Rule-based method for packaging spools of fiber

A rule-based method for packing a customer delivery unit containing a predetermined plurality of spools of filamentary product thereon comprises the steps of: (a) uniquely identifying each of a plurality of spools; (b) recording for each spool information regarding the kind of product on the spool, the grade of the product on the spool, and the weight of the product on the spool; (c) based on the product kind, grade, and weight information, assigning to each spool an appropriate one of a plurality of packing rules; and (d) selecting a predetermined plurality of tubes for inclusion in a customer delivery unit in accordance with the packing rule assigned to each selected tube. In another aspect the invention is directed to a method for manufacturing spools of a filamentary product in which information regarding predetermined process conditions in existence during the manufacture of the filamentary product are monitored and stored in a database, the improvement comprising: (a) storing in a database information regarding predetermined properties of the fiber on each spool, and (b) for at least one of the spools, correlating the manufacturing process information and the fiber property information.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates a rule-based system for selecting finished spools of fiber for inclusion in a customer delivery unit.

2. Description of the Prior Art

Synthetic filamentary product, such as nylon fiber, is produced by extruding a molten polymer material through a multi-orifice spinneret plate housed in the spin pack of a spinning machine and then winding the fiber onto a spool. Various process conditions of the polymer and the spinning machine are monitored and controlled in an attempt to insure that the fiber produced meets acceptable product standards.

Heretofore, no systematic effort is expended to track the production history of a given spool of product as that spool moves along the manufacturing floor. Therefore, whenever a spool of unacceptable product has been produced, it is often difficult to ascertain exactly what process variable is responsible for the product unacceptability. Also, there is no available system to insure that plural spools of product shipped to a given customer have undergone similar processing and have similar product qualities.

In view of the foregoing, it is believed advantageous to provide a monitoring system whereby information concerning the properties exhibited by the fiber on each finished spool may be gathered and recorded. It is also believed advantageous to be able to use information regarding the kind and quality of product on any given spool to select differentially spools of fiber for inclusion in a given shipment to a customer.

SUMMARY OF THE INVENTION

The invention relates to a rule-based method for packing a customer delivery unit containing a predetermined plurality of spools, each having a filamentary product thereon. The method comprises the steps of:

(a) uniquely identifying each of a plurality of spools;

(b) recording for each spool information regarding the kind of product on the spool, the grade of the product on the spool, and the weight of the product on the spool;

(c) based on the product kind, grade, and weight information, assigning to each spool an appropriate one of a plurality of packing rules; and

(d) selecting a predetermined plurality of tubes for inclusion in a customer delivery unit in accordance with the packing rule assigned to each selected tube.

In another aspect the invention is directed to a method for manufacturing spools of a filamentary product in which information regarding predetermined process conditions in existence during the manufacture of the filamentary product are monitored and stored in a database, the improvement comprising:

(a) storing in a database information regarding predetermined properties of the fiber on each spool, and

(b) for at least one of the spools, correlating the manufacturing is process information and the fiber property information.

DETAILED DESCRIPTION OF THE INVENTION

Throughout the following detailed description similar reference numerals refer to similar elements in all figures of the drawings.

FIG. 1is a stylized schematic representation of the physical layout of the floor of a facility for manufacturing and shipping a filamentary product, such as nylon fiber, from which an understanding of the operation of the Tracking And Grading System (“TAG System”) of the present invention may be gained. The TAG System here described, generally indicated by the reference character10, provides a system whereby each spool of nylon fiber is completely traceable throughout the manufacturing process and whereby finished spools may be grouped into “customer delivery units” (as defined herein) in accordance with various predetermined packing rules. The packing rules are configurable in the sense that they may be varied from site to site in accordance with local requirements.

In the preferred instance the TAG System10is a computer-implemented system that includes a database10B and a logic unit10L. The TAG System10operates to track each spool of nylon fiber as the same moves through a manufacturing facility, from production to warehouse/storage or delivery.

