Abstract:
An exemplary embodiment is a method and system for using electronic downloadable control plans. The electronic downloadable control plans contain production line equipment settings corresponding to a product on a production line. The system includes a processor integrated with the production line for obtaining production line data for a product produced by the production line, generating an electronic production schedule for the product, generating an electronic production run sheet including the production line data for the product, receiving a product selection from the electronic production schedule, obtaining the electronic downloadable control plan corresponding to the product and downloading the production line equipment settings to production line equipment. A network is connected to the processor, and a user system is coupled to the network for accessing the electronic downloadable control plan. A database is coupled to the processor for storing data relating to the production line.

Description:
BACKGROUND  
         [0001]    The invention relates generally to production line management, and more specifically, to a method and system for using electronic downloadable control plans.  
           [0002]    Many production lines, such as in the plastics industries, involve numerous processes to create an end product. In production lines where intricate or otherwise information-sensitive manufacturing is performed, correctly transferring critical production information is essential. Any number of factors may be significant to the proper running of the production line at any given time, but without the efficient, fast and accurate transfer of this information, numerous errors may occur.  
           [0003]    For example, in the finishing of plastic pellets (which have been produced previously in a resin process), the finishing process encompasses adding various materials to the pellets. The added materials may be flame-retardants, pigment, glass, etc., depending on the final use thereof. After the addition, or what is typically called the compounding process, the pellets are extruded into an end product.  
           [0004]    Typically, a production operator is required to manually enter the production equipment settings, such as temperatures, feeder rates, and equipment speeds. Further, information such as lot number, production identification, production settings, production readings and quality assurance (QA) data (such as physical properties and appearance results) are manually entered onto a production “run sheet.” Manual entry to the run sheet is required every time a new product, or production lot, is run on each production line (approximately once every eight hours for each production line). The task is manually intensive, requiring the operator to: 1) search for an appropriate unique control plan; 2) enter each setting on the equipment; and 3) write each setting on the run sheet. Therefore, valuable operator time is used, and manual entry often results in clerical data entry errors that may affect the quality and consistency of the products being produced. Moreover, the operator is often required to search for the handwritten data, which may be located in several different locations throughout the production site. In other words, the current practices are ripe for error.  
           [0005]    Thus, there is a need for a more efficient, fast and accurate method and system for production line management.  
         SUMMARY  
         [0006]    An exemplary embodiment is a method and system for using electronic downloadable control plans. The electronic downloadable control plans contain production line equipment settings corresponding to a product on a production line. The system includes a processor integrated with the production line for obtaining production line data for a product produced by the production line, generating an electronic production schedule for the product, generating an electronic production run sheet including the production line data for the product, receiving a product selection from the electronic production schedule, obtaining the electronic downloadable control plan corresponding to the product and downloading the production line equipment settings to production line equipment. A network is connected to the processor, and a user system is coupled to the network for accessing the electronic downloadable control plan. A database is coupled to the processor for storing data relating to the production line.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    Referring now to the drawings wherein like elements are numbered alike in several FIGURES:  
         [0008]    [0008]FIG. 1 depicts an exemplary electronic production run sheet in an embodiment of the invention.  
         [0009]    [0009]FIG. 2 is a block diagram of a computer system in an embodiment of the invention.  
         [0010]    [0010]FIG. 3 depicts an exemplary product data summary screen in an embodiment of the invention.  
         [0011]    [0011]FIG. 4 illustrates an exemplary method for an electronic downloadable control plan in an embodiment of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0012]    This application relates generally to commonly owned and invented U.S. application Ser. No. 09/498,035, filed Feb. 4, 2000, entitled “Method and System for Electronically Capturing, Storing, Searching and Retrieving Production Data,” the teachings of which are incorporated by reference herein.  
