Patent ID: 8702908

Claim:
A system for providing automated recognition and categorization of product output variations generated by machine processes as a function of variance partition analysis sensor data, the system comprising: a processing unit in communication with a computer-readable memory and a tangible computer-readable storage medium; wherein the processing unit, in response to executing program instructions stored on the tangible computer-readable storage medium via the computer readable memory: determines from a plurality of variance partition analysis data boxes acquired from scan sensor data for a current reel of paper produced by a paper process machinery system, and stores in a variance partition analysis data repository, normalized values of: an average value of variability of machine direction long-term scan energy over a first time period from an initial time of making two scans of the paper through an end time required to produce the reel of paper (MDL); an average value of variability of cross direction profile scan energy observed in a spatial domain over a second time period from an initial time based on a width of two of the data boxes through an end time required to scan a width of the reel of paper (CD); and an average value of variability of energy of a remainder of data points that are averaged out from a total of the machine direction long-term scan average energy variability and the cross direction profile scan average energy variability during a third time period time from an initial time of making two data boxes through an end time required to make two scans (MDS); determines a total variability value (TOT) as equal to: [ 2 × ( MDS 2 ) 2 + ( MDL 2 ) 2 + ( CD 2 ) 2 ] ; determines an MDL percentage as a percentage that the MDL is of the TOT, a CD percentage as a percentage that the CD is of the TOT, and an MDS percentage as a percentage that the MDS is of the TOT; compares the MDL percentage to an MDL threshold limit value, the CD percentage to a CD threshold limit value, and the MDS percentage to an MDS threshold limit value; and performs an automated diagnosis and analysis function that is specific to the machine direction long-term scan average energy variability determined for the reel of paper in response to the MDL percentage exceeding the MDL threshold limit value, that is specific to the cross direction profile scan average energy variability determined for the reel of paper in response to the CD percentage exceeding the CD threshold limit value, or that is specific to the data points remainder average energy variability determined for the reel of paper in response to the MDS percentage exceeding the MDS threshold limit value.