Method of managing a system for the manufacture of tobacco products

Abstract

A system for manufacturing tobacco products is managed using a method whereby, having programmed a number (Pn) into a master control unit (33) that represents a nominal production target for products of a given brand, such as boxes filled with cartons containing cigarettes of the particular brand, and programmed a number (Cmax) representing the maximum output capacity of the system, or in practice the maximum quantity of products in process that the system is able to handle, a tally (P) of products is kept, and, at a given moment (t1) following the completion of a number (Pr) of products that matches the target (Pn=Pr+Cmax), a first check is run on the quantity (C1) of the product actually turned out by the system; should it emerge from this first flash check that the actual quantity (C1) is equal to the maximum output capacity (Cmax), then a brand changeover procedure will be initiated by the master control unit (33), whereas if the actual quantity (C1) produced is less than the maximum output capacity (Cmax), further flash checks will be run at intervals established by events dependent on the measured output, and repeated until the sum of the number (P) of single products counted plus the actual quantity (C) turned out is equal to the nominal production target (Pn).

Description

TECHNICAL FIELD

The present invention relates to a method of managing a system for the manufacture of tobacco products.

BACKGROUND ART

Systems for manufacturing tobacco products will generally comprise a plurality of machines linked one to another along a common production line. In particular, such machines will include a cigarette maker at the upstream end of the line and, arranged in succession proceeding toward the downstream end, a filter tip attachment, a packer, a cellophaner, a cartoner and finally a machine by which pluralities of cartons are parcelled into boxes of whatever type, ready for despatch. Where large boxes are used, the despatch area will be equipped with an end-of-line palletizer.

The system may also comprise a filter plug maker associated with the filter tip attachment, and a number of inline storage units located between the single machines of the system, serving to compensate any differences in operating speed between one machine and the next.

In manufacturing systems of the type in question, each machine needs to be re-supplied periodically with consumables and packaging materials, including tobacco filler, filter plugs, rolls of cigarette paper, metal foil paper and thermoplastic material, packet blanks, coupons, revenue stamps, and so forth. To this end, each machine is equipped with at least one sensor monitoring the depletion of the relative materials, as well as a counter positioned at the outfeed stage of the machine and serving to indicate the number of items turned out.

The demands of the market at the present time are such that individual brands tend to be manufactured in short runs. This means that there are frequent changeover operations, which impact negatively on the long-term productivity of manufacturing systems. With each changeover, in effect, the machines have to be shut down and emptied, and the various consumables replaced entirely or in part.

Conventionally, the task of renewing the supply of consumables to the various machines is carried out by production line operators, relying on an approximate and empirical approach and allowing generous margins of safety so as to ensure the scheduled production target can be reached comfortably, in readiness for changeover to another brand. This results in a measure of overproduction, compared to the original target, and/or the waste of a notable quantity of consumable materials already occupying the production line of the system, which cannot be used in the subsequent run to manufacture tobacco products of a different brand. The operation of removing large quantities of material from the production line and returning these same materials to stock possibly for subsequent use is one that requires a relatively long period of time to complete, and, besides the negative impact on the productivity of the system as already intimated, there is also the risk that the materials could be damaged during handling and transit.

The object of the present invention is to provide a method of managing a system for the manufacture of tobacco products, such as will be unaffected by the drawbacks mentioned above and, more particularly, effective in minimizing the waste of consumables, avoiding damage to consumable materials and limiting overproduction in respect of scheduled targets.

A further object of the invention is to provide a method of managing a system for the manufacture of tobacco products that will be easily implemented and can be run automatically by a monitoring, processing and control system using a limited number of sensing and computing operations.

DISCLOSURE OF THE INVENTION

The stated objects are realized in a method according to the present invention, of which the characterizing features are readily discernible from the content of claim 1 appended and preferably from any one of the claims directly or independently dependent on claim 1.

The invention will now be described in detail, by way of example, with the aid of the accompanying drawings, in which:

FIG. 1 shows a schematic illustration of a system for the manufacture of tobacco products allowing implementation of the method according to the present invention;

FIG. 2 is a block diagram showing a first preferred procedure for implementation of the method of managing and controlling the system illustrated in FIG. 1;

figure is a block diagram showing a second procedure for implementation of the method of managing and controlling the system illustrated in FIG. 1.

Referring to FIG. 1 of the drawings, 1 denotes a system for the manufacture and packaging of tobacco products, in its entirety, comprising a plurality of machines linked one to another along a production line denoted 2. More exactly, and proceeding from the upstream to the downstream end of the line 2 along the flow path, the system 1 incorporates a cigarette maker 3 turning out cigarette sticks 4, a filter tip attachment 5 turning out filter cigarettes 6, and a packer 5 turning out packets 9 of cigarettes. The packer 7 is connected on the one hand to the filter tip attachment 5, by way of a buffer 8 allowing temporary inline storage of the filter cigarettes 6, and on the other to a cellophaner 10 turning out overwrapped packets 11. The overwrapped packets 11 emerging from the cellophaner 10 are directed into a cartoner 12 by which the selfsame packets 11 are packaged in cartons 13. The cartons are then conveyed into a parceller 14, by which they are packed into boxes 15 of whatever size and style and 9 directed toward an outfeed station of the line 2.