         [0013]    As previously discussed, typically, the production operator is required to manually enter information to the run sheet, such as production equipment settings, every time a new product or production lot is run on each production line. The operator is required to search for the particular product control plan, and then manually enter the appropriate equipment settings according to the control plan. Further, the operator is required to manually record each equipment setting on the run sheet. In contrast, the invention does not require such manual entry, and therefore, the errors and problems associated with manual entry of production line data and equipment settings are eliminated.  
         [0014]    In general, an embodiment includes an electronic production run sheet  80 , FIG. 1, containing production readings and quality data for a particular production line product. The manual version of a run sheet is usually in a tabular form with various columns in which the operator must record the production information by hand. After recording the product and lot number, date and time, the operator must hand write the temperature set points at  12  for the various zones of the extruder. The operator must also record various feeder set points  14 . The electronic production run sheet  80  also includes lab result data points  16 . The properties of the product during the various runs  18   a - 18   f  are determined and plotted in a Statistical Quality Control Graph (SQC)  20 .  
         [0015]    Also included is an electronic downloadable control plan  53 , (corresponding to the particular production line product), which contains production equipment settings for the product. The electronic downloadable control plan  53  is automatically downloaded to the production equipment when the corresponding product is selected from the electronic production schedule. The information contained in the electronic downloadable control plan  53  can also be downloaded to the electronic production run sheet  80 . Thus, the operator is no longer required to search for the appropriate control plan to set up the production equipment for a particular product. Therefore, productivity is increased, errors are eliminated and costs associated with manual entry methods are reduced. Further, the quality and consistency of the products produced on the production line are improved by eliminating errors and problems associated with manual entry methods. Also, historical analysis of the production line data is quicker and more accurate.  
         [0016]    Although the system of an embodiment is described with relation to plastics finishing, it should be appreciated that the system and method described herein can be applied to various other manufacturing and data retrieval and storage environments.  
         [0017]    An embodiment utilizes a manufacturing execution system (MES) computer system  30 . Referring to FIG. 2, the computer architecture of the MES computer system  30  will be described. The MES computer system  30  includes a database server  40  and computers  44 . Although only two computers  44  are shown for simplicity it should be appreciated that a plurality of computers can be located at different locations in the production site for use by a plurality of operators. Moreover the database server  40  can be identical to computer  44  and is distinguishable as an embodiment only in that server  40  is the primary data storage source with which data stored in computers  44  can be synchronized therewith.  
         [0018]    Computer(s)  44  are coupled to the database server  40  by communications channel  60 . Communications channel  60  can be a network, such as a wide area network (WAN), local area network (LAN), Ethernet, intranet, a direct cable connection, a connection via phone lines and modems, or the like. Further, communications channel  60  can be continuous or intermittent and can be any mechanism for providing the communications described below. For example, communications channel  60  can include removable media, such as a diskette. Data can be sent over communications channel  60  in any appropriate format, such as e-mail in simple mail transfer protocol (SMTP), as attachments to email, as ASCII or binary files using file transfer protocol (FTP), or the like.  
         [0019]    Even further, communications channel  60  can be the Internet. In such an embodiment, computer(s)  44  execute a user application (e.g., web browser) for interacting with the database server  40 . Communication with computer(s)  44  can be achieved in any manner consistent with Internet information transfer, including but not limited to, HTTP and FTP, or a client/server connection.  
         [0020]    Likewise, system components may be located remotely from each other and coupled via communications channel  60 . For example, the database server  40  may be located off-site of the production line and communicates with corresponding components via communications channel  60  as a network, such as the Internet, WAN, LAN, Ethernet, intranet, a direct cable connection, a connection via phone lines and modems, or the like. Such remote locating is useful if, for example, the production facility environment is too extreme for the components.  
         [0021]    The database server  40  is managed by a relational database management system (RDBMS)  70 , such as the ORACLE RELATIONAL DATABASE MANAGEMENT SYSTEM by Oracle Corporation of Redwood Shores, Calif. RDBMS  70  manages a relational database to store the data. The data records, data tables, and data relationships contained in the database managed by RDBMS  70  enable the MES computer system  30  to provide increased reliability in searching and analyzing quality assurance (QA) lab testing data.  
