Patent Publication Number: US-2006010166-A1

Title: Production information managing system and method

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The invention relates to a production information managing system and method thereof. More particularly, the invention provides different identification codes for each of the main devices and the semi-products, which are used for producing the electronic products, at the start of each producing stage. Moreover, based on the identification codes associated with each producing stage, the invention records the operation information of the main device and the semi-product in each producing stage, such that the operation information can be queried and displayed on-line.  
      2. Description of the Prior Art  
      Over the years, manufacturing processes have become more automated. Where repeated procedures are required, such as welding, machining or riveting, the use of automation has enhanced productivity and improved quality control by greatly reducing human error in the manufacturing process. However, in many cases, manual control is often necessary to initiate and/or terminate a process or to change out tooling and/or equipment.  
      Standardization of repeat operations is a primary feature of automation, though automation of manufacturing processes may take many forms and can be done at almost any phase of the process, from fabrication to inspection and packaging of a completed product. In true automation, the process or step being automated involves a sensing system for making decisions about the device or process and then a control system that reacts to the sensed information and provides control reaction. Several prior arts, for example, describe intelligent tools for assembly and machining through the use of sensing devices. The tools provide information with regard to part location, machining, detail location, and automation.  
      Manufacturing systems are also becoming more integrated. Workers involved in the manufacturing process, by controlling and operating the machinery on the shop floor, are gaining greater efficiencies through “smarter” shop floor control systems.  
      Still, new processes are needed to further reduce errors during assembly and provide greater efficiencies through the use of smart systems.  
     SUMMARY OF THE INVENTION  
      Accordingly, an objective of the invention is to provide a production information managing system and method thereof. More particularly, according to the production information managing system and method thereof, the invention records the operation information of whole producing line, such that the operation information can be referred to and displayed on-line, so as to increase the producing efficiency.  
      Accordingly, another objective of the invention is to provide a production information managing system and method thereof. More particularly, according to the production information managing system and method thereof, the invention provides different identification codes to each of the main devices and the semi-products, which are used for producing the electronic products, at the start of each producing stage, and then based on the identification codes associated with each producing stage, the invention records the operation information of the main device and the semi-product in each producing stage, such that the operation information can be queried and displayed on-line.  
      Accordingly, another objective of the invention is to provide a production information managing system and method thereof. More particularly, according to the production information managing system and method thereof, the invention incorporates the identification codes used for external control with the internal production information managing system and controls the producing line with economic benefits.  
      According to a preferred embodiment of the invention, a data processing system manages production information associated with N1 electronic products requested according to a work order. N2 main devices are prepared based on the information of the work order and produced through a manufacturing line to produce N3 semi-products, and further through an assembling line to produce the N1 electronic products. Each of the main devices is provided with a respective first identification code at the start of the manufacturing line. Each of the semi-products is provided with a respective second identification code at the start of the assembling line. The manufacturing line and the assembling line both include a plurality of workstations. Each of the workstations includes at least one equipment for implementing a respective operation charged by said one workstation. Furthermore, each of the workstations includes at least one computer communicating with the system and collecting operation information associated with the corresponding equipment(s). In the above, N1 is a natural number, N3 is an integer equal to or larger than N1, and N2 is an integer equal to or larger than N3. According to a preferred embodiment of the invention, the data processing system includes a first recording module, a second recording module, a first querying module, a second querying module, and a displaying module. The first recording module, based on the first identification code of each main device, is used for recording the operation information associated with said one main device produced through the equipments of the manufacturing line. The second recording module, based on the second identification code of each semi-product, is used for recording the operation information of said one semi-product produced through the equipments of the assembling line. The first querying module, according to at least one first criterion, is used for querying from the record of the first recording module. The second querying module, according to at least one second criterion, is used for querying from the record of the second recording module. The displaying module is used for displaying the querying results of the first querying module and the second querying module.  
      The advantage and spirit of the invention may be understood by the following recitations together with the appended drawings. 
    
    
     BRIEF DESCRIPTION OF THE APPENDED DRAWINGS  
       FIG. 1A  through  FIG. 1C  are schematic diagrams illustrating a production line utilizing the production information managing system according to the invention.  
       FIG. 2  is a schematic diagram illustrating the production information managing system according to a preferred embodiment of the invention.  