The various machines 3, 5, 7, 10, 12 and 14 are interconnected along the line 2 by means of conveyor devices, of which the conveyor 16 linking the filter tip attachment 5 and the packer 7 and the conveyor 17 linking the packer 7 and the cellophaner 10, in particular, are indicated in FIG. 1.

The line 2 is supplied at points alongside each of the machines 3, 5, 7, 10, 12 and 14 with respective wrapping materials, all denoted 18 and consisting in rolls of paper, metal foil and polypropylene, cardboard blanks and the like. Also supplied to the line 2 are additional and/or auxiliary materials such as coupons and revenue stamps, denoted 19 generically in FIG. 1.

Associated with each of the machines 3, 5, 7, 10, 12 and 14, and indicated by relative blocks, are respective counters such as will generate a signal indicating the number of products turned out by each machine 3, 5, 7, 10, 12 and 14. In particular, two counters denoted 20 and 21 are associated with the machines 3 and 5 producing the cigarette sticks 4 and filter cigarettes 6, respectively; two counters 22 and 23 are associated respectively with the packer 7 and the cellophaner 10, serving to keep a tally of erected packets 9 and overwrapped packets 11; and two further counters 24 and 25 associated with the cartoner 12 and the parceller 14 serve respectively to keep a tally of the cartons 13 and of the filled boxes 15 at the aforementioned outfeed station.

Also forming part of the system, and illustrated by relative blocks, are sensors able to generate a signal indicating the consumption of the wrapping materials 18 and the additional and/or auxiliary materials 19 utilized by the corresponding machine during its operation. In particular, sensors 26 and 27 associated respectively with the cigarette maker 3 and with the filter tip attachment 5 serve to monitor the consumption of the rolls 18 of paper material used to make the cigarette sticks 4 and the filter cigarettes 6, respectively; similarly, sensors 28, 29, 30 and 31 associated with the packer 7, the cellophaner 10, the cartoner 12 and the parceller 14 serve to monitor the consumption of the materials 18 used by these same machines, typically rolls,,blanks and the like. In addition, a counter 32 associated with the packer 7 will generate a signal indicating the number of revenue stamps or coupons 19 used by this same machine 7.

A sensor 8a associated with the cigarette buffer 8 serves to generate a signal indicating the number of cigarettes 6 occupying the buffer.

The counters 20, 21, 22, 23, 24, 25 and 32 and the sensors 8a, 26, 27, 28, 29, 30 and 31 are connected on the output side to a master control unit 33 which in turn is connected in conventional manner, not illustrated, to the internal control units of the single machines making up the system 1.

The connections between the single counters and sensors and the control unit 33 are not illustrated in FIG. 1.

The master control unit 33 is able to store and process data received from the counters and sensors.

Also connected to the master control unit 33 are a terminal device 34 by way of which to preset a nominal target number P_n of products, for example boxes 15, to be turned out by the system 1 during a given production run, and a terminal device 35 by way of which to preset a constant factor C_max indicating the maximum output capacity of the system 1, that is to say its maximum capability, in terms of the maximum quantity of products in process that the system can accommodate.

Factor C_max is a number that will be dependent on the type of machines making up the system, and in particular their capacity to store finished products or products in process temporarily, on the length and capacity of the conveyors used in the system, and on the maximum capacity of buffers or other inline storage facilities installed. The value of C_max can be expressed as a number of cigarettes, that is to say elementary products, or alternatively, according to respective conversion factors that will be constant and predetermined for each brand of products, as a number of packets, cartons or boxes. For whatever system and for any given brand of products, at all events, factor C_max remains a constant.

The method of managing the system 1 according to the present invention involves counting the number P of at least one among the aforementioned products turned out by one of the machines. In particular, the number P of boxes 15 turned out by the parceller 14 is monitored by the relative counter 25, which relays a corresponding signal to the master control unit 33.

At a given moment t₁ when the number of products P equals a reference value P_r such that the master control unit 33 recognizes a match between the aforementioned target number P_n of boxes 15 and the sum of the number P_r of boxes 15 already packaged plus the value C_max indicating the maximum number of boxes 15 the system 1 is able to produce, in other words when P_n=P_r+C_max, the master control unit 33 runs a first flash check on the actual quantity C₁ of products 15 turned out by the system 1.