         [0022]    In the MES computer system  30 , the database server  40  is a computer having sufficient resources to support RDBMS  70 . Moreover, the database server  40  supports multi-operator access to RDBMS  70  over a computer network. Each operator computer terminal  44  should be sufficient to support an operating system such as WINDOWS 98, UNIX or other similar operating systems. These systems are used for communication with the Laboratory Information Management System (LIMS)  52 , which executes on computers  44 , as well.  
         [0023]    As discussed, computers  44  execute application programs, which communicate with RDBMS  70  to query the databases managed by RDBMS  70  and to provide data for that database. The LIMS database  52  in this process involves the display and storage of the lab tests, along with the required specifications, and is another source of production data, such as the test results of the product properties.  
         [0024]    The QA lab test data are available electronically throughout the LIMS database  52  described above (an electronic database system on the network). The production readings are the readings from the production line captured real time through the MES computer system  30 . Using the configuration of the MES computer system  30 , this data can be captured at a specified interval (such as, every second, every ten minutes, or whatever is required) or when there is a change in the data greater than a predetermined threshold (such as, a change of 2 degrees in temperature, or a change in 1 pound per hour feed rate). Once again, this data is stored in the database system and is available electronically through the communications channel  60 .  
         [0025]    During a production line check, which occurs when a QA lab test occurs, the operator enters appropriate information into the computerized system. This causes a “snap shot” of the production process to be captured. However, the snap shot may occur at any point in the production process. The production readings are the sensor readings for production: temperatures, pressure, motor speeds, motor amps, humidity, feeder rates, feeder selection, production rates, etc. The QA lab test data are the results of the required product tests: rheology measurement, appearances, compositional analysis, strength tests, color, etc. This information is captured with the additional capability to record operator comments. The QA lab test data is stored electronically in LIMS  52  and can be updated at any time. Thus, the operators can add comments following the QA lab test entry whenever they want or are required to (for example, 10 minutes later or even 10 days later). The date/time stamp of the production data report will include all updates to the database system up to that date/time.  
         [0026]    The data captured by the LIMS is displayed using SQC graphs to indicate quality of the product and/or process. The data can be captured each time a QA lab test occurs (or at other convenient times), also known as a production line check.  
         [0027]    The MES computer system  30  includes a variety of features. Data exchange between the database server  40  and the different databases, such as LIMS  52 , can occur due to the use of the MES integration system  50 . This acts as an interface between the database server  40  and LIMS  52 , database  54 , electronic downloadable control plan (EDCP) database  58 , process control operations (PCO) system  55  for controlling the production equipment operations, programmable logic controller (PLC) interface  56  with production real-time data or distributed control system (DCS)  57  and other additional production data, such as scheduling via another production data database  59 . Data exchange also occurs due to the use of a compliant language such as VISUAL BASIC (VB) from Microsoft Corporation of Redmond, Wash. For example, the line schedule can be determined via VB application programming interface (API) to the RDBMS  70  and other databases. If necessary, functionality modules can be used to group the production data by batches or lots. The line schedule also can be determined via various methods, such as manually, via DATABASE  54  or via an electronic schedule program interfaced with the RDBMS  70 .  
         [0028]    A PLC interface  56 , for example GE  90 - 70 , allows for the snap shot of the process to be retrieved at a particular sample time. The PLC interface  56  allows production parameters to be set and controlled. As such, this system has the electronic capability to capture the production parameters and send them to a database system with the appropriate date/time stamps.  
         [0029]    The VB API program also allows the operator to retrieve the production run data in the snap shot format by entering the line number, product number or date in the appropriate windows of the electronic production run sheet  80  screen. The line number and product number are pull-down menus that the operators can select. The date is a manual entry block. Each of these allows the operator to search the database system for historical batches (or lots). Because there are several thousand lots made each year, this makes it easier for data retrieval.  
