods for enabling and disabling operation of manufacturing machines

A system for enabling and disabling operation of manufacturing machines provides a manufacturing machine user interface that facilitates receiving quality control information regarding the manufacturing machine from a user. For quality assurance purposes, the computer system of the manufacturing machine may decide whether to enable operation of the manufacturing machine based on the received quality control information. The computer system of the manufacturing machine may also decide to disable operation of the manufacturing machine if the quality control information provided is incomplete, out of date, or otherwise insufficient to indicate the manufacturing machine is ready for safe and effective operation. In some embodiments, one or more client systems, telecommunications devices, and/or personal digital assistant (PDA) devices on which the user interface is displayed and with which the manufacturing machine is in communication may enable operation of the manufacturing machine based on the received quality control information.

TECHNICAL FIELD

This disclosure generally relates to manufacturing machines, and particularly to quality control of manufacturing machines.

BRIEF SUMMARY

In one embodiment, a manufacturing machine user interface facilitates receiving quality control information regarding the manufacturing machine from a user. For quality assurance purposes, the computer system of the manufacturing machine may decide whether to enable operation of the manufacturing machine based on the received quality control information. The computer system of the manufacturing machine may also decide to disable operation of the manufacturing machine if the quality control information provided is incomplete, out of date, or otherwise insufficient to indicate the manufacturing machine is ready for safe and effective operation. In some embodiments, one or more client systems, telecommunications devices, and/or personal digital assistant (PDA) devices on which the user interface is displayed and with which the manufacturing machine is in communication may enable operation of the manufacturing machine based on the received quality control information.

DETAILED DESCRIPTION

FIG. 1is an overview block diagram illustrating an example networked environment100, including a number of servers, clients and manufacturing machines communicatively coupled to each other by one or more networks, of which systems and methods for enabling and disabling operation of manufacturing machines may be a part, or in which they may be implemented, according to one illustrated embodiment.

Before providing additional details regarding the operation and constitution of methods and systems for enabling and disabling operation of manufacturing machines, the example networked environment100, within which a manufacturing machine may operate, will briefly be described.

The networked environment100includes a number of server computing systems102a-102n(collectively102). The server computing systems102include processors that execute server instructions (i.e., server software) stored on computer-readable storage media to provide server functions in the networked environment100. For example, the server computing systems102may electronically receive, store, generate, analyze, track and transmit quality control information regarding one or more of the manufacturing machines103a-103non the network108. This quality control information regarding one or more of the manufacturing machines may be stored in one or more databases or other computer-readable storage media104a-104n(collectively104). The quality control information regarding one or more of the manufacturing machines103a-103nincludes, but is not limited to, information regarding one or more of: maintenance records, inspection records, certifications, standards, quality assurance, manufacturing machine training, quality goals, manufacturing machine documentation, manufacturing machine conformance, manufacturing machine compliance, manufacturing machine history information, manufacturing machine standards, quality standards, manufacturing machine warranties, operator qualifications and certifications, manufacturing machine monitoring, health and safety requirements, manufacturing policies, manufacturing machine operational readiness, manufacturing machine performance records, operator credentials, etc.

The networked environment100includes a number of client computing systems106a-106n(collectively106) selectively communicatively coupled to one or more of the server computing systems102and/or manufacturing machines103a-103nvia one or more communications networks108. The client computing systems106include one or more processors that execute one or more sets of communications instructions stored on any of a variety of non-transitory computer-readable storage media110(only one illustrated inFIG. 1). The client computing systems106may take a variety of forms, for instance desktop, laptop or notebook personal computers, tablet computers, workstations, mini-computers, mainframe computers, or other computational devices with microprocessors or microcontrollers which are capable of networked communications. The client computing systems106may be communicatively coupled to the rest of the network108via wired, wireless or a combination of wired and wireless communications channels.

The manufacturing machines103a-103nmay include machines configured to manufacture any physical product or parts of products and/or perform any physical process. For example, one or more of the manufacturing machines103a-103nmay be located on a factory floor of a manufacturer or processing plant of one or more of said products or parts of products. Also, one or more of the manufacturing machines103a-103nmay be located at different manufacturing or processing facilities. The one or more of the manufacturing machines103a-103nmay also be different manufacturing machines configured to make different products and perform different processes.

The networked environment100includes a number of telecommunications devices111(only one illustrated). Such telecommunications devices111may, for example, take the form of Internet or Web enabled cellular phones or smart phones (e.g., iPHONE®). The networked environment100also includes a number of personal digital assistant (PDA) devices112(only one illustrated). Such PDA devices112may, for example, take the form of Internet or Web enabled PDAs or tablet computers (e.g., iPHONE®, iPAD®, TREO®, BLACKBERRY®), which may, for example, execute a set of browser instructions or program or other networking program. The networked environment100may include any number of a large variety of other devices that are capable of some type of networked communications. The telecommunications devices110, PDA devices112, as well as any other devices, may be communicatively coupled to the rest of the network108via wired, wireless or a combination of wired and wireless communications channels.