The TAG System10may be implemented on any computing platform, such as one based upon any suitable processor sold by Intel Corporation, Santa Clara, Calif., running under Windows® NT® operating system available from Microsoft Corporation, Redmond, Wash. Suitable for use as the database engine is Microsoft SQL Server, also available from Microsoft Corporation. The functional requirements for the code for the logic portion10L of the TAG System is discernible from the following description. The code is preferably written in Microsoft C++ and Visual Basic languages.

As will be developed the database10B of the TAG System10stores information regarding each manufactured spool of nylon received from information sources located throughout the manufacturing floor. Based upon the information stored in the database10B and/or received from the information sources located throughout the floor of the manufacturing facility, the logic unit10L decides which of the plurality of packing rules is applicable to a particular spool and whether the properties of a given spool conform to a particular packing rule. Generally speaking, the particular packing rule to be employed in a given situation is selected from a rules table in accordance with the “kind” of product produced (termed “merge”), the quality (“grade”) of the product produced, and the weight of the product carried on a given spool. The logic unit10L also serves to determine whether a given spool conforms to its applicable packing rule to merit inclusion in a particular customer delivery unit.

It should be apparent that although the TAG system10is described in terms of packing spools of nylon fiber, its principles may be readily extended to the packing spools of other filamentary materials, or even more broadly, to the packing of various manufactured products.

A facility for manufacturing a filamentary product, such as a nylon fiber, typically includes several fiber spinning machines, one of which is generally indicated inFIG. 1by the reference character12. Molten polymer is pumped by a meter pump15to each spinning machine12through a transfer line14.

Each spinning machine12may include a plurality of spinning positions12-1through12-N. Each spinning position produces a plurality of fiber filaments. Groups of filaments are gathered (either manually or automatically) to define one or more threadlines of fiber. Typically, there are from two to eight threadlines of fiber produced at each spinning position. One or more of the threadlines produced at a given spinning position is (are) gathered by an operator or automatically strung-up to is form one threadline yarn on each core18.

A wind-up mechanism16is provided at each spinning position. The wind-up mechanism16includes a plurality (on the order of two to eight) spindles, each of which is operative to wind a yarn produced at the spinning position onto a core18. The core18is typically a hollow cardboard cylinder, although it may be formed of other material, such as plastic. The core18, when carrying a length of fiber, is termed a finished “spool”, although the terms “bobbin” or “tube” are also employed in the art. The finished spool is indicated by the reference character20.

Prior to the start of production the intended properties of a fiber to be produced by a given machine are defined and stored in the database10B of the TAG System10. These intended (or “target”) product properties, termed “product merge” or simply “merge”, collectively define the “kind” of product to be produced on the machine during production. Properties included within a given fiber “merge” include the “recipe” (“type”) of the polymer in the transfer line14, and the fiber denier, luster and filament count.

Each spinning machine12is controlled and its operating conditions monitored by a real-time controller24. During operation of the spinning machine12information is provided from the controller24to the TAG System10over a link26. The information provided to the TAG system10includes both “machine level” and “position level” information.

“Machine level” information includes the beginning and end times for the period during which fiber is being continuously produced on a given machine12(termed a “production run”), the conditions of the polymer being supplied to the machine12throughout each production run, as well as various machine set-points.

In the database10B all spools of fiber produced on a given machine (regardless of position) share the same production run identifier. Moreover, each spool18produced on given machine during a given production run also shares the same “merge” identifier in the database10B.

In general, any or all of the process conditions may be reported to the TAG System10from the controller24during each production run. Included among the various conditions reported are, for example, polymer temperature and polymer viscosity, and meter pump speed. Information transmitted to TAG System10is used by the logic unit10L to derive an indication of the grade of the fiber on each spool of fiber produced during a production run. Based upon the reports of conditions monitored by the controller14the logic unit10L is able to derive an indication of the “grade” of the fiber being produced. “Grade” is a measure of the quality of the fiber produced and measures the degree to which the intended product “merge” has been achieved. The grade of fiber produced by a given machine may change over the course of a production run. As will be developed, various sources of product grade information are available to TAG System10.

