Patent Publication Number: US-2002010524-A1

Title: Method and system for introducing a new material into a product design system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     [0001] This application claims the benefit of provisional patent application Ser. no. 60/173,701, filed Dec. 30, 1999, the disclosure of which is incorporated herein by reference. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] The present invention relates generally to systems and methods for designing and manufacturing products in a supply chain. More particularly, the present invention relates to providing a comprehensive system for facilitating the introduction of new materials or new material uses into a product design system.  
       [0003] Conventionally, distributed global manufacturing and design companies have struggled to efficiently introduce new materials, products and/or designs into their design systems. Because of inherent differences in both site development and requirements, new material introduction processes generally evolve differently at each site, thereby requiring time consuming translation and searching across the different sites in order to avoid inconsistent or redundant determinations. Further, multiple considerations must be taken into account when determining whether to approve a request introduction. Such considerations include environmental health and safety concerns, material sourcing or vendor concerns, and overall quality concerns. Since determinations regarding the material introduction must be made at each of these levels, the merging of dissimilar systems and the physical documentation associated with each system further compounds the inefficiency in conventional introduction methods.  
       [0004] Therefore, there is a need in the art of product design systems to facilitate the introduction of new materials or new material uses into the system. There is a further need for a method and system for providing globalized, automated introduction of new materials across distributed locations.  
       BRIEF SUMMARY OF THE INVENTION  
       [0005] The present invention overcomes the problems noted above, and provides additional advantages, by providing for a method and system for introducing a new material into a product design system. A computer program application receives basic material use information from a requesting party and facilitates a determination as to whether a new material introduction (NMI) is necessary for acquiring approval to use the material. If an NMI is required, the program receives details of the NMI and electronically notifies appropriate approval departments of the NMI. The various approval departments are simultaneously supplied with specific NMI information. Once the NMI information has been reviewed, the program receives approval determinations from the various departments. If approvals have been received from all required departments, the requesting party is notified of the approval and a database of NMI&#39;s is updated to reflect the approved NMI. Correspondingly, the code for the newly approved material and its specification are electronically transmitted to appropriate manufacturing systems throughout the world. However, if the NMI is not approved by all departments, the requesting party is so notified and the NMI database is not updated. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0006] The present invention can be understood more completely by reading the following Detailed Description of exemplary embodiments, in conjunction with the accompanying drawings, in which:  
     [0007]FIG. 1 is a flow chart describing a new material introduction process;  
     [0008]FIG. 2 is a flow chart describing a preferred operation of step  102  set forth in FIG. 1;  
     [0009]FIG. 3 is a flow chart describing a NMI for research and development option;  
     [0010]FIG. 4 is a flow chart describing one preferred embodiment of the operation of step  106  set forth in FIG. 1;  
     [0011]FIG. 5 is a flow chart describing a second preferred embodiment of the operation of step  106  set forth in FIG. 1, particularly related to vendor/sourcing information;  
     [0012]FIG. 6 is a flow chart describing a method for notifying appropriate approval departments about the NMI; and  
     [0013]FIG. 7 is a flow chart describing one preferred embodiment of a method for determining vendor/sourcing approval. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0014] The system and method of the present invention described below, are preferably implemented by an interactive computer software application incorporated within a computer-readable medium such as a hard disk drive, an optical medium such as a compact disk, or the like. Further, the medium may be available to a user either locally on a user&#39;s computer or remotely over a computer network, such as a local area network (LAN) or the Internet. The inventive computer software application is designed to receive a plurality of new material introduction information from a NMI requester. The application then facilitates previously approved NMI searching and multi-party review.  
     [0015] Referring to the Figures and, in particular, to FIG. 1, there is shown a flow chart describing a new material introduction (NMI) process, generally designated by the numeral  100 . This introduction essentially ensures that the NMI has been approved for use on a variety of levels and further incorporates the NMI into an overall product line design system, thereby enabling subsequent searching and retrieval of the received information. Essentially NMI approval authorizes a material for use in one or more specific processes or products, at a specific site, at a specific building or group of buildings within the site (since different buildings may have different air and water regulations)—commonly referred to as a “plant”, with specific maximum loading, within a specific process or product, and from a specific supplier. Prior to approval on all fronts, a material may not be used in production. The inventive methods provides a comprehensive means for introducing the new material use into the design process, and obtaining the requisite authorizations.  
