Abstract:
An exemplary embodiment is a method and system for electronic raw material tracking and quality control. The system includes a processor integrated with the production line for receiving inventory data corresponding to raw material for the product, generating an electronic production schedule for the product, generating an electronic production run sheet including the inventory data, receiving a product selection from the electronic production schedule, receiving a quantity selection for the product from the electronic production schedule, downloading data from the electronic production schedule to the electronic production run sheet and determining whether the raw material is acceptable for the product in the quantity based on the inventory data. A network is connected to the processor, and a user system is coupled to the network for accessing the electronic production schedule and the electronic production run sheet. 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 electronic raw material tracking and quality control.  
           [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 visual inspection 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]    Routinely, production is performed with very little information or knowledge about the inputs to the manufacturing process, namely the raw material and its physical properties. This lack of information may make it difficult for manufacturing engineers and quality specialists to improve the quality of products, especially when trying to determine the root cause of a problem. Further, tracking the location of a specific raw material and its available quantity within the manufacturing facility or facilities may be difficult. In other words, determining raw material availability, and its location, typically requires manually intensive logistical efforts. Also, without having accurate information regarding raw material inventory, the raw material maintenance and storage expenses can be costly. In addition, statistical information regarding the raw material&#39;s physical properties is not typically collected. Therefore, controlling the quality of the raw materials (thus, the quality of the end product) used in a production line may be difficult. Even further, the individual(s) responsible for any problems, produced as a result of errors with raw material inventory, is not typically identified. Therefore, a lack of accountability may exist.  
           [0006]    Thus, there is a need for a more efficient, fast and accurate method and system for raw material tracking and quality control.  
         SUMMARY  
         [0007]    An exemplary embodiment is a method and system for electronic raw material tracking and quality control. The system includes a processor integrated with the production line for receiving inventory data corresponding to raw material for the product, generating an electronic production schedule for the product, generating an electronic production run sheet including the inventory data, receiving a product selection from the electronic production schedule, receiving a quantity selection for the product from the electronic production schedule, downloading data from the electronic production schedule to the electronic production run sheet and determining whether the raw material is acceptable for the product in the quantity based on the inventory data. A network is connected to the processor, and a user system is coupled to the network for accessing the electronic production schedule and the electronic production run sheet. A database is coupled to the processor for storing data relating to the production line. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    Referring now to the drawings wherein like elements are numbered alike in several FIGURES:  
         [0009]    [0009]FIG. 1 depicts an exemplary electronic production run sheet in an embodiment of the invention.  
         [0010]    [0010]FIG. 2 is a block diagram of a computer system in an embodiment of the invention.  
         [0011]    [0011]FIG. 3 depicts an exemplary method for determining raw material inventory in an embodiment of the invention.  
         [0012]    [0012]FIGS. 4A and 4B illustrate an exemplary method for electronic raw material tracking and quality control in an embodiment of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0013]    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.  
         [0014]    As previously discussed, typically, the production operator is required to manually enter information to the run sheet every time a new product or production lot is run on each production line. In contrast, the invention does not require such manual entry, and therefore, the errors and problems associated with manual entry of production line data are eliminated. Therefore, productivity is increased and costs 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. The information contained in the electronic production run sheet  80  helps to insure that only “quality” raw materials are used to produce the product, improve the analysis of the product (such as providing useful information for determining the root cause of a problem) and optimize the production process through improved tracking of the identity, location, quantity and physical properties of the raw materials to be used in the product.  
         [0015]    Furthermore, cumbersome manual logistical tracking techniques are eliminated by the use of a method and system that electronically tracks the raw material. Thus, the raw material may be efficiently and accurately tracked and delivered to the production equipment without the errors and problems associated with manual logistical tracking techniques. For example, raw material inventory data may be entered to a database by merely scanning a bar-coded label associated with the raw material. Further, the raw material inventory data may include the raw material&#39;s physical properties, thus, allowing for greater quality control. Of course, greater quality control allows for improved product consistency, simplified root cause analysis and reduced raw material waste. Plus, improvements in predicting and eliminating production downtime (due to shortages, location and/or quality problems with the raw material) are achieved.  
         [0016]    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 .  
         [0017]    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.  
         [0018]    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.  
         [0019]    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.  
         [0020]    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.  
         [0021]    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.  
         [0022]    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, California. 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.  
         [0023]    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.  
         [0024]    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 , 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 other 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 .  
         [0025]    Data 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.  
         [0026]    Feeder rate settings of the extruder can be displayed from database  54  due to VB API and the DATABASE RDBMS interface. Generic production settings (such as feeders, temperatures, etc.) can be downloaded from other system databases. This could be sent to the PLC interface  56  or to the electronic production run sheet  80  via the MES interfaces.  
         [0027]    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.  
         [0028]    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.  
         [0029]    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.  
         [0030]    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.  
         [0031]    [0031]FIGS. 4A and 4B illustrate an exemplary method for electronic raw material tracking and quality control. The method of FIGS. 4A and 4B 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  111 , a production schedule is received. The production schedule may be previously stored in the database for retrieval by an operator. The production schedule may include the quantity, production line, time and date for producing a particular product. Next, in step  115 , the raw material requirements are determined based on the information in the production schedule. Then, in step  117 , the existing raw material in inventory is determined and the inventory data is downloaded to the database. The inventory may include “lots”/“batches” of raw material that have unique codes or assignments for identifying the particular lot/batch. A flow chart of an exemplary method for determining the existing raw material in inventory is shown in FIG. 3, and discussed later.  
