Abstract:
A system, method, and computer-readable medium for tracking manufacturing steps comprising: tracking kinetic movements of an assembler over a period of time to provide kinetic tracking information, the kinetic movements comprising product assembly movements; storing the kinetic tracking information in a kinetic tracking information repository; identifying a defect in an item manufactured during the period of time; and, analyzing the kinetic tracking information to determine whether the kinetic movements of the assembler contributed to the defect.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates in general to the field of computers and similar technologies, and in particular to software utilized in this field. Still more particularly, it relates to a method, system and computer-usable medium for kinetic tracking in manufacturing to predict and prevent defects. 
     Description of the Related Art 
     It is known to communicate with and control many devices via the Internet. This communication and control is often referred to as the Internet of Things (IoT) and the devices are referred to as IoT devices. The IoT allows devices to be sensed and controlled remotely as well as to provide information based upon the type of IoT device across existing network infrastructure. 
     In many manufacturing environments, manual manufacturing steps (i.e., steps manually performed by an individual) can be prone to errors such as when the individual is tired or distracted and does not properly complete the manufacturing step (i.e., does not adhere to correct procedures). With many manufacturing environments, it can be difficult to correlate poor manufacturing techniques with poor product quality. With many manufacturing environments, it can be difficult to prevent or minimize manufacturing detects of products. 
     SUMMARY OF THE INVENTION 
     A system, method, and computer-readable medium are disclosed for tracking manufacturing steps comprising: tracking kinetic movements of an assembler over a period of time to provide kinetic tracking information, the kinetic movements comprising product assembly movements; storing the kinetic tracking information in a kinetic tracking information repository, identifying a defect in an item manufactured during the period of time; and, analyzing the kinetic tracking information to determine whether the kinetic movements of the assembler contributed to the defect. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element. 
         FIG. 1  depicts an exemplary client computer in which the present invention may be implemented. 
         FIG. 2  is a simplified block diagram of a manufacturing environment. 
         FIG. 3  shows a flow chart of a manufacturing tracking operation. 
         FIG. 4  is a simplified block diagram of a manufacturing environment. 
     
    
    
     DETAILED DESCRIPTION 
     A method, system and computer-usable medium are disclosed for a manufacturing tracking operation. The manufacturing tracking operation uses a sensor (such as an IoT type kinetic sensor) in a manufacturing environment where items are manually assembled. The sensors track repeated motions of the assembler. The sensors tracks the motion at all times and associates the tracking information to an item manufactured by the assembler. Quality control on the item is also associated with the assembler. The manufacturing tracking operation then applies analytics to determine whether certain motions are causing the defective parts. The manufacturing tracking operation also correlates certain identified motions with certain defects. Such a correlation allows remediated action to be applied to decrease manufacturing defects in future manufacturing operations. The correlation information can also be applied to training of other assemblers. 
     As will be appreciated by one skilled in the art, the present invention may be embodied as a method, system, or computer program product. Accordingly, embodiments of the invention may be implemented entirely in hardware, entirely in software (including firmware, resident software, micro-code, etc.) or in an embodiment combining software and hardware. These various embodiments may all generally be referred to herein as a “circuit,” “module,” or “system.” Furthermore, the present invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium. 
     Any suitable computer usable or computer readable medium may be utilized. The computer-usable or computer-readable medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), an optical storage device, or a magnetic storage device. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. 
     Computer program code for carrying out operations of the present invention may be written in an object oriented programming language such as Java, Smalltalk, C++ or the like. However, the computer program code for carrying out operations of the present invention may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user&#39;s computer, partly on the user&#39;s computer, as a stand-alone software package, partly on the user&#39;s computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user&#39;s computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). 
     Embodiments of the invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. 
     These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks. 
     The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. 
       FIG. 1  is a block diagram of an exemplary client computer  102  in which the present invention may be utilized. Client computer  102  includes a processor unit  104  that is coupled to a system bus  106 . A video adapter  108 , which controls a display  110 , is also coupled to system bus  106 . System bus  106  is coupled via a bus bridge  112  to an Input/Output (I/O) bus  114 . An I/O interface  116  is coupled to I/O bus  114 . The I/O interface  116  affords communication with various I/O devices, including a keyboard  118 , a mouse  120 , a Compact Disk-Read Only Memory (CD-ROM) drive  122 , a floppy disk drive  124 , and a flash drive memory  126 . The format of the ports connected to I/O interface  116  may be any known to those skilled in the art of computer architecture, including but not limited to Universal Serial Bus (USB) ports. 
     Client computer  102  is able to communicate with a service provider server  152  via a network  128  using a network interface  130 , which is coupled to system bus  106 . Network  128  may be an external network such as the Internet, or an internal network such as an Ethernet Network or a Virtual Private Network (VPN). Using network  128 , client computer  102  is able to use the present invention to access service provider server  152 . 
     A hard drive interface  132  is also coupled to system bus  106 . Hard drive interface  132  interfaces with a hard drive  134 . In a preferred embodiment, hard drive  134  populates a system memory  136 , which is also coupled to system bus  106 . Data that populates system memory  136  includes the client computer&#39;s  102  operating system (OS)  138  and software programs  144 . 
     OS  138  includes a shell  140  for providing transparent user access to resources such as software programs  144 . Generally, shell  140  is a program that provides an interpreter and an interface between the user and the operating system. More specifically, shell  140  executes commands that are entered into a command line user interface or from a file. Thus, shell  140  (as it is called in UNIX®), also called a command processor in Windows®, is generally the highest level of the operating system software hierarchy and serves as a command interpreter. The shell provides a system prompt, interprets commands entered by keyboard, mouse, or other user input media, and sends the interpreted command(s) to the appropriate lower levels of the operating system (e.g., a kernel  142 ) for processing. While shell  140  generally is a text-based, line-oriented user interface, the present invention can also support other user interface modes, such as graphical, voice, gestural, etc. 