       FIG. 3A  and  FIG. 3B  respectively show an example displayed by the displaying module according to the production information managing system of the invention.  
       FIG. 4  is a flowchart of the production information managing method according to a preferred embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to  FIG. 1A  through  FIG. 1C ,  FIG. 1A  through  FIG. 1C  are schematic diagrams illustrating a producing line  10  utilizing the production information managing system according to the invention. As shown in  FIGS. 1A through 1C , the producing line  10  includes a manufacturing line  12 , an assembling line  14 , and a packing line  16 .  
      As shown in  FIG. 1A , the manufacturing line  12  includes a plurality of workstations  122 . Each of the workstations  122  includes at least one equipment  1222  for implementing a respective operation charged by said one workstation  122 . Furthermore, each of the workstations  122  includes at least one computer  1224  communicating with the production information managing system and collecting operation information associated with the corresponding equipment(s)  1222 .  
      Before each batch of products is produced, the materials have to be pre-manufactured according to the production information of the work order. If the work order requests N1 electronic products to be produced, the production manager will manufacture N2 main devices beforehand based on the information of the work order, the experience, the wastage, the yield rate, and so on. According to the invention, each of the main devices is provided with a respective first identification code at the start of the manufacturing line  12 . Each of the main devices is processed through the equipment  1222  of the manufacturing line  12  and along the direction of the arrow  11  shown in  FIG. 1A . When the main device passes through all of the workstations  122  of the manufacturing line  12 , the semi-product would be produced. In general, the main devices would have wastage during the producing process, that is to say, N2 main devices can only produce less than N2 semi-products. In the following, N3 semi-products are produced when N2 main devices are processed through the manufacturing line  12 , wherein N1 is a natural number, N3 is an integer equal to or larger than N1, and N2 is an integer equal to or larger than N3. Afterward, the accomplished semi-products are sent to the assembling line  14  to be assembled.  
      As shown in  FIG. 1B , the assembling line  14  includes a plurality of workstations  142 . Each of the workstations  142  includes at least one equipment  1422  for implementing a respective operation charged by said one workstation  142 . Furthermore, each of the workstations  142  includes at least one computer  1424  communicating with the production information managing system and collecting operation information associated with the corresponding equipment(s)  1422 .  
      According to the invention, each of the semi-products is provided with a respective second identification code at the start of the assembling line  14 . Each of the semi-products is processed through the equipment  1422  of the assembling line  14  and along the direction of the arrow  13  shown in  FIG. 1B . When the semi-product passes through all of the workstations  142  of the assembling line  14 , the electronic product would be produced. In general, the semi-products would have wastage during the assembling process, that is to say, N3 semi-products can only produce less than N3 electronic products. Afterward, the accomplished electronic products are sent to the packing line  16  to be packed.  
      As shown in  FIG. 1C , the packing line  16  includes a plurality of workstations  162 . Each of the workstations  162  includes at least one equipment  1622  for implementing a respective operation charged by said one workstation  162 . Furthermore, each of the workstations  162  includes at least one computer  1624  communicating with the production information managing system and collecting operation information associated with the corresponding equipment(s)  1622 .  
      Referring to  FIG. 1A  again, at least one first repairing shop  124  is further set up in the manufacturing line  12 . Each of the first repairing shops  124  corresponds to at least one of the workstations  122  of the manufacturing line  12 . When a main device on a workstation  122  of the manufacturing line  12  fails to be operated, the main device will be sent to the first repairing shop  124  corresponding to the workstation  122  for reparation. When the main device is repaired completely, it will be sent back to the original workstation  122 , so as to proceed with the follow-up operations. If the main device cannot be repaired, the system will determine that the operation of the main device is failed. Each of the first repairing shops  124  includes at least one computer  1242  communicating with the production information managing system and collecting operation information associated with the first repairing shop  124 .  
      Referring to  FIG. 1B  again, at least one second repairing shop  144  is further set up in the assembling line  14 . Each of the second repairing shops  144  corresponds to at least one of the workstations  142  of the assembling line  14 . When a semi-product on a workstation  142  of the assembling line  14  fails to be operated, the semi-product will be sent to the second repairing shop  144  corresponding to the workstation  142  for reparation. When the semi-product is repaired completely, it will be sent back to the original workstation  142 , so as to proceed with the follow-up operations. If the semi-product cannot be repaired, the system will determine that the operation of the semi-product is failed. Each of the second repairing shops  144  includes at least one computer  1442  communicating with the production information managing system and collecting operation information associated with the second repairing shop  144 .  