The one or more communications networks108may take a variety of forms. For instance, the communications networks108may include wired, wireless, optical, or a combination of wired, wireless and/or optical communications links. The one or more communications networks108may include public networks, private networks, unsecured networks, secured networks or combinations thereof. The one or more communications networks108may employ any one or more communications protocols, for example TCP/IP protocol, UDP protocols, IEEE 802.11 protocol, as well as other telecommunications or computer networking protocols. The one or more communications networks108may include what are traditionally referred to as computing networks and/or what are traditionally referred to as telecommunications networks or combinations thereof. In at least one embodiment, the one or more communications networks108includes the Internet, and in particular, the Worldwide Web or (referred to herein as “the Web”). Consequently, in at least one embodiment, one or more of the server computing systems102execute server software to serve HTML source files or Web pages114a-114d(collectively114), and one or more client computing systems106, telecommunications devices110and/or PDAs112execute browser software to request and display HTML source files or Web pages114.

The networked environment100includes an interactive system for electronically for enabling and disabling operation of the manufacturing machines103a-103n. The interactive system electronically for enabling and disabling operation of the manufacturing machines1-3a-103nmay include one or more server computing systems102, databases104and one or more client systems106, telecommunications devices111, and/or PDA devices112.

The one or more server computing systems102execute instructions stored on non-transitory computer-readable storage media that cause the server computing systems102to electronically receive, store, generate, track, act on, analyze and transmit quality control information regarding one or more of the manufacturing machines103a-103nwith respect to and/or between one or more client systems106, telecommunications devices111, manufacturing machines103a-103n, and/or PDA devices112, and provide communications during or in connection with such services to and between one or more client systems106, telecommunications devices111, manufacturing machines103a-103n, and/or PDA devices112. One or more of the client systems106, telecommunications devices111, manufacturing machines103a-103n, and/or PDA devices112may instead or also execute instructions stored on non-transitory computer-readable storage media that cause such devices to electronically receive, store, generate, track, act on, analyze and transmit quality control information regarding one or more of the manufacturing machines103a-103nwith respect to and/or between one or more other client systems106, telecommunications devices111, manufacturing machines103a-103nand/or PDA devices112, and provide communications during or in connection with such services to and between one or more client systems106, telecommunications devices111, manufacturing machines103a-103nand/or PDA devices112.

Although not required, the embodiments will be described in the general context of computer-executable instructions, such as program application engines, objects, or macros stored on computer- or processor-readable storage media and executed by a computer or processor. Those skilled in the relevant art will appreciate that the illustrated embodiments as well as other embodiments can be practiced with other affiliated system configurations and/or other computing system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, personal computers (“PCs”), network PCs, mini-computers, mainframe computers, and the like. The embodiments can be practiced in distributed computing environments where tasks or acts are performed by remote processing devices, which are linked through a communications network. In a distributed computing environment, program engines may be located in both local and remote memory storage devices.

One or more of the manufacturing machines103a-103nmay include one or more processors, computers, memories and/or controllers, either integrated with the respective manufacturing machine or coupled to the respective manufacturing machine as one or more peripheral devices. The one or more processors, computers, memories and/or controllers are configured to execute instructions stored on non-transitory computer-readable storage media that cause the respective manufacturing machine to electronically receive, store, generate, track, act on, analyze and transmit quality control information regarding one or more of the manufacturing machines103a-103nwith respect to and/or between one or more client systems106, telecommunications devices111, manufacturing machines103a-103n, and/or PDA devices112; provide communications during or in connection with such services to and between one or more client systems106, telecommunications devices111, manufacturing machines103a-103n, and/or PDA devices112; and provide a user interface for facilitating performance of such functions.

FIG. 2is a diagram of an example manufacturing machine user interface200, according to one illustrated embodiment. For example, the manufacturing machine user interface200may be a user interface of one or more of the manufacturing machines103a-103n(e.g., manufacturing machine103a). The manufacturing machine user interface200may be generated and/or presented by the manufacturing machine103aon a local display of the manufacturing machine103aand/or may be generated and/or presented on a display of one or more of the client systems106, telecommunications devices111, and/or PDA devices112.

The manufacturing machine user interface200provides an interface that facilitates receiving of quality control information regarding the manufacturing machine103afrom a user. For quality assurance purposes, the computer system of the manufacturing machine103amay decide whether to enable operation of the manufacturing machine based on the received quality control information. In some embodiments, one or more of the more client systems106, telecommunications devices111, and/or PDA devices112on which the user interface200is displayed and with which the manufacturing machine103ais in communication may enable operation of the manufacturing machine based on the received quality control information.