     [0016] In step  102 , the system receives basic material use information. In step  104 , the system, based upon the material use information provided by the requester, facilitates a user determination as to whether a NMI program should be generated or not. That is, the inventive system may be initially used to investigate whether the material use has been previous approved. If so, no NMI program is required, since approval has already been obtained. However, if the material or material use in question is new, an new NMI program is initiated, wherein approval from various entities is required prior to implementation. Generally, NMI&#39;s are used to introduce a variety of different types of material information into a supply chain process. Although not limited thereto, in a preferred embodiment particularly directed to the industrial plastics/polymers industry, suitable types of material information include: new raw material/colorant information; new material sourcing information; new material use information; material tolling information; new internal resin information; new physical form information (e.g., powder, etc.); and indirect material/chemical information. Essentially requests for any new material, new use for an existing material, or new supplier for an existing material are received by the system for approval. A preferred operation of step  102  is set forth in additional detail in FIG. 2.  
     [0017] In step  200 , the system displays an NMI request screen to the requester. Preferably, the NMI request screen includes options enabling the requester to indicate whether the NMI involves a known raw material or an unknown raw material. In step  202 , the system receives an indication from the requester that the NMI involves an unknown raw material. The term “unknown” is meant to include materials for which a cataloged code, name, or number is not known to the requester, thereby modifying the manner in which the system searches for the particular material. In step  204 , the system receives the general material information that is known, such as pertinent specifications, or a particular material category into which the material falls. Next, in step  206 , the system, using the general information received in step  204 , conducts a raw material search of a database of previously established raw materials. In step  208 , the results of the search are displayed from the user including a listing of existing raw materials that match or closely match the requested material.  
     [0018] If an existing material meets the requester&#39;s requirements, the system, in step  210  receives a selection of a particular existing material from the requester. In response, the system, in step  212 , displays an approved usage screen to the requester detailing the various plants and/or product lines for which the selected material has been approved. If, upon review, it is determined that the material has been previously approved for the new plant/product line combination (“PPC”), the requester recognizes that no NMI is needed and stops the NMI request process in step  213 . However, if upon review of the approved plants/product lines, it is determined that the new use has not been previously approved, the requester proceeds to step  228  for a determination as to whether the NMI is for experimental or manufacturing use.  
     [0019] Returning back to step  200 , if the requester knows the specific raw material he wants to use already exists within the system, the system receives, in step  214  an indication that the raw material is a known raw material. Next, in step  216 , specific raw material information from the requester, such as a specific raw material code, etc. Upon receipt of this information, the system in step  218 , upon user request, conducts a search of existing NMI information to determine whether the submitted information corresponds to an existing raw material. If the requester determines that the submitted information corresponds to an existing raw material, the system proceeds to step  212 , described above, where a listing of approved plant/product line combinations (“PPC&#39;s”) for the raw material are displayed.  
     [0020] If, through the process described above, the requester determines that the raw material in question does not previously exist within the system, the system, receives, in step  220 , a request to establish a new raw material profile associated with the new material. Upon receipt of this request, the system, in step  222 , displays a new raw material information screen. Preferably, the new raw material information screen is configured to receive information related to the various characteristics of the particular material. In particular, the new raw material information includes a description of the material, the type of raw material, the requested plant/product line, the planned start and end dates, any known supervisors or other related personnel, and a material safety data sheet (MSDS) for the requested material. In step  224 , the system receives the new material information submitted by the user. Upon receipt of the new material information, the system, in step  226 , generates a new material code and stores the code and material information for subsequent retrieval.  