      Referring to  FIG. 2 ,  FIG. 2  is a schematic diagram illustrating the production information managing system  20  according to a preferred embodiment of the invention. As shown in  FIG. 2 , the production information managing system  20  includes a first recording module  22 , a second recording module  24 , a first querying module  26 , a second querying module  28 , and a displaying module  30 . The production information managing system  20  further includes an input/output interface  21  for respectively communicating with the computer  1224  of the manufacturing line  12 , the computer  1242  of the first repairing shop  124 , the computer  1424  of the assembling line  14 , and the computer  1442  of the second repairing shop  144 .  
      The first recording module  22 , via the input/output interface  21  and based on the first identification code of each main device, is used for recording the operation information associated with the main device produced through the equipments  1222  of the manufacturing line  12 . In other words, the first identification code of each main device is the primary key when the first recording module  22  records the operation information. Accordingly, the location of a specific main device on the manufacturing line  12  can be traced on-line by the first identification code corresponding to the location.  
      In an embodiment, N2 main devices are circuit boards, and all kinds of electronic components are soldered onto the circuit boards through the manufacturing line  12 .  
      The second recording module  24 , via the input/output interface  21  and based on the second identification code of each semi-product, is used for recording the operation information associated with the semi-product produced through the equipments  1422  of the assembling line  14 . In other words, the second identification code of each semi-product is the primary key when the second recording module  24  records the operation information. Accordingly, the location of a specific semi-product on the assembling line  14  can be traced on-line by the second identification code corresponding to the location.  
      The first querying module  26 , according to at least one first criterion, is used for querying from the record of the first recording module  22 . The second querying module  28 , according to at least one second criterion, is used for querying from the record of the second recording module  24 . The displaying module  30  is used for displaying the querying results of the first querying module  26  and the second querying module  28 . In an embodiment, the displaying module  30  transforms the querying results of the first querying module  26  and the second querying module  28  into a graphic user interface and then displays the querying results.  
      In an embodiment, based on the at least one first criterion, the first querying module  26  can query the status of the manufacturing line  12 . The first criterion can be a quantity of the main devices to be operated between two of the workstations  122  of the manufacturing line  12 , a ratio of the main devices operated successfully and the main devices been operated by one of the workstations  122  and the equipments  1222  of the manufacturing line  12 , a ratio of the main devices first operated successfully and the main devices been operated by one of the workstations  122  and the equipments  1222  of the manufacturing line  12 , and a quantity of the main devices operated unsuccessfully by one of the workstations  122  and the equipments  1222  of the manufacturing line  12 . Accordingly, the status of whole or partial manufacturing line  12  can be queried on-line in accordance with the demand. As shown in  FIG. 2 , the production information managing system  20  of the invention further includes an operating interface  23 . The production manager can input the requested criterion to the first querying module  26  via the operating interface  23 .  
      For example, when the production manager wants to query the yield rate of a specific workstation  122  of the manufacturing line  12  during a specific span of time, the first criterion represents the ratio of the main devices operated successfully to the main devices been operated by the specific workstation  122  during the specific span of time. According to the above-mentioned first criterion, the first querying module  26  queries the first recording module  22 , and then the displaying module  30  displays the querying results of the first querying module  26  for the production manager.  
      In an embodiment, based on the at least one second criterion, the second querying module  28  can query the status of the assembling line  14 . The second criterion can be a quantity of the semi-products to be operated between two of the workstations  142  of the assembling line  14 , a ratio of the semi-products operated successfully and the semi-products been operated by one of the workstations  142  and the equipments  1422  of the assembling line  14 , a ratio of the semi-products first operated successfully and the semi-products been operated by one of the workstations  142  and the equipments  1422  of the assembling line  14 , and a quantity of the semi-products operated unsuccessfully by one of the workstations  142  and the equipments  1422  of the assembling line  14 . Accordingly, the status of whole or partial assembling line  14  can be queried on-line in accordance with the demand. The production manager can input the requested criterion to the second querying module  28  via the operating interface  23 .  