The flash check run by the master control unit 33 consists in comparing the value of quantity C₁ registering at moment t₁ with the aforementioned constant factor C_max, so it can establish what action needs to be applied to the system 1 on the basis of the comparison. The procedure in question will now be described with reference to FIG. 2.

Referring to the block diagram of FIG. 2, the master control unit 33 will execute the following sequence of steps, of which the first step, or start, is indicated by a block denoted 36.

The start block 36 is followed by a block 37 that indicates both the step of presetting the target number P_n of boxes 15 by way of the device denoted 34 in FIG. 1, and the step of presetting a value C_max representative of the maximum quantity of boxes 15 the system is able to produce, by way of the device denoted 35 in FIG. 1.

The presetting block 37 is a followed by a block 38 that indicates the step of counting the number P of products turned out by the single machines 3, 5, 7, 10, 12 and 14, and in particular, to reiterate, the number of boxes 15 turned out by the parceller 14, the last machine of the line 2.

The counting block 38 is followed by a comparison block 39 that indicates the step of verifying a condition of parity between the number P and the value P_n=P_r+C_max. It will be observed that, like P_n and C_max, P_r is also a predetermined constant. At the moment t₁ when P matches P_r and the condition P_n=P_r+C_max is satisfied, a control signal will be relayed from the comparison block 39 by way of the YES route to a successive monitoring block 40 which is in receipt of input signals from the counters 20, 21, 22, 23, 24, 25 and 32 and the sensors 8a, 26, 27, 28, 29, 30 and 31, of which the outputs are connected to the master control unit 33, and capable of running the first flash check on the basis of the input data to verify the actual quantity C₁ of boxes 15 turned out by the system 1 at the predetermined moment t₁.

It will be observed that a signal returned via the NO route from the comparison block 39 indicates that no control response is triggered, deferring the flash check as long as value P remains less than P_r.

On receiving the control signal from the comparison block 39, the monitoring block 40 relays a signal indicating the actual quantity C₁ of products to a second comparison block 41, which compares this quantity C₁ with the preset quantity C_max so it can establish what action needs to be applied to the system 1 on the basis of the comparison.

In the event that the value C₁ registering at moment t_i is substantially the same as value C_max, a signal is relayed via the YES route to a block denoted 42, instructing preparation and initiation of the procedure for changeover to another brand of tobacco products. The procedure in question may be confined to a single machine, the cigarette maker 3 for example, and concerned in particular with the operation of emptying this same machine, or it might also cover the other machines of the system 1.

In the event that the value C₁ registering at moment t₁ is less than the value C_max, no signal is relayed to the changeover block 42, whereas a signal is returned via a NO route to an event generator block denoted 43 located externally of the master control unit 33, indicating the difference between value C_max and value C₁ measured at moment t₁.

Assuming the difference in question corresponds to a given number of cartons 15, say X, then at the moment t₂ when the counter 25 associated with the outfeed of the parceller 14 gives a tally of boxes 15 corresponding to P_r+X, the event generator block 43 will relay a control signal to a further monitoring block 44 instructing a second flash check of the actual quantity C₂ of boxes 15 turned out by the system 1 at the second moment t₂. On receiving the signal from the event generator block 43, the monitoring block 43 relays a signal indicating the actual quantity C₂ of products to a further comparator block 45, which proceeds to compare this value C₂ with the previous value C₁.

Should it emerge from this comparison that C₂ is equal to C₁, a signal is relayed by the comparator block 45 via the YES route to the changeover block 42, instructing preparation and initiation of the procedure for the switch to another brand of products. Conversely, if C₂ is less than C₁, a signal is returned by the comparator block 45 to the event generator block 43, via the NO route, indicating the difference X′ between value C₁ and value C₂.

At the moment t₃ when the counter 25 associated with the outfeed of the parceller 14 gives a tally of boxes 15 corresponding to P_r+X+X′, the event generator 43 will relay a control signal to the monitoring block 44 instructing a third flash check of the actual quantity C₃ of boxes 15 turned out by the system 1 at the third moment t₃.

The steps of the method are repeated, and the flash checks will continue until the comparison produces a match expressed as C_i=C_i-1, where i=2, 3 . . . , which signifies that the target number P_n has been reached.

It will be appreciated that in order to avoid overproduction, C_i must never be greater than C_i-1. This can be ensured simply by piloting the system 1 to respond, with effect from the first flash check, by emptying the buffer 8 at least in part, and more generally by depleting all reserves of materials at the various machines, during the interval between generic moments t_i and t_i-1.

Similarly, it will be noted that the method of management described above uses a non-programmed, event-controlled type of loop where the single events are the consequence of measuring output numbers P equivalent respectively, starting from the first event, to P_r, P_r+X, P_r+X+X′, etc.

It has been found by experiment that the procedure can be concluded with a minimal number of flash checks, for example two or three.