     [0021] Once the new material has been coded or retrieved, the system, in step  228 , receives an indication from the user relating to whether the new material use is for research and development only (i.e., experimental and not commercial). If a research and development use is desired, the user initiates a experimental raw material notification workflow in step  300  of FIG. 3. In step  302 , the system displays an experimental raw material notification workflow screen. In step  304 , the system receives a listing of individuals who the project owner wishes to notify of the experimental use. These individuals may include a local hygienist, or similar individual. In step  306 , the system electronically notifies the designated individuals of the raw material experimental use and, in step  308 , the system informs the requesting party that the notification was successful and that the material may be used for experimental purposes.  
     [0022] In an alternative embodiment, it may be necessary to obtain a lower level of approval prior to using a raw material for experimental purposes. In these circumstances, the system would require that additional information relating to health and safety of the material be input in accordance with an experimental use approval workflow. Following entry of the additional information, the system would require identification of appropriate approvers. The system would then electronically notify the designated approvers of the experimental raw material and the system would further require approval from these individuals prior to granting authorization to proceed to subsequent manufacturing approval stages use the material in production.  
     [0023] If a research and development use is not indicated, the system proceeds to step  230 , where a full manufacturing use NMI program is generated. Following NMI program generation, the system receives an indication from the user regarding what type of NMI is being requested in step  232 . As described briefly above, NMI&#39;s are instituted for various reasons such as completely new raw materials, material supplier changes, use translations for existing materials, etc. A selection of a particular NMI type determines the scope of the NMI and determines from whom approvals are required prior to material implementation in a manufacturing environment.  
     [0024] Once it has been determined that a NMI is required and the scope of the NMI has been ascertained, the system proceeds to step  106 , where the system interacts with the user to receive specific information and additional details regarding the particular NMI. This information preferably relates to three distinct areas: 1) environmental health and safety (EHS); 2) vendor/sourcing; and 3) quality. Generally speaking, EHS refers to the safety concerns related to the use of a particular material for a particular use or location; vendor/sourcing refers to vendor specific information such as vendor name, capacity and contact information; and quality relates to the quality of the suggested material/PPC combination based upon similar specifications, the supplier&#39;s work practices, etc.  
     [0025] Referring now to FIG. 4, there is shown a flow chart describing one preferred embodiment of the operation of step  106  set forth above, particularly addressed to receiving EHS-related information. In step  400 , the system receives material use information from the user related to the particular material and the intended use of the material. Upon receipt of the information, the system, in step  402 , electronically transmits the received information to a product stewardship entity for review and a determination of completeness, composition, and compliance. In step  404 , the system receives modified material use information, if available, from the product stewardship entity. The modified material use information remedies defects in the information provided by the NMI requester. At this point, the system determines, in step  406 , whether the NMI request is ready for review. If the system is not ready for the approval process, the system, in step  408 , notifies the requester that required information was either not obtained from the product stewardship entity in step  404  or not properly received from the requester in step  400 . If however, the system determines that the NMI request is ready for the approval process, the system proceeds to step  108  of FIG. 1, wherein EHS, Vendor/Sourcing, and Quality are electronically notified of the NMI for approval.  
     [0026] Referring now to FIG. 5, there is shown a flow chart describing a second preferred embodiment of the operation of step  106  set forth above, particularly addressed to receiving vendor/sourcing-related information. In step  500 , the system receives vendor/sourcing information related to the proposed supplier for the particular material. Preferably, this information includes contact information as well as the supplier&#39;s identification for the material. Upon receipt of the vendor/sourcing information, the system, in step  502 , electronically transmits the received information to a sourcing entity for review and a determination of completeness, composition, and compliance. In step  504 , the system receives additional information from the sourcing entity relating to the selected vendor. At this point, the system determines, in step  506 , whether the NMI request is ready for review. If the system is not ready for the approval process, the system, in step  508 , notifies the requester that required information was either not obtained from the sourcing entity in step  504  or not properly received from the requester in step  500 . If however, the system determines that the NMI request is ready for the approval process, the system proceeds to step  108  of FIG. 1, wherein EHS, Vendor/Sourcing, and Quality are electronically notified of the NMI for approval.  