         [0030]    The data from a particular line check can be maintained for at least three years due to VB API access and a 40-gigabyte RAID-5-disk array. The particular storage amount is dependent upon the storage capacity, whereas the required length of storage is dependent upon policy dictating document retention.  
         [0031]    Feeder rate settings of the extruder can be displayed from database  54  due to VB API and the database  54  RDBMS interface. Generic production settings (such as feeders, temperatures, etc.) can be downloaded from other system databases, such as database  54 . This could be sent to the PLC interface  56  or to the electronic production run sheet  80  via the MES interfaces.  
         [0032]    RDBMS  70  also allows for the operator to manually enter operator comments for each line check. This is also accomplishable by the VB API access to RDBMS  70  and other databases. The VB API is a visual basic program, which allows for an additional field in the database system, which can store the operator comments. There is a control function, or button on the electronic production run sheet  80  which will allow the operator to enter and to display comments for each line check of for the entire production run. The VB API program will prompt the operator to enter his/her data and will then send it to the appropriate database system.  
         [0033]    The VB API program also allows the operator to print a hard copy of the electronic production run sheet  80  and to print a pre-configured report for the production run. This will retrieve the appropriate batch (or lot) production and QA lab test data for printout on the pre-configured report format, similar to the one displayed in FIG. 1.  
         [0034]    As discussed above, a statistical quality control (SQC) graph can chart the melt flow index, melt viscosity or any other property of interest due to RDBMS  70 , and other databases. The data for the SQC charts would come from the various databases, depending upon which property was chosen for graphing. The actual charting of the SQC graph will either be done using existing statistical graphing packages or through programming using generic (well-known) equations.  
         [0035]    The system can include production alarms to indicate that a feeder has stopped or a product property is no longer within specification. These alarms are available in the electronic production run sheet  80  which allow operators the required information in real-time to make corrections. The database system contains the appropriate tolerances for the parameters and other software, such as TELALERT. It also contains the appropriate alarming system for activating alarms such as lights, horns, etc. The electronic production run sheet  80  contains a graphical alarm and a text display indicating what the alarm is for.  
         [0036]    The database server  40  acts as a universal user interface due to RDMS  70 , GE  90 - 70  PLC interface  56 , EDCP RDBMS, VB API access. Furthermore, utilizing standard technology and tool sets such as VB, structured query languages (SQL), object linking and embedding (OLE) for process control, open database connectors (ODBC) and ActiveX controls also allow for universal user interface.  
         [0037]    Referring to FIG. 3, the LIMS will be described in relation to the screen capture shown. The product data summary screen  79  shown in FIG. 3 involves an automatic system for capturing the lot number, product identifiers, machine set points, production readings and the QA lab test data. The production readings and the QA lab test data are available electronically through the MES and LIMS computer systems. During a production line check an operator can enter information such as the line number in window  82  or the lot number in window  84  and pull up the data on the particular production line by pressing a fetch lot button (not shown).  
         [0038]    Lot information such as the grade and color may also appear in windows on the product data summary screen  79  (not shown). Product window  85  may include a product code to identify special product requirements for a customer. Test Id column  90  may include a plurality of different tests identified by, for example, Test 1 -Test 4 . Each product made in the plastics finishing process has different tests and test codes, and the system has a test ID relating to a particular test preformed. For example, a specific gravity test could have a test ID of SP GRAV, which would appear in column  90 .  
         [0039]    For each data reading, a lower spec and an upper spec are displayed in tabular form at  92  and  94 . In order to determine which individual performed which test, the tester&#39;s initials can be added in another column (not shown). The line check data is shown in columns  100  through  106 , etc., with the final run  106  appearing to the right. It should be appreciated that there is no time limit or a limit to the amount of line checks that can be performed.  
