Method and apparatus for monitoring the processing of articles

A method and apparatus is provided for monitoring the processing of a group of articles having different properties, for example differing weights and/or quality grades. The method includes the steps of obtaining information about the differing properties of the group, using this information to provide a main visual model of the property distribution within the group, and providing a first subsidiary visual model relating to the processing of a first sub-group of articles from within the group, the provision of the first subsidiary model causing a modified form of the main visual model to appear, related to the remaining articles of the group after removal of the articles forming the first sub-group. The method is particularly effective for use in monitoring the processing of poultry carcasses being conveyed in succession along a path, for sorting by weight and grade of carcass. The method may be used in advance of processing, to run a test as to what might happen during processing according to different parameters, and it can also be used during actual processing, to monitor what is actually happening, against a target time, numbers and maximum processing capacities.

The invention relates to a method of monitoring the processing of a group
 of articles, the articles of the group having differing properties, for
 example having differing weights and/or differing quality grades.
 The method and apparatus have been developed for use in monitoring the
 processing of poultry carcasses being conveyed in succession along a path,
 for sorting by weight and grade of carcass, and one example of a
 processing apparatus with which the method and apparatus of the present
 invention could be used is disclosed in GB-1,603,860. However, the method
 and apparatus are not restricted in their use to poultry carcass
 processing systems and could have useful application in the processing of
 many different types of article. Other types of food article may include
 lamb or pork.
 The invention has been developed because the processing of poultry
 carcasses presents many problems. Any given flock of birds to be processed
 will not be absolutely identical to the previous flock and there will be
 many variations without the group as to weight and quality of carcass.
 Furthermore, the way in which a given flock is to be processed will vary
 from day to day, and may vary during a day. One reason for this is that
 customer requirements vary and one customer may require a first number of
 carcasses within one weight range, and a different customer may require a
 different number of carcasses lying within a different weight range. These
 weight ranges may overlap. Some orders will have a higher priority than
 others and trying to ensure that the varying demands are matched with the
 supply provided by a given flock is very difficult.
 The invention provides a method of monitoring the processing of a group of
 articles having differing properties, for example having differing weights
 and/or quality grades, the method comprising the steps of obtaining
 information about the differing properties of the group, using this
 information to provide a main visual model of the property distribution
 within the group, and providing a first subsidiary visual model relating
 to the processing of a first sub-group of articles from within the group,
 the provision of the first subsidiary model causing a modified form of the
 main visual model to appear, related to the remaining articles of the
 group after removal of the articles forming the first subgroup.
 The method may be used in advance of processing, to run a test as to what
 might happen during processing according to different parameters, and it
 can also be used during actual processing, to monitor what is actually
 happening, against target time, numbers and maximum processing capacities.
 The method could also be used after processing, to review what did happen.
 The first step may be achieved by using known statistical data relating to
 the relevant group, by random sampling of the actual group, or in any
 other desired manner. For example, given flocks of birds from a given farm
 may have weight distributions and quality distributions which are fairly
 consistent, and so a reasonably reliable databank of statistics may be
 built up and used.
 Preferably the method comprises the step of providing at least a second
 subsidiary visual model relating to the process of a second sub-group of
 articles from within the group, the provision of the second subsidiary
 model causing a second modified form of the main visual model to appear,
 related to the remaining articles of the group after removal of the
 articles from the first and second sub-groups.
 Preferably the first sub-group of articles will relate to the highest
 demand priority.
 The method enables a series of demand parameters to be worked through, in
 order of priority, and after each demand priority has been selected, the
 user of the method has a visual indication of the property profile of the
 remaining articles, to assist in selecting subsequent demands of lower
 priority.
 The main visual model may comprise a graph.
 The graph may for example be a line graph or a bar graph.
 Alternatively, or in addition, a numerical visual model may be provided.
 Preferably the or each modified form of the visual model is numerical.
 The method may be such that the main visual model remains in view, in
 addition to the modified forms of the main visual model.
 The, or each, subsidiary visual model relating to the processing of a
 sub-group of articles may comprise a band width spanning the desired range
 of properties.