     [0027] Returning now to FIG. 1, upon receipt of the various material information set forth in FIGS. 4 and 5, the system, in step  107 , determines whether all required/mandatory information relating to the NMI has been received. If not, the system returns to step  106  where the additional necessary information is received. However, if all required information has been received, the system proceeds to step  108 , where the system electronically notifies the selected approval department about the NMI. That is, an EHS approval department is notified about the EHS-related information received in accordance with FIG. 4, a vendor/sourcing approval department is notified about the vendor/sourcing-related information received in accordance with FIG. 5, and a quality approval department is notified about the quality-related information received in step  106 . Further, based upon the information received by the system in FIGS. 4 and 5, the requester determines which entities to notify regarding the NMI. In other words, information such as type of NMI, site location, etc. are used to determine who approves the NMI for use. In this manner, independent approval determinations are made regarding each of the distinct NMI components. The results of the various approval determinations may then be shared with interested individuals across the system.  
     [0028] Referring now to FIG. 6, there is shown a flow chart describing the process of notifying the appropriate approval departments about the NMI as described in step  108  above. In step  600 , the system receives a request from the requester to initiate the NMI approval process. Upon receipt of this request, the system, in step  602 , displays a NMI recipient screen to the requester preferably including a menu driven interface for receiving information relating to the type of NMI, the location, and the product line. It is then up to the requester to select whom shall receive the NMI approval request. The designated approval departments or individuals are received by the system in step  604 . In step  606 , the system receives a user request to launch the NMI approval process and electronically notify the listed departments of the NMI. Preferably, the system conducts, in step  608 , a final check of required NMI information. If all any required information is not present, the system, in step  610 , interrupts the notification process and generates an appropriate error message to the requester. However, if all required information is present, the system in step  612  locks the NMI information from subsequent modification and electronically notifies the listed approval departments about the NMI.  
     [0029] Referring back to FIG. 1, once notice of the NMI has been transmitted to the various approval departments, preferably by electronic mail or the like, the system, in step  110 , provides NMI information to the various departments in parallel and receives approval determinations from each of the selected departments. FIG. 7 is a flow chart describing one preferred embodiment of a method for determining vendor/sourcing approval in accordance with step  110 , described above.  
     [0030] In step  700 , the system receives a vendor/sourcing representative&#39;s request to review the NMI. Upon receipt of this request, the system, in step  702 , provides the vendor/sourcing representative with the various available pieces of NMI information related to vendor/sourcing approval as well as additional vendor/sourcing information such as the supplier&#39;s EHS information, etc. After review of this information the system, in step  704 , receives an supplier approval determination from the vendor/sourcing representative. If the representative denies approval of the supplier, the system, in step  706 , updates the supplier accordingly and notifies the requester of the status. If the vendor/sourcing representative provisionally approves the supplier pending a test period or additional information, the system, in step  708 , updates the status accordingly and notifies the requester of the provisional approval. If the vendor/sourcing representative non-provisionally approves supplier, the system, in step  710 , updates the status accordingly and notifies the requester of the non-provisional approval of the supplier.  
     [0031] It should be understood that the additional approval departments proceed substantially in the manner set forth in FIG. 7 above, wherein relevant information is provided to them for NMI review and an approval determination is received and stored by the system.  
     [0032] Returning to FIG. 1, once approval determinations have been received from all selected departments, the system, in step  112 , determines whether approvals have been obtained from all departments. If approvals have not been obtained from all departments, the system, in step  114 , notifies the requester that the NMI has not been approved. However, if approval has been obtained from all departments, the system, in step  116 , notifies the requester that the NMI has been approved and that implementation of the material use may commence. Accordingly, in step  118 , the system updates the NMI database to include the approved NMI for subsequent searching and review by future users.  
     [0033] By providing a comprehensive system for searching and requesting NMIs, the system of the present invention enhances the efficiency of the new material introduction process. In particular, by enabling the compilation and sharing of all relevant information, the entire NMI process is streamlined and usable by various organizations throughout the world.  
     [0034] While the foregoing description includes many details and specificities, it is to be understood that these have been included for purposes of explanation only, and are not to be interpreted as limitations of the present invention. Many modifications to the embodiments described above can be made without departing from the spirit and scope of the invention, as is intended to be encompassed by the following claims and their legal equivalents.