The user interface200includes user interface elements such as an authentication dialog box202, a Quality Control Queries dialog box204, a Quality Control Query Answers dialog box206, a Provide Quality Control Documentation208dialog box, and a “Confirm” button312. Various other embodiments may include the same, fewer or more user interface elements displayed in different configurations for receiving input of quality control information from a user.

The authentication dialog box202is configured to receive input from a user such as a PIN, password, user name, biometric data or other user credentials to identify an authorized user of the manufacturing machine or quality control system. For example, particular users may be certified or otherwise identified as authorized to input required quality control information to enable operation of the manufacturing machine103a. In some embodiments, any authorized operator of the manufacturing machine may be authenticated and authorized to input the required quality control information to enable operation of the manufacturing machine103a. Also, in embodiments, where the manufacturing machine user interface200is configured to be displayed on one or more of the client systems106, telecommunications devices111, and/or PDA devices112, a manufacturing machine ID may be required to be input to the authentication dialog box202to identify for which particular manufacturing machine the quality control information is being input, such as to enable operation of that particular manufacturing machine. The manufacturing authentication dialog box202also displays a manufacturing machine current status. The manufacturing authentication dialog box202shows an initial or default status of “locked” (indicating operation of the manufacturing machine103ais being prevented) because the required quality control information has yet to be input and verified by the manufacturing machine103aor one or more server systems102, client systems106, telecommunications devices111, and/or PDA devices112.

The quality control queries of the Quality Control Queries dialog box204may include one or more queries related to the quality control information required to enable operation of the manufacturing machine103a. For example, the query may be regarding whether and/or when the most recent inspection had taken place, particular upgrades had been performed, required maintenance had been performed, etc. Other queries may instead or in addition be regarding quality control information including, but not limited to, information regarding one or more of: maintenance records, inspection records, certifications, standards, quality assurance, manufacturing machine training, quality goals, manufacturing machine documentation, manufacturing machine conformance, manufacturing machine compliance, manufacturing machine history information, manufacturing machine standards, quality standards, manufacturing machine warranties, operator qualifications, manufacturing machine monitoring, health and safety requirements, manufacturing policies, company manufacturing policies, manufacturing machine operational readiness, manufacturing machine performance records, operator credentials, etc. The Quality Control Query Answers dialog box206is configured to receive answers to such queries such as in the form a yes/no answer, dates an action or check had been performed, other information related to the query, etc.

The Provide Quality Control Documentation dialog box208is configured to facilitate input of entire records or portions of entire records containing quality control information, whether they are in electronic format, printed documents, or other standard or non-standard format. For example, if the user interface200is being displayed on one or more of the server systems102, client systems106, telecommunications devices111, and/or PDA devices112with which the manufacturing machine103ais in communication, then a user of such a device may have stored on that device particular records which may be uploaded directly to the manufacturing machine103a or to one or more server systems102using the Provide Quality Control Documentation dialog box208. Furthermore, if the user interface200is being presented on a display of the manufacturing machine103a, the manufacturing machine103amay have a scanner, document reader, smart card reader, near field communication (NFC) reader, radio frequency identification reader (RFID), etc., to read printed or electronic documents directly from a compatible external source. In some embodiments, one or more of the client systems106, telecommunications devices111, and/or PDA devices112may also include such a scanner, document reader, smart card reader, NFC reader, RFID reader, etc., to read printed or electronic documents directly from an external source. The Provide Quality Control Documentation dialog box208may have further submenus for the user to indicate, specify, and or select other quality control records to be input or to make an inquiry regarding which records are required to enable operation of the manufacturing machine103a.

Once the required quality control information has been entered, uploaded, input or otherwise provided by the user via the manufacturing machine user interface200, then the user may select a “confirm” button312or other selectable user interface element to indicate the user is ready for operation of the manufacturing machine103ato be enabled.

The manufacturing machine103a, or one or more of the server systems102, client systems106, telecommunications devices111, and/or PDA devices112with which the manufacturing machine103ais in communication, then verifies the provided quality control information that had been entered, uploaded, input or otherwise provided by the user. For example, such verification may include comparing the provided quality control information with stored quality standards related to the required quality control information, checking accuracy of the provided quality control information, verifying authenticity of the provided quality control information, verifying credentials of the user, etc., providing the provided quality control information for manual inspection, replying via the user interface with follow-up queries or requests for additional information, etc. For example, if a date entered by a user of the most recent particular upgrade to the manufacturing machine is older than a stored date set and a threshold standard, then the provided quality control information may be deemed insufficient to enable operation of the particular manufacturing machine103afor which the quality control data was provided. The provided quality control data would therefore not be accepted to enable operation of the particular manufacturing machine103a.