 For example, the properties may be represented as weight bands, the
 preselected band width comprising a visual indicator extending across the
 optimum desired weight band.
 The indicator may comprise a horizontal bar.
 The indicator may be extendable at one or both ends, when it is permissible
 to fill a given demand with articles which vary slightly from the optimum,
 when insufficient articles having the optimum property are available.
 When, in a practical situation, a given form of processing within the group
 has to be changed or stopped, the method may include highlighting the
 relevant visual indicator to warn the user what is happening.
 Where the indicator comprises a horizontal bar, the nature of the bar may
 change when processing is altered or stopped.
 For example a solid bar may be used in normal conditions, with the bar
 becoming hollow when processing changes or stops.
 When one form of processing within the group is changed or stopped, this
 can have a dramatic effect on further processing downstream. For example
 too many articles may suddenly reach a given processing point causing
 jamming or other difficulties.
 The method may include means to provide a visual model of the consequent
 effect of changing or stopping one aspect of the processing.
 For example the method may cause a visual model to be created showing
 articles rapidly bunching up and jamming.
 The method may be such that a visual model can be provided of what is
 happening at certain particular processing points. For example, where the
 method is being used to monitor the processing of poultry carcasses,
 linked with an apparatus such as that shown in GB-1,603,860, it may be
 possible to monitor what is happening at each individual carcass drop-off
 point.
 The method defined above is particularly effective in monitoring the
 processing of poultry carcasses being conveyed in succession along a path.
 The carcasses being processed during any given time period, for example one
 day, may well be drawn from several different flocks of birds being
 delivered to a poultry processing plant during that time period.
 We have appreciated that by controlling the order in which flocks are
 processed, independence on processing requirements during the time period,
 processing efficiency can be improved and the likelihood of processing
 problems occurring can be reduced.
 Accordingly, a preferred aspect of the method according to the invention
 comprises obtaining information about sub-groups of articles being
 received for processing, comparing this information with processing steps
 to be carried out, and using this comparison to select the order in which
 sub-groups are processed.
 The invention includes apparatus for carrying out the method of the
 invention.
 The apparatus may comprise an appropriately programmed computer and a
 visual display unit on which the visual models appear.
 The computer, and the visual display unit, may be a stand alone system, or
 it may be part of the overall computer system which controls and operates
 the processing equipment.

FIG. 1 illustrates an embodiment of visual model for use in planning and
 monitoring the processing of articles using a conveyor system such as that
 disclosed in GB-1,603,860, the contents of which are incorporated herein
 by reference.
 The method according to this embodiment is related to the sorting of a
 plurality of poultry carcasses by weight and grade.
 A particular flock of birds will be sorted and processed according to the
 requirements of various customers. Requirements on products to be produced
 from the same flock may include carcasses graded as small, medium and
 large, and these carcasses may be required whole or cut up into pieces.
 FIG. 1 represents the screen of a visual display unit and at the start of
 the method a visual profile of the weight properties of the flock is
 entered at the top of the screen and is represented by the graphical line
 10.
 Below this graphical line 10, the screen is divided up into any desired
 weight bands by vertical lines 11.
 Projected demands are entered on the screen using horizontal bands such as
 12. In this example the band 12 represents the demand of highest priority
 where no deviation from the preset parameters is permitted. With some
 lower priority demands, such as 13, 14 and 15, some deviation may be
 permitted if there are insufficient birds having the desired weight
 parameters to fill the main criteria. It will be seen for example that
 band 13 comprises one long band and two smaller bands at one end of the
 long band. This indicates that if necessary the band can be extended at
 one end. The band 14 can be extended at both ends.
 FIG. 2 shows an almost identical arrangement except that the supply graph
 10 is represented as a bar graph, rather than a line graph.
 In addition to the graphical representations of FIGS. 1 and 2, with regard
 to supply, the information is also represented numerically by a line of
 figures 16 immediately below the graph. It is not essential that the
 information be represented both graphically and numerically and in the
 embodiment of FIG. 3, the information is purely numerical.
 FIG. 3 also illustrates how the method is used to set up a complete visual
 representation of, for example, a whole day's production.