In one practical implementation the controller24may be arranged to provide to the TAG System10with only those process conditions which are “out-of-limit”, that is, which fall outside predetermined operational levels. The out-of-limit conditions are captured by the TAG System10to relay a clear understanding as to why the grade of the spools being doffed at a particular time are not “first grade” (or highest quality). The recordation of particular out-of-limit conditions allow the TAG system10to group spools experiencing the same conditions to permit consistent analysis and disposition of all spools involved.

The conditions monitored by the controller24over the time of plant operation are also provided to a process historian database170over a link172, for a purpose to be described. In practice, all process conditions monitored for the entire period of machine operation are forwarded to the process historian database170.

Machine level information provided to TAG system10from the controller24also includes the speed set-point for each wind-up mechanism16on the machine12.

Position level information provided from the controller24to the TAG System10includes the beginning and ending wind-up times for each spool20produced at a position. From this wind-up information (and knowing the tare weight of the core18) the logic unit10L is able to calculate a weight for the fiber on the finished spool20. The ending wind-up time also serves as the basis for assigning a time during a production run at which a given spool20was finished. From this ending wind-up time the “age” of the fiber on that spool may be calculated by the logic10L. The controller24would also provide an indication to the TAG System10as to the number of the position on which a given spool has been wound. From this information the logic10L is able to calculate whether the spool is produced at an “even” or an “odd” machine position.

Each finished spool20, when doffed from the wind-up mechanism16on which it is wound, is identified by a unique identifier tag26. The TAG System10uses the unique identifier tag26to link together the various pieces of information derived about a given spool20as it moves over the production floor from manufacture to warehouse storage.

The identifier tag26is applied to the finished spool20by the operator. In the usual case the tag26is manually applied on the inside surface of the core18. The tag20may be produced locally by the controller24, which outputs a command over a line28to a suitable apparatus, such as a label printer30. Suitable for use as the label printer is that device manufactured and sold by Intermec as model3440. Alternatively, the tag26may be produced under the control of the TAG System10by a signal transmitted to the label printer30over a line34.

FIG. 2Aillustrates a representative example of a typical identifier tag26. The tag26includes various information fields. Field26A contains information identifying the denier (“DDD”), number of filaments (“FFF”) and type (“TTTTT”) of the yarn on the spool. Field26B identifies the Merge (“MMMMMM”) of the yarn. Field26C includes information that identifies the position number producing the yarn (e.g., “6”), and the ending wind-up time (“hh:mm:ss”, in hours, minutes and seconds). Field26D is the barcode-format identifier of the spool. Although the spool identifier is printed on the label26using a machine readable bar code, any other suitable identifier indicia may be used.

As a finished spool20moves over the manufacturing floor, information is transmitted to and from the TAG System10using strategically positioned interface units34. Although not expressly rendered in the drawing for economy of illustration, each interface unit34includes a bar code reader connected to the TAG System. The interface unit34also includes a visual display and keyboard or other suitable input/output device, whereby the operator is able to communicate with (i.e., both to and from) the TAG System10over the link36. At each interface unit34the identifier tag26on the spool20is read and information concerning the spool is transmitted to the TAG System10or received from TAG system10over the display. Any suitable equipment capable of reading the chosen barcode or other symbology on the label26and capable of effecting or simulating keyboard entry may be selected for the interface unit34. Examples of equipment suitable for use are the barcode scanner manufactured and sold by Intermec as model 1552, of that manufactured by Datalogic as model SDD176. The interactions between the TAG System10and the operators via the interface units34is multi-lingual and can be specified by an operating system setup. When spools20are doffed manually the actual weight of each finished spool20is ascertained. Each finished spool20is manually placed by the operator on a suitable scale38located proximally to the spinning machine12. The results (along with spool identity transmitted via the barcode reader at the proximal interface unit34) are transmitted to TAG system10over a link40. Any suitable scale may be used. Examples of scales suitable for use is the scale manufactured and sold by Schenck Inc., as model DHF 500, or a scale manufactured by Mettler-Toledo, such as that sold as the “Panther”.