On the other hand, if the date entered by a user of the most recent particular upgrade to the manufacturing machine is equal to or more recent than the stored date set as the threshold, then the provided quality control information may be deemed sufficient to enable operation of the particular manufacturing machine103afor which the quality control data was provided. The provided quality control data would therefore be accepted to enable operation of the particular manufacturing machine103a.

FIG. 3is a diagram of the example manufacturing machine user interface200ofFIG. 2after the quality control information has been accepted, according to one illustrated embodiment.

Shown is the example manufacturing machine user interface200including an “Information Accepted” dialog box302indicating that the quality control information previously entered is deemed sufficient to enable operation of the particular manufacturing machine103a. Note that since the quality control information previously entered is deemed sufficient to enable operation of the particular manufacturing machine103a, the current status of the manufacturing machine103ais displayed on the user interface200as being operational. For example, a computer processor or controller of the manufacturing machine103amay have generated and/or received a signal activating a switch or other electronic or mechanical device to enable operation of the mechanical elements of the manufacturing machine103a. Also shown is an “operate machine” button304that when selected causes the manufacturing machine user interface to display the normal operation interface, if any, of the manufacturing machine103a.

FIG. 4is a diagram of the example manufacturing machine user interface200ofFIG. 2after the quality control information has not been accepted, according to one illustrated embodiment.

Shown is the example manufacturing machine user interface200including an “Information Not Accepted” dialog box402indicating that the quality control information previously provided is deemed insufficient to enable operation of the particular manufacturing machine103a. The “Information Not Accepted” dialog box402may also indicate specific parts, categories, or types of the provided quality control information that was deemed insufficient, or that was missing (e.g., “XYZ” information). Note that since the quality control information previously entered is deemed insufficient to enable operation of the particular manufacturing machine103a, the current status of the manufacturing machine103ais displayed on the user interface200as being locked. For example, a computer processor or controller of the manufacturing machine103amay have generated and/or received a signal activating a switch or other electronic or mechanical device to disable operation of the mechanical elements of the manufacturing machine103a. This may occur in instances where quality control information is required during operation of the manufacturing machine103a. In other embodiments, if the manufacturing machine103awas already in a locked state, the manufacturing machine103amay have done nothing to change the current state from locked to operational if the provided quality control information was not accepted.

Also shown is a “Provide XYZ Information” button404that, when selected, causes the manufacturing machine user interface200to display an interface that allows the user to input the required quality control information such as the user interface shown inFIG. 2or another user interface customized to provide the required incorrect or missing “XYZ” information. Also, additional information regarding why the provided quality control information was not accepted may also be displayed on the user interface200.

FIG. 5is a flow diagram of a method500of deciding whether to enable operation of a manufacturing machine, according to one illustrated embodiment.

At502, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, receives quality control information regarding the manufacturing machine103a.

At504, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, decides whether to enable operation of the manufacturing machine based on the received quality control information.

FIG. 6is a flow diagram of a method600showing a portion of the method500ofFIG. 5in more detail, according to one illustrated embodiment. In particular, step502of deciding whether to enable operation of the manufacturing machine based on the received quality control information is shown in more detail in the method600ofFIG. 6.

At602, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, compares the received quality control information to a quality standard.

At604, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, determines whether the received quality control information meets the quality standard.

At606, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, decides not to enable operation of the manufacturing machine103aif the received quality control information does not meet the quality standard.

At608, the manufacturing machine103a, or one of the server systems102, client systems106, telecommunications devices111, or PDA devices112, decides to enable operation of the manufacturing machine103aif the received quality control information does meet the quality standard.

FIG. 7is a flow diagram of a method of providing quality control information regarding a manufacturing machine, according to one illustrated embodiment.

At702, one of the server systems102, client systems106, telecommunications devices111, or PDA devices112receives a request from a manufacturing machine for quality control information regarding the manufacturing machine and provides the requested quality control information regarding the manufacturing machine to the manufacturing machine. For example, manufacturing machine may request such information to in order to enable operation of the manufacturing machine at the request of a user.

At704, one of the server systems102, client systems106, telecommunications devices111, or PDA devices112receives a request from the manufacturing machine for information indicative of a quality standard specific to the manufacturing machine and provides the requested information indicative of the quality standard specific to the manufacturing machine. For example, manufacturing machine may request such information to in order to verify, check, certify or validate the received quality control information to enable operation of the manufacturing machine. Also, manufacturing machine may request compliance information regarding the manufacturing machine produced by the server system if the server system had already performed the verifying, checking, certifying and/or validating of the quality control information and had stored the results as the compliance information.

While various embodiments have been described hereinabove, it is to be appreciated that various changes in form and detail may be made without departing from the spirit and scope of the invention(s) presently or hereafter claimed. The various embodiments described above can be combined to provide further embodiments. Accordingly, the claims are not limited by the disclosure.