 The band 12 representing the highest priority is entered first and this
 causes the numerical figures of line 16 to be re-calculated to represent
 the remaining supply, and these figures appear on the screen immediately
 below band A. As the successive bands 13, 14, 15 and so on are entered on
 the screen, the remaining supply figures are re-calculated each time and
 reappear below the latest priority that has been entered.
 In FIG. 3 about half the screen has been completed and the re-calculated
 figures appear at line 17 immediately below the last entered band, shown
 at 18.
 The method enables an operator who was planning the day's production to see
 at each stage the details of the remaining supply to enable the operator
 to assess the ability to meet the demand of next priority.
 The method may be adapted to deal also with the supply and demand of
 carcasses of a specific grade and in FIG. 1 the upper graph line 19
 provides a visual representation of grade supply.
 On occasions, it becomes necessary to shut down part of a processing line,
 for example because of a malfunction at a particular operating station.
 The method according to the invention enables the operator to receive a
 visual indication that this has happened. In this embodiment, the
 cessation of an operation is indicated by the relevant band becoming
 hollow, rather than solid, as indicated by the band 12 in FIG. 1.
 It will thus be seen that the method and apparatus according to the
 invention provide much improved planning and control, including real time
 monitoring and reporting.
 Many variations are possible. While the method has been described in
 relation to continuous path processing, with reference to GB-1 603 860,
 the processing may also occur on a conveying system having branch lines.
 This may be particularly applicable to the processing of lamb or pork,
 where portions of meat may be conveyed into sidings for subsequent
 processing.
 While the method has been described by way of example in relation to a
 day's production, other time periods may of course be selected, to cover
 one or more hours, or specific shifts.
 The method according to the invention enables many different parameters to
 be utilised, and the method can cope with information about flock or group
 profile provided from an agricultural department, from previous processing
 information, or from actual sampling, for example by weighing lambs and
 pigs. Information about order consolidation and modifications thereto may
 be received from a sales or planning department. Information about product
 specification may be received from a factory database and information
 about target times may be received from a shipping department. The method
 according to the invention substantially simplifies planning an operation,
 and makes it easier to fill the highest priority orders, while at the same
 time endeavouring to ensure that each production unit on a processing line
 is used to its capacity for maximum efficiency.
 In a poultry processing factory, flocks of birds are being delivered to the
 factory for subsequent processing on a substantially continuous basis. No
 two flocks will be identical and some flocks may be better suited for
 fulfilling certain product order requirements than others.
 During any given time period, for example one day, there will be certain
 key orders that must be fulfilled for major customers. The remaining
 orders may be less important or more flexible in their requirements.
 We have further developed the visual modelling method described above so
 that a user of our method can optimise the chances of satisfying key
 customer orders, while maximizing profitability and reducing the risk that
 unforeseen problems will occur during processing.
 The method involves sophisticated advance production planning including a
 study of the flocks to be processed during a given time period, and
 selecting the optimum order in which to process the flocks on the day of
 production.
 The method examines raw material profiles, critical product requirements,
 and further processing capacity. Comparisons are then used to send birds
 to the most appropriate destination, including sending them to cutting
 regions, further processing, packing and the like.
 The preferred embodiment will now be described in detail with reference to
 FIGS. 4 to 10.
 FIG. 4 provides information generally similar to FIG. 2. Thus there is a
 graph 20 representing the consolidated raw material, from all flocks,
 during the given time period, including, in line 21, the number of birds
 available in certain weight bands.
 Below the graph 20, the requirements of key orders for that time period are
 listed, on lines 22, 23 and 24.
 Column 25 lists the numerical requirements for each order and column 26
 lists the birds available.
 In this example, the availability exactly matches the requirements for the
 first two orders in lines 22 and 23. This suggests a potential problem
 because there is no flexibility, and so column 27 provides a visual
 warning in the form of the lightly shaded boxes 28, 29.
 With the third order, in line 24, there is insufficient capacity and so
 there is definitely going to be a problem, unless the utilised plans are
 changed. This warning is indicated by the darkly shaded box 30 in column
 31.
 Line 32 provides the modified visual model relating to the remaining birds
 of the group, after removal of the birds needed to fulfil the key orders.