      For example, when the production manager wants to query the yield rate of a specific workstation  142  of the assembling line  14  during a specific span of time, the second criterion represents the ratio of the semi-products operated successfully to the semi-products been operated by the specific workstation  142  during the specific span of time. According to the above-mentioned second criterion, the second querying module  28  queries the second recording module  24 , and then the displaying module  30  displays the querying results of the second querying module  28  for the production manager.  
      In another preferred embodiment, the first recording module  22 , based on the first identification code of each main device, also records the operation information, if any, associated with the main device repaired by one of the first repairing shop(s)  124 . In an embodiment, the first criterion can be a quantity of the main devices been repaired by one of the first repairing shop(s)  124 , and a ratio of the main devices repaired successfully and the main devices been repaired by one of the first repairing shop(s)  124 .  
      For example, when a user wants to query the repair rate of a specific first repairing shop  124  of the manufacturing line  12  during a specific span of time, the first criterion represents the ratio of the main devices repaired successfully to the main devices been repaired by the specific first repairing shop  124  during the specific span of time. According to the above-mentioned first criterion, the first querying module  26  queries the first recording module  22 , and then the displaying module  30  displays the querying results of the first querying module  26  for the production manager.  
      In another preferred embodiment, the second recording module  24 , based on the second identification code of each semi-product, also records the operation information, if any, associated with the semi-product repaired by one of the second repairing shop(s)  144 . In an embodiment, the second criterion can be a quantity of the semi-products been repaired by one of the second repairing shop(s)  144 , and a ratio of the semi-products repaired successfully and the semi-products been repaired by one of the second repairing shop(s)  144 .  
      For example, when a user wants to query the repair rate of a specific second repairing shop  144  of the assembling line  14  during a specific span of time, the second criterion represents the ratio of the semi-products repaired successfully to the semi-products been repaired by the specific second repairing shop  144  during the specific span of time. According to the above-mentioned second criterion, the second querying module  28  queries the second recording module  24 , and then the displaying module  30  displays the querying results of the second querying module  28  for the production manager.  
      In another preferred embodiment, the N1 electronic products are, based on the information of the work order, further produced by the packing line  16 . According to the invention, each of the electronic products is provided with a respective third identification code at the start of the packing line  16 . As shown in  FIG. 2 , the production information managing system  20  of the invention further includes a third recording module  32  and a third querying module  34 . The third recording module  32 , based on the third identification code of each electronic product, is used for recording the operation information associated with the electronic products produced through the equipments  1622  of the packing line  16 . Accordingly, the location of a specific electronic product on the packing line  16  can be traced on-line by the third identification code corresponding to the location. The third querying module  34 , according to at least one third criterion, is used for querying from the record of the third recording module  32 . The displaying module  30  also displays the querying results of the third querying module  62 . In an embodiment, the N1 electronic products are all wireless communication apparatus, such as cellular phone, personal digital assistant (PDA), etc. The third identification code is a unique international mobile equipment identity (IMEI) code. Accordingly, the third identification code can be taken as the identification code for external control, and even the cost of IMEI can be merged with the internal production information managing system  20  for control with economic benefits.  
      In an embodiment, based on the at least one third criterion, the third querying module  34  can query the status of the packing line  16 . The third criterion can be a quantity of the electronic products to be operated between two of the workstations  162  of the packing line  16 , a ratio of the electronic products operated successfully and the electronic products been operated by one of the workstations  162  and the equipments  1622  of the packing line  16 , a ratio of the electronic products first operated successfully and the electronic products been operated by one of the workstations  1625  and the equipments  1622  of the packing line  16 , and a quantity of the electronic products operated unsuccessfully by one of the workstations  162  and the equipments  1622  of the packing line  16 . Accordingly, the status of whole or partial packing line  16  can be queried on-line in accordance with the demand. The production manager can input the requested criterion to the third querying module  34  via the operating interface  23 .  
      For example, when the production manager wants to query the yield rate of a specific workstation  162  of the packing line  16  during a specific span of time, the third criterion will represent the ratio of the electronic products operated successfully to the electronic products been operated by the specific workstation  162  during the specific span of time. According to the above-mentioned third criterion, the third querying module  34  queries the third recording module  32 , and then the displaying module  30  displays the querying results of the third querying module  34  for the production manager.  