Alternatively, some installations where spools are doffed automatically the weight of each spool is calculated by the logic unit10L. The weight calculation is based upon the meter pump speed, meter pump factor (constant that given unit weight per revolution of pump), known monomer loss constant, and known moisture gain constant denier of the fiber (all available from the spinning recipe) and the time required by the wind-up mechanism16to wind the fiber on the particular spool20(derived from the controller24).

In either fashion (i.e., manually and/or automatically) an indication of the actual weight of each finished spool20doffed from each position of the machine12is entered into the database10B.

At an inspection station44each finished spool20is visually inspected by the operator and the results of the inspection (along with the spool identity) are transmitted to TAG System10using the proximal interface unit34. As will be developed the results of the visual inspection are used by TAG System10in determining the “grade” of the fiber on the particular spool20.

Product grade information is also available to TAG System10from another source. At various intervals during a production run a physical sample of the fiber produced at each position is taken and forwarded to a laboratory50for physical and/or chemical analyses. The results of these physical and/or chemical analyses are transmitted to the TAG system10from the lab50over the link52. The information from the lab50is used by the logic10L to determine the “grade” of the fiber on the particular spools produced during the interval covered by the analysis.

It should be noted that since the physical and/or chemical analyses in the lab50do not occur in real time, the spools containing fiber covered by the analyses are identified on the basis of the time (Field26C,FIG. 2A) that a particular spool20is wound on the machine12.

For example, suppose that lab analyses of the fiber produced at a given position on the machine12are performed on twelve-hour intervals. The results of the lab analysis for any given interval are entered into the data record corresponding to each spool produced during that interval. The database10B is able to associate the lab information with the appropriate spools on the basis of the wind-up time at which a spool is produced at the given position. The wind-up time of a particular spool thus serves as an indication that a particular spool has been manufactured during the interval covered by the lab analyses.

Based upon wind-up time of each spool, the lab analyses information for an interval is associated with spools manufactured in that interval. Spools that have been wound during the same interval are believed to carry product that shares the same product quality, or “grade”. These spools may be marked in the database10B with a segregation identifier, termed a “held” or “segregated” spools. This prevent such spools from being packed with product that has a different or no segregation.

The logic10L is thus provided with various bases which may be used to determine the grade of the fiber on a particular spool. These bases include the product merge (or intended grade), the visual inspection, the reports of conditions as viewed by the controller24from which the logic10L may derive a grade, and the lab analysis. Any discrepancy among those bases selected for use in determining product grade is resolved by the logic10L applying the lowest grade level to the particular spool.

Wind-up time information is used by the logic10L to give calculate another information entry, the “age” of the fiber produced (the difference between the fiber wind-up time and real time). Wind-up time information may also be used by the logic10L to give calculate another information entry relating two spools to each other. The “age span” of fiber on two spools is the time period between the wind-up times for the fiber on each spool.

Summarizing to this point, it should be appreciated that as a result of the various interactions between the manufacturing process and the TAG System10the data record in the database10B for each uniquely identifiable spool includes the following information:the “kind” of the fiber intended to be produced, including denier and luster (“merge”);the “quality” of the fiber actually produced (“grade”);the machine producing the fiber (“spin machine”);the position producing the fiber (“position”, from which a determination as to whether the position is an “odd” or “even” position may be made);the production run of the producing machine (“Production Run”);the wind-up time during the given production run at which the fiber was wound (from which the “age” and “age span” of the fiber may be determined);the type of core on which the fiber is wound (“tube type”); andthe actual weight of the fiber on the spool.

After visual inspection, finished spools20are automatically or manually conveyed from the visual inspection area44to a packing station52. The spools20may not be immediately conveyed to the packing station52, but could be reposed in a holding zone for some predetermined time, in order to afford the fiber time to cure.

At the packing station52a plurality of spools are manually or robotically loaded to form a “customer delivery unit”. A “customer delivery unit” may alternatively be known as a “bulk pack” or a “package”. A “customer delivery unit” for purposes of this application is any formation of spools packed for shipment to a customer. Finished spools may be held in place by a polyethylene wrapping or placed in a carton or container.