         [0040]    A window for operator comments may be included at the bottom of the screen (not shown). When complete the operator can print a final report. The SQC graph can also be displayed on the electronic production run sheet  80 . The format or display of the data in the SQC graph is determined by the configuration parameters, such as the frequency of reports, whether actual data points or average data points are used, etc.  
         [0041]    As discussed, the MES computer system  30  also includes an EDCP database  58  containing the electronic downloadable control plan  53  for a particular product. As previously mentioned, the electronic downloadable control plan  53  eliminates the errors and problems associated with manual entry of production equipment settings. An electronic downloadable control plan interface screen is used for entering the production information for a particular product. The equipment settings and other information are entered in the electronic downloadable control plan  53 , via the electronic downloadable control plan interface screen, and then the electronic downloadable control plan  53  and its information is saved in the EDCP database  58 . Of course, other embodiments for entering the production information may be used.  
         [0042]    The MES interfaces have the capability to connect to the EDCP database  58  to allow for downloading the information in the electronic downloadable control plan  53  to the production equipment via the PCO system  55 . Further, the information contained in the electronic downloadable control plan  53  can also be downloaded to the electronic production run sheet  80 . As mentioned, the electronic downloadable control plan  53  is stored in the EDCP database  58 , which is accessed when a product is selected from the electronic production schedule.  
         [0043]    [0043]FIG. 4 is a flow chart of an exemplary method for an electronic downloadable control plan. The method of FIG. 4 may be implemented by an operator using one of the computer(s)  44  or even automatically based on production schedule information previously entered to the MES computer system  30 . First, in step  119 , the electronic production run sheet  80  is initiated. The electronic production run sheet  80  may be initiated automatically or by operator selection. Next, in step  120 , a specific product is selected for production from an electronic production schedule. The electronic production schedule may be integral to or accessed via the electronic production run sheet  80 . Product selection can be determined any number of ways, such as by selecting a product according to its unique production lot number or serial number. The production lot number can correspond to a particular product grade, color, customer and production line. Each product will also correspond to a particular electronic downloadable control plan  53 .  
         [0044]    In step  122 , the EDCP database  58  is accessed to obtain the corresponding electronic downloadable control plan  53 . Next, in step  123 , the formulation data is obtained. The formulation data may be previously stored in a database. Next, in step  124 , the user is prompted to select whether to download the information from the electronic downloadable control plan  53  to the electronic production run sheet  80 . If the operator chooses to download the information to the electronic production run sheet  80 , in step  126 , the operator can do so by selecting a “download to run sheet” button (not shown). In step  127 , any necessary adjustments are made to the equipment settings. The adjustments may require a certain authorization if the attempted adjustments are outside a specified range or the operator is not authorized to make the adjustments. In other words, a password or software key may be required to make the adjustments. The specified range may be included in the electronic downloadable control plan  53 . In step  128 , the operator is prompted to download the information from the electronic downloadable control plan  53  to the production equipment. If, in step  128 , the operator chooses to download the information to the production equipment immediately, then in step  130 , the operator can select a “download to equipment” button (not shown). However, if the operator chooses to delay downloading the information to the production equipment, then in step  132 , the operator can select a “delay download to equipment button” (not shown). This allows the user to selectively control the timing of the download to the production equipment.  
         [0045]    Of course, further embodiments for selecting to download the information can be employed, such as voice prompts, keyed entry, etc. Other embodiments may not even require the operator to select to download the information. Instead, the information could be automatically downloaded to the electronic production run sheet  80  and the production equipment at a preprogrammed interval.  
         [0046]    The description applying the above embodiments is merely illustrative. As described above, embodiments in the form of computer-implemented processes and apparatuses for practicing those processes may be included. Also included may be embodiments in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. Also included may be embodiments in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or as a data signal transmitted, whether a modulated carrier wave or not, over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.  
         [0047]    While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.