         [0032]    In step  119 , the quality of the raw material is determined and the quality data is downloaded to the database. Determining the raw material quality may be accomplished by comparing the physical properties (such as viscosity and molecular weight) of the raw material to a specification requirement. This may be done with standard tests using common lab instruments. The quality data may be received several ways. For example, the quality data may be received directly from the raw material vendor and entered manually or automatically (such as using bar-code scanning techniques) to the database. Also, the quality data may be received at the production facility in a quality control laboratory and entered manually or automatically (such as through the LIMS) to the database. The quality data may even be obtained statistically using samples tested in the quality control laboratory.  
         [0033]    Step  108  determines whether the raw material is within the specification requirement. If a batch of raw material is within the specification requirement, then in step  121 , the quantity of raw material required is compared to the quantity in the raw material inventory. The next step proceeds to step  112 , as discussed below. If a batch of the raw material is not within the specification requirement, in step  116 , the batch of raw material is rejected and the inventory data is updated to show the rejection. The properties falling outside the specification requirements may also be indicated or flagged. The inventory data may be changed to identify the batch of raw material as “rejected,” and thereafter coded so that the material will not be allowed for use in production. For example, a code may be associated with the rejected batch of raw material that automatically sends an alarm to the operator if the rejected raw material is erroneously transferred to the production equipment (via the electronic production run sheet  80 ), or even interlocks the production equipment to prevent the rejected raw material from being transferred to the production equipment. The interlock may be in any form (such as mechanical, electrical and/or computer program) that will prevent the production equipment from operating, if needed. Step  118  determines whether the remaining raw material is within the specification requirement. If not, in step  120 , the quantity of “new” raw material still needed is determined, and the raw material is ordered in step  122 . If, in step  118 , the remaining raw material is within the specification requirement, then step  112  determines whether the “accepted” raw material meets the production quantity requirement. If not, then, in steps  120  and  122 , the quantity of “new” raw material still needed is determined and ordered. If, in step  112 , the raw material inventory meets the production quantity requirements, then, in step  113 , the database is updated so that the data for each production run may include the location, quantity and physical properties of the corresponding “accepted” raw material. This data may be downloaded to the electronic run sheet  80  for tracking the raw material used on a specific production run. Next, step  114  determines whether to begin production.  
         [0034]    If, in step  114 , production is to begin, then in step  123 , the electronic production run sheet  80  is initiated. The electronic production run sheet  80  may be initiated automatically or by operator selection. Then in step  124 , a product is selected from an electronic production schedule. Otherwise, the process ends. The electronic production schedule is an electronic version of the production schedule and may be integral to, or accessed by the electronic production run sheet  80 . Product selection can be determined any number of ways, such as by selecting the 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. Note that the steps leading up to step  124  may be previously completed, and the database may archive the data until step  124  is performed. Furthermore, other embodiments may include performing those same steps subsequent to step  124 . In step  126 , the quantity of the product to be produced is selected from the electronic production schedule. In step  127 , the electronic production schedule data is downloaded to the electronic production run sheet  80 . The data transfer may be automatic or via operator prompting and selecting. Next, step  130  determines whether the raw material was previously rejected. This helps prevent batches of rejected raw material (that may be reintroduced into the raw material inventory) from being used. If the raw material was previously rejected, then in step  132 , the database is updated to show that a batch of rejected raw material was erroneously reintroduced to inventory. Then, in step  134 , the data showing that an error occurred is downloaded to the electronic production run sheet, and in step  136 , production is stopped. Again, production may be stopped by sending an alarm to the operator or interlocking the production equipment.  
         [0035]    If, in step  130 , the raw material was not previously rejected, then step  138  determines whether the raw material was previously accepted. If not, then the process (beginning with step  111 ) is repeated. Otherwise, in step  140 , the raw material data is downloaded to the electronic production run sheet, and in step  142 , the raw material is transferred to the production equipment. The actual raw material usage may be monitored and included on the electronic production run sheet  80  to allow for adjustments and future raw material purchases and production planning. Due to the variety of information that may be included on the electronic production run sheet  80 , the raw material usage may be monitored according to production run, product, operator and/or other properties, such as a particular production process. This information may be received several ways. For example, the information may be entered via keyed entry, voice input, bar-code type scanning of identification labels, and the information may even be automatically entered based on production information previously entered to the MES computer system  30 .  
         [0036]    As discussed, FIG. 3 is a flow chart of an exemplary method for determining the raw material inventory. First, step  152  determines whether the raw material data was previously entered to the database. As discussed, an embodiment utilizing the MES computer system  30  may include the RDBMS for managing the relational database to store the data. Again, the inventory data may include raw material type, quantity, location and physical properties (and even whether a quality test has been conducted). If the raw material data was previously entered, the steps of FIG. 3 are not needed. Otherwise, step  154  determines whether the raw material includes a bar-coded label with raw material data. The bar-coded label may contain information such as material type, quantity, lot number, physical properties, destination location and any other useful information. If the raw material does not include a bar-coded label, then in step  162 , the raw material data is entered to the database. In step  162 , the information may be entered via keyed entry, voice input and even automatically entered based on production information previously entered to the MES computer system  30 . However, if the raw material includes a bar-coded label with raw material data, then in step  156 , the bar-coded label is scanned and the data is downloaded to the database. Then, step  158  determines whether an operator is involved in entering the raw material data or scanning the bar-coded label. If not, the process ends. Otherwise, in step  160 , the operator&#39;s identity is received and downloaded to the database. The operator&#39;s identity may be useful when determining accountability for errors or raw material usage. Again, the operator&#39;s identity may be received several ways, such as via keyed entry, voice input, bar-code type scanning of the operator&#39;s identification badge, and the identity may even be automatically entered based on production information previously entered to the MES computer system  30 .  
         [0037]    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.  
         [0038]    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.