The overall goal of the TAG system10is to produce a customer delivery unit which collects together spools of fiber that closely match each other in terms of product kind, grade and various other characteristics. Each customer delivery unit is assembled in accordance with predetermined “packing rules”, as will be described.

A customer delivery unit may be configured in any one of a variety of configurations (“CDU Config.”) using a variety of packing materials. A common configuration is one that includes a top cap and bottom cap, each having single bullet tray thereon. A single bullet tray is a member having an array of projections, termed “bullets”, disposed over one surface. Each bullet is sized to correspond to the inside diameter of the core18on which the fiber is wound. The bottom cap may be carried on a conveyor, or placed on a pallet, depending upon the conveyance facilities at a given manufacturing facility. Layers of spools are separated by double bullet separators. A double bullet separator is a member having bullets disposed over both its upper and lower surfaces. The number and spacing of the bullets on the trays and/or separators determines the number of spools present in each layer in a package. Empty cores may be used for the purpose of occupying positions in a given layer of a customer delivery unit. When used for this purpose, such an empty core is termed a “spacer”. The carton or container for a package may also receive trays and separators.

Each particular configuration of these packing materials used in forming a customer delivery unit is assigned a predetermined CDU configuration (“CDU Config.”) The CDU configuration serves as a pointer which identifies for the logic unit10L the packing materials to be used in forming a given customer delivery unit, as well as providing tare weight information from which the weight of fiber being shipped may be calculated.

As mentioned above, packing rules are the regulations in accordance with which a customer delivery unit is assembled and which govern the degree to which spools having various properties can be packaged together. In addition, packing rules insure that the assembled customer delivery unit is sized consistent with factory, warehouse, and transport handling requirements. The packing rules are stored in the TAG System10and may be altered by a user to conform the TAG System10to the situation at a given manufacturing site.

Packing rules in accordance with the present invention are designed in such a way that a spool with a given merge, a given grade and a given weight will fall within only a single packing rule. Moreover, each packing rule specifies only one CDU configuration (including the number of layers) and sets forth the total number of spools in a customer delivery. The packing rule may also specify the number of empty cores that may be allowed per layer of the customer delivery unit and whether “odd/even” packing is to be observed.

With reference toFIG. 3shown is a table setting forth a hypothetical set of packing rules in accordance with the present invention.

The vertical columns70-1through70-16set forth various parameters addressed by the packing rules. The packing rules themselves are the specific collection of parameters defined across each horizontal row72-1to72-6.

Generally speaking, the parameters addressed by the packing rules in accordance with the present invention relate to:

similarity of fiber properties, viz., merge and grade (columns70-1,70-2, respectively);

parameters related to fiber production (columns70-8to70-12); and

parameters related customer delivery unit configuration (columns70-13to70-16).

The merge parameter addressed in column70-1and the grade parameter addressed in column70-2have been earlier discussed.

Columns70-3and70-4respectively address the upper and lower weight limits of a spool. Column70-5sets forth the allowable amount by which a spool may be under the lower weight limit. Note that there is no comparable leeway setting forth the allowable amount by which a spool may be exceed the upper weight limit. Overweight spools are forbidden in the table of rules shown in FIG.3. Column70-6sets forth the number of undersized spools allowed in a package. Column70-7identifies the type of core used in the spool.

The fiber production parameters related to similarity of merge (column70-8), the similarity of spin machine (column70-9), and the similarity of production run (column70-10) should be clearly understandable in view of the discussion set forth earlier. The parameter “Age” (column70-11) specifies the minimum allowable age (e.g., in days) of the fiber on the spool before that spool may be packed. The parameter “Age Span” (column70-12) specifies the maximum allowable time span (e.g., in days) between the production dates of the “newest” and “oldest” spools in the package.

The parameter “Even Odd Position” addressed in column70-15relates to whether the customer delivery unit may contain only fiber produced at an even or an odd production position, calculated as discussed earlier.