 To assist in changing the production schedule, during the pre-planning
 stage, to avoid or reduce potential problems highlighted on the initial
 visual models, arrangements are made to show on-screen the ability of
 flocks to satisfy key orders and an example of such a screen is shown in
 FIG. 5.
 The key order requirements are listed in lines 33, 34 and 35 and
 information about eight different flocks, A to H, is given in columns 36
 to 43.
 Information about the abilities to utilize individual flocks can be
 obtained, for example using the screen shown in FIG. 7, 8 and 9, and an
 analysis of these utilization capabilities enables the production manager
 or planner to revise the plan production schedule for a particular time
 period, for example by changing the order in which flocks will be
 processed. Such a modified production schedule is shown in FIG. 6, where
 the production periods for flocks C and E have been swopped around.
 All the necessary data and software can be loaded onto to common databases
 within the factory, with the information provided on a plurality of
 screens.
 There may for example be a forward planning module available to the
 production manager or planner, a production schedule module available to
 the production supervisor, with certain on-screen information available to
 line supervisors and operatives on the shop floor, for information only or
 with a strictly limited degree of control.
 A typical operational sequence will now be described.
 A Forward Planning
 This takes place well in advance of the related production day (referred to
 as D-day in this example). It is based on a set of assumptions which are
 refined as more data becomes available.
 The flocks planned for D-day are combined into one profile, for example as
 in FIG. 4.
 A demand picture for D-day is built up, starting with the highest priority
 demand.
 Birds remaining are then calculated, for example as in line 32 of FIG. 4,
 and shortages are noted. At this stage reports may be made to
 sales/purchasing departments where necessary.
 It is also possible to carry out "what if" analyses using a selection of
 the screens shown in the figures.
 B. Production Scheduling
 This can involve pre-planning over a period of days prior to D-day and the
 pre-planning may for example take place over a seven day period, taking
 into account production targets, the time at which targets are reached,
 and production capacities.
 During this time the forward plan will be fine tuned, requirements for
 supply and demand will be up-dated, and balances will be re-calculated.
 Eventually a provisional production schedule is initiated, by shuffling
 flocks (where possible) into the best order to satisfy early priorities,
 producing a series of plans (per flock) based on rates, to check balance,
 and using plans to automatically generate processing settings for each
 flock.
 C. Interaction Between A and B
 This takes place on a flock by flock basis, with shaded portions on the
 screens highlighting mismatches, which enables corrective action to be
 taken before a problem occurs. Data may also be released at this stage
 from the production manager/planners level to the production supervisors
 level, for example on the day before D-day.
 D. D-day
 On the actual day of production, fine tuning can take place at the
 production supervisors level, local line controls may be made at the line
 supervisor/operative level on the shop floor, but unexpected major
 variances can also be handled at the production manager/planner level.
 For example at the production supervisor level the production schedule
 visual model is used to monitor production against targets and if
 necessary to make short term corrections.
 The forwarding planning visual model highlights the knock on effects of any
 major changes to supply or demand. This enables managers to decide their
 own degree of intervention when the system highlights variances.
 The reader's attention is directed to all papers and documents which are
 filed concurrently with or previous to this specification in connection
 with this application and which are open to public inspection with this
 specification, and the contents of all such papers and documents are
 incorporated herein by reference.
 All of the features disclosed in this specification (including any
 accompanying claims, abstract and drawings), and/or all of the steps of
 any method or process so disclosed, may be combined in any combination,
 except combinations where at least some of such features and/or steps are
 mutually exclusive.
 Each feature disclosed in this specification (including any accompanying
 claims, abstract and drawings), may be replaced by alternative features
 serving the same, equivalent or similar purpose, unless expressly stated
 otherwise. Thus, unless expressly stated otherwise, each feature disclosed
 is one example only of a generic series of equivalent or similar features.
 The invention is not restricted to the details of the foregoing
 embodiment(s). The invention extends to any novel one, or any novel
 combination, of the features disclosed in this specification (including
 any accompanying claims, abstract and drawings), or to any novel one, or
 any novel combination, of the steps of any method or process so disclosed.