     As depicted, OS  138  also includes kernel  142 , which includes lower levels of functionality for OS  138 , including essential services required by other parts of OS  138  and software programs  144 , including memory management, process and task management, disk management, and mouse and keyboard management. Software programs  144  may include a browser  146  and email client  148 . Browser  146  includes program modules and instructions enabling a World Wide Web (WWW) client (i.e., client computer  102 ) to send and receive network messages to the Internet using HyperText Transfer Protocol (HTTP) messaging, thus enabling communication with service provider server  152 . In various embodiments, software programs  144  may also include a manufacturing tracking module  150 . In these and other embodiments, the manufacturing tracking module  150  includes code for implementing the processes described herein below. In one embodiment, client computer  102  is able to download the manufacturing tracking module  150  from a service provider server  152 . 
     The hardware elements depicted in client computer  102  are not intended to be exhaustive, but rather are representative to highlight components used by the present invention. For instance, client computer  102  may include alternate memory storage devices such as magnetic cassettes, Digital Versatile Disks (DVDs), Bernoulli cartridges, and the like. These and other variations are intended to be within the spirit, scope and intent of the present invention. 
     Referring to  FIG. 2 , a simplified block diagram of a manufacturing environment  200  is shown. The environment  200  includes a manufacturing tracking server  202  which includes a manufacturing tracking system  210  and a manufacturing tracking information repository  206  (e.g., a database). In certain embodiments, the manufacturing tracking system  210  comprises some or all of the manufacturing tracking module  150 . 
     The environment  200  further includes one or more motion sensing devices  220  (e.g., kinetic sensors). The motion sensing devices provide information to the manufacturing tracking system  210  via a network such as network  140 . The environment  200  further includes one or more products  240  being manufactured by one or more assemblers  242 . The environment  200  further includes defect information  250  which is provided to the manufacturing tracking system  210  via the network. 
     In various embodiments, some or all of the motion sensing devices include a kinetic motion sensor and/or a camera. In various embodiments, one or more of the motion sensing devices  220  include wearable devices. In various embodiments, one or more of the motion sensing devices  220  include IoT type devices. 
     The manufacturing environment  200  is used for performing a manufacturing tracking operation via a manufacturing tracking system  210 . The manufacturing tracking operation uses one or more motion sensing devices  220  (such as an IoT type kinetic sensor) in the manufacturing environment  200  where items are manually assembled. The motion sensing devices  220  track repeated motions of the assembler. The motion sensing devices  220  tracks the motion at all times and associates the tracking information to an item manufactured by the assembler. Quality control on the item is also associated with the assembler. The manufacturing tracking operation then applies analytics to determine whether certain motions are causing the defective parts. The manufacturing tracking operation also correlates certain identified motions with certain defects. Such a correlation allows remediated action to be applied to decrease manufacturing defects in future manufacturing operations. The correlation information can also be applied to training of other assemblers. 
     Referring to  FIG. 3 , a flow chart of a manufacturing tracking operation  300  is shown. More specifically, the manufacturing tracking operation begins at step  310  with configuring kinetic tracking for an individual. In certain embodiments, the configuring includes associating a kinetic tracking device with the individual. In certain embodiments, the configuring can also include associating other types of sensing devices such as one or more manual sensors, one or more cameras, etc. Next, at step  320 , kinetic tracking information is generated during while the individual is performing their manual manufacturing steps. Next, at step  330 , the manufacturing tracking operation determines whether other individuals are involved in the manufacturing of the item. If so, then the operation returns to step  310  to configure kinetic tracking for the next individual. If all individuals involved in the manufacturing of the item have been configured and tracked, then at step  340  the kinetic tracking information is associated with the item being manufactured and stored within a manufacturing tracking repository. 
     At step  350 , if it is determined that an item is defective, such as via a quality control analysis, then the kinetic tracking information associated with the item is retrieved at step  360 . The kinetic tracking information associated with the item is analyzed at step  370 . This analysis can include identifying a standard range of motion for items produced with quality and a standard range of motion for items produced with defects and performing a comparison of the ranges of motion. 
     Referring to  FIG. 4 , a simplified block diagram of a manufacturing environment  400  is shown. With the environment  400 , the manufacturing tracking system  410  (which executes on a manufacturing tracking server  402  and includes a manufacturing tracking repository  406 ) includes a baseline tracking function. With the baseline tracking function, the manufacturing tracking system  410  sets a baseline with respect to a range of motions that produce items of quality. An additional step can be added into the manufacturing tracking operation  300  to generate a warning  420  when kinetic tracking information for an individual does not meet the baseline range of motions. Additionally, in certain embodiments, a risk analysis can be performed based on the kinetic tracking information to identify a level of risk of a defective product based on historical kinetic tracking information. 
     Additionally, in certain embodiments, the manufacturing tracking operation can be used to track defective parts in general. More specifically, if a specific product or component begins to experience defects from the field (i.e., after the product is deployed), then information obtained during the manufacturing tracking operation can be used to aid in determining how the product was assembled and whether the assembly is contributing to the defect. If the information indicates that the product was properly assembled, then this information can be used to narrow down a cause of the defect by removing questions regarding whether the product were properly assembled from the analysis. 
     Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.