Each horizontal row72-1to72-6defines a single packing rule. InFIG. 3all rules72-1through72-6relate to fiber having the same merge, i.e., merge “101”. Rules72-1and72-2are packing rules respectively directed to “High” grade, “101”-merge fiber. Rule72-1is directed to heavy spools of the merge/grade fiber (i.e., spools having a weight in the range from 15 to 19.9 pounds). Rule72-2is directed to lighter-weight spools of the merge/grade fiber (i.e., spools having a weight in the range from 12.5 to 14.9 pounds).

Rules72-3and72-4are packing rules respectively directed to “Medium” grade, “101”-merge fiber, while Rules72-5and72-6are packing rules respectively directed to “Low” grade, “101”-merge fiber. It will be noticed that the first rule in each of the recited rule-pair (e.g.,72-3,72-4and72-5and72-6) is directed to heavy spools, while the second rule in the pair is directed to light-weight spools.

It is be seen fromFIG. 3that the particular packing rule to be applied to a given spool is determined in accordance with the merge of product on the spool, the grade of the product on the spool, and the weight of the product carried on a given spool. The packing rules are designed such that one, and only one, packing rule applies to a spool.

The manner in which the TAG System10uses a selected one of the packing rules72to govern the assembly of a package at the packing station52may now be discussed in view of the program flow diagram of FIG.4A and FIG.4B. Spools may be packed manually or robotically.

In practice, the applicable packing rule is determined by the logic unit10L based upon the kind, grade and weight of the first spool proposed for the customer delivery unit. For example, suppose an operator (or robot) selects a light-weight spool carrying “101”-merge, “Medium” grade fiber. FromFIG. 3it should be apparent that based on the kind, grade and weight of the fiber on that first spool, the logic unit10L would select packing rule72-4to govern the inclusion of the other spools proposed for that customer delivery unit.

With specific reference to FIG.4A andFIG. 4Bshown are comparisons performed by the logic unit10L in adding a spool to a customer delivery unit. (For clarity of discussion, it should be that the term “tube” is used in the flow diagram of FIG.4A andFIG. 4Bto indicate a shed spool.)

Preliminarily, as indicated at block102, each customer delivery unit being constructed is itself uniquely identified either by an interim identification number. The operator at the packing station may affix to the customer delivery unit a tag having a unique, bar code readable identifier number printed thereon. The tag number is input to TAG System10via the bar code reader at the interface unit34positioned adjacent to the packing station44. Alternatively, a tag with the interim identification number may be provided to the operator from the TAG System10via the interface unit34. In this case, the interface unit34would include a label printer.

Once the customer delivery unit is identified by the interim identification number the identity of each spool attempted to be added to the customer delivery unit is identified to TAG System10via the bar code reader at the interface unit34.

As seen at blocks104,106, and108, the logic unit10L in TAG system10verifies that status of the customer delivery unit is “open”, verifies that the customer delivery unit is not yet full, and verifies a spool with the same identifier has not already been packaged.

Based upon the configuration code (parameter70-13) contained within the selected packing rule the logic10L indicates to the operator via the interface unit34the permissible packing components and the number of layers of spools that may be used in forming the customer deliver unit. The total number of spools in the customer delivery unit (parameter70-14) and the allowable number of spacers (parameter70-16) is also transmitted to the operator.

Assuming that these precautions are satisfied, for each spool proposed for inclusion in a customer delivery unit, the logic10L in the TAG System10verifies compliance with the parameters mandated by the appropriate packing rule through a series of comparisons. It is noted that the sequence of the comparison is not critical.

The following correspondence Table associates each of the decision blocks indicated in the flow diagram of FIG.4A andFIG. 4Bwith the corresponding parameters70-n (FIG. 3) of the applicable packing rule.

In block134, the logic verifies that all of the laboratory analyses on the fiber on the spool in question have been completed.

If a spool proposed for inclusion in a customer delivery unit does not meet a parameter as required by the packing rule, the logic unit10L notifies the operator that inclusion of that spool in the customer delivery unit is not permitted.

Upon completion of the packing the identifier numbers of all of the spools packed in the customer delivery unit identified by the given interim identification number are contained in the database10B.