      Referring to  FIG. 3A  and  FIG. 3B ,  FIG. 3A  and  FIG. 3B  respectively show an example displayed by the displaying module  30  according to the production information managing system  10  of the invention. According to the production information managing system  10  of the invention mentioned in the above, the requested criterion can be inputted by the production manager via the operating interface  23 , the results recorded in the recording module can be queried by the corresponding querying module, and the querying results can be displayed by the displaying module  30 . The diagram shown in  FIG. 3A  shows the yield rate of six workstations (taking the workstations on the manufacturing line as an example) requested by the production manager. The diagram shown in  FIG. 3B  shows the repair rate of each first repair shop corresponding to each of the workstations. The production manager can determine the current status of the manufacturing line on-line according to the displayed querying results. For example, when the yield rate of a specific workstation is lower than before, the production manager can overhaul the equipments corresponding to the specific workstation to eliminate the breakdown as soon as possible. The production manager can also query the specific workstation step by step to determine whether there is an error when preparing materials, the specific workstation is out of order, or a specific equipment has a breakdown.  
      Referring to  FIG. 4 ,  FIG. 4  is a flowchart of the production information managing method according to a preferred embodiment of the invention. The application of the invention can be the producing line  10  including the manufacturing line  12  and the assembling line  14 , as shown in  FIG. 1A  and  FIG. 1B . Each of the main devices is provided with a respective first identification code at the start of the manufacturing line  12 . Each of the semi-products is provided with a respective second identification code at the start of the assembling line  14 . The production information managing method includes the following steps:  
      Step S 40 : Successively collect operation information associated with the equipments ( 1222 ,  1422 ) of the workstations ( 122 ,  142 ) of the manufacturing line  12  and the assembling line  14 .  
      Step S 42 : Based on the first identification code of each main device, record the operation information associated with said one main device produced through the equipments  1222  of the manufacturing line  12 .  
      Step S 44 : Based on the second identification code of each semi-product, record the operation information of said one semi-product produced through the equipments  1444  of the assembling line  14 .  
      Step S 46 : According to at least one first criterion, query from the record of step S 42 .  
      Step S 48 : According to at least one second criterion, query from the record of step S 44 .  
      Step S 50 : Display the querying results of step S 46  and step S 48 .  
      The preferred embodiment of the first criterion and the second criterion is mentioned in the above, and the related description is neglected.  
      In another preferred embodiment, both step S 40  and step S 42  are performed as the following:  
      Step S 40 : Successively collecting operation information associated with at least one first repairing shop  124 .  
      Step S 42 : Based on the first identification code of each main device, record the operation information, if any, associated with the main device repaired by one of the first repairing shop(s)  124 .  
      In another preferred embodiment, both step S 40  and step S 42  are performed as the following:  
      Step S 40 : Successively collecting operation information associated with at least one second repairing shop  144 .  
      Step S 42 : Based on the second identification code of each semi-product, record the operation information, if any, associated with the semi-product repaired by one of the second repairing shop(s)  144 .  
      In another preferred embodiment, the N1 electronic products, based on the information of the work order, are further produced via the packing line  16 , as shown in  FIG. 1C . According to the invention, each of the electronic products is provided with a respective third identification code at the start of the packing line  16 . In step S 40 , the operation information associated with the equipments  1622  of the workstation  162  of the packing line  16  is also collected. In this embodiment, there is an additional step being performed except the steps shown in  FIG. 4 . Based on the third identification code of each electronic product, the operation information of the electronic product produced through the equipments  1622  of the packing line  16  is recorded. Afterward, according to at least one third criterion, the record of preceding one step is queried, and then the querying results are displayed. The preferred embodiment of the third criterion is mentioned in the above, and the related description is neglected.  
      In accordance with the detailed description of the invention mentioned in the above, the characteristics and the advantages of the invention are summarized as the following: 
          (a) The invention can collect the information of whole producing line on-line, and the information can be queried and further displayed, so as to improve the producing rate of the producing line.     (b) The main devices and the semi-products, used for producing the electronic products, are provided with different identification codes at each start of the producing stages, and based on the identification codes associated with each producing stage, the system will record the operation information of the main devices and the semi-products in each producing stage for the production manager to query on line.     (c) The invention incorporates the identification code used for external control with the internal production information managing system and controls the producing line with economic benefits.     (d) The production manager can change the querying criterion based on the requirement, and the changed querying results can be displayed instantaneously.        

      With the example and explanations above, the features and spirits of the invention will be hopefully well described. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teaching of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.