After the package is constructed, it is moved to a weighing station140. At the weighing station the actual weight of the customer delivery unit is ascertained by a suitable scale. Scales suitable for use at the weighing station include those devices manufactured by Mettler-Toledo and sold as models ID7.

PM300, or Toledo 8142. Information representative of the gross weight of the customer delivery unit is transmitted to TAG System via the link142.

The logic unit10L determines actual weight of the fiber in the customer delivery unit by subtracting the tare weights of the packaging components (determined by the packing rule) from the measured gross weight of the customer delivery unit. The logic unit also calculates the “commercial” weight of the customer delivery unit by applying a moisture regain factor for North America sites that follow American Standards Testing Method guidelines.

From the weighing station140the package is moved to a wrapping station150where the customer delivery unit is wrapped with polyethylene wrapping or sealed, as the case may be.

The package is thereafter moved to a labeling station156where suitable label158is applied to the customer delivery unit. All of the information imprinted on the label158is transmitted from TAG system10over the link36to the interface unit34disposed adjacent the labeling station156. For this purpose the interface unit34at this location includes a label printer.

FIG. 2Billustrates a representative example of a typical label158for a customer delivery unit. The label158includes various information fields. Field158A shows the final identity number for the customer delivery unit, as assigned by the logic10L, in both plain text and two barcode readable strips. The merge of the product in the customer delivery unit, in both clear text and in barcode readable format is set forth in fields158B and158C, respectively. The size (inside diameter) of the spools in the customer delivery unit, the number of spools and the production date of the oldest spool are indicated in fields158D,158E and158F, respectively. The commercial weight of the fiber and the gross weight of the customer delivery unit are indicated in fields158G and158H, respectively.

The customer delivery unit may thereafter go to a warehouse for storage, or to a shipping area for transport to a customer. Information concerning the customer delivery unit and the spools contained therein is transmitted from the TAG System to the Sales and Distribution database164, over the link166. This update to Sales and Distribution database164places the customer delivery unit along with the attributes required by that system in an environment where it can be selected for shipment to fill a customer order when sold.

Information concerning each customer delivery unit and the spools contained therein is also transmitted from the TAG System to a Product Historian database180over the link182. The Product Historian database180thus contains the detailed information discussed herein about the properties of the fiber on each spool of manufactured in the facility.

As noted earlier, the Process Historian database170has stored therein predetermined manufacturing process information regarding predetermined process conditions extant during the manufacture of the fiber on each spool. This process information is derived from the controller24. The process information is recorded and stored on a time-wise basis.

The information in these two databases may be correlated, as indicated by the arrows184when correlated. One variable for use in correlating the information in these two databases is the beginning and ending windup times for each spool20produced at a position. By correlating the process condition information during the interval that a spool is being wound, provides a powerful insight into correlating fiber properties and fiber process conditions.

It should be readily appreciated by those skilled in the art that the TAG System as herein described provides significant advantages.

By being Table driven, the packing rules may be made configurable to the conditions and equipment available at a given manufacturing facility.

By monitoring each spool produced, the properties of each spool in each customer delivery unit may be controlled in accordance with the packing rules.

The TAGS System of the present invention is implemented in what may be described as use a three-tiered architecture that keeps data separate from application is also seen as advantageous. The first tier includes the user's workstations and contains programs that understand the way in which users input data and the way in which information is displayed to them. The second tier resides on the NT-based server and implements all business logic, including the packing rules. The third tier also resides on an NT-based server and supplies a data storage repository via the SQL Server. The three-tier implementation is believed to minimize support costs and increase the longevity of the fiber.

However, perhaps the most significant advantage is ability to correlate the process and product information in the process and product historian databases170,180respectively. The ability to correlate the process and product information is believed to enable deeper and richer learnings around the relationship between the nylon manufacturing process and the conditions thereof with the properties of the resulting fiber.

Those skilled in the art, having the benefit of the teachings of the present invention, as hereinabove set forth, may effect numerous modifications thereto. It should be understood that all such modifications lie within the contemplation of the present invention as defined by the appended claims.