The objects stated at the outset are thus realized with the method described above, in that consumable materials can be organized so as to minimize waste and avoid damage, and overproduction reduced to minimal levels, by virtue of a logic that is simple to implement and can be run automatically by a monitoring, processing and control system using a limited number of sensing and computing operations.

In a variation on the method described above, illustrated in particular by the block diagram of FIG. 3, the single events are dictated by the value of output numbers P which, starting from the first event, will be compared with thresholds expressed respectively as P_r, P_r+1, P_r+2, etc. In other words, the production threshold that determines the first event corresponds to P_r=P_n−C_max and each threshold determining a successive event is obtained by applying a unitary increment of the previous threshold.

In accordance with the principle already mentioned, the flash checks occur at moments t₁, t₂, t₃ . . . that are not programmed, but rather dependent on the production thresholds of one of the products turned out by one of the machines 3, 5, 7, 10, 12 and 14 making up the system 1. It might be advantageous, for example, to monitor the cigarette maker 3 and consider the unitary increment in output from the machine as a further number of cigarettes equivalent to the contents of one box 15.

To this end, the unitary increments in output from the cigarette maker 3 will be constants typical of the brand in production.

Likewise in this instance it has been found by experiment that the procedure can be concluded with a minimal number of flash checks, for example two or three.

The block diagram of FIG. 3 differs from the block diagram of FIG. 2 essentially in that the event generator denoted 43 is replaced by a different event generator denoted 46, again separate from the master control unit 33.

As illustrated in FIG. 3 and described previously with reference to FIG. 2, as soon as P equals P_r, the monitoring block 40 will receive a control signal from the first comparator block 39 and direct a signal indicating the actual quantity C₁ of products to the second comparator block 41, which in turn measures this value C₁ against the preset value C_max indicating the maximum capacity of the system so as to establish what action needs to be applied on the basis of the comparison.

In the event that the value C₁ registering at moment t₁ is substantially the same as value C_max, a signal will be relayed via the YES route to the changeover block 42 instructing preparation and initiation of the procedure for a switch to another brand of tobacco products.

In the event that the value C₁ registering at moment t₁ is less than the value C_max, no signal is relayed to the changeover block 42, whereas a signal will be returned via a NO route to the event generator block 46 enabling the generation of events subsequent to the first.

At the moment t₂ when the counter 20 associated with the cigarette maker 3 registers an incremental number of cigarettes 4 equivalent to the contents of one box 15, hence P=P_r+1, the event generator block 46 relays a control signal to the monitoring block 44 ordering a second flash check of the actual quantity C₂ of boxes turned out by the system 1 at the second moment t₂.

The signal corresponding to value C₂ is sent to a comparator block 47 which measures this same value C₂ against a value indicating the difference between P_n and the number P=P_r+1 of boxes turned out up to moment t₂.

If the values match, a signal will be relayed by the comparator block 47 via the YES route to -the changeover block 42 instructing preparation and initiation of the procedure for a switch to another brand of tobacco products. If not, then a signal will be returned by the comparator block 47 to the event generator block 46, via the NO route, enabling the generation of events subsequent to the second.

The steps of the method are repeated until the comparisons produce a match expressed as P_n−P=C_i, where i=2, 3 . . . .

It will be seen that the moments t₁, t₂, t₃ . . . at which flash checks are run could also be dependent on the consumption thresholds for any one of the wrapping materials 18 or any one of the additional and/or auxiliary materials 19, for example the revenue stamps.

In all of the cases illustrated by way of example, moreover, the method disclosed could include the further step of establishing production thresholds for at least one of the products turned out by a given machine 3, 5, 7, 10, 12 or 14 operating in the system on the basis of a correction factor determined by statistical and/or experimental events. The step of defining a production threshold on the basis of a correction factor will take place following the last of a plurality of successive flash checks to measure the actual quantities of products turned out by the system 1.

Claims

1) A method of managing a system for the manufacture of tobacco products comprising a plurality of machines, typically cigarette makers, cigarette packers, cartoners, cellophaners, parcellers and the like, turning out products consisting respectively in cigarettes, packets, cartons, overwrapped packets or cartons, and packs or boxes, wherein the machines of the system can be supplied respectively with wrapping materials consisting typically in paper, metal foil, polypropylene and like, also with additional and/or auxiliary materials consisting typically in revenue stamps, coupons and the like, characterized in that it includes at least the steps of: programming a number (Pn) into a master control unit, representing a nominal production target for at least one predetermined product among those turned out by the machines of the system; programming a value (Cmax) into the master control unit, representing the maximum output capacity of the system expressed as a quantity of the predetermined product; counting the number (P) of at least one of the products emerging from the relative machine of the system and relaying a corresponding item of data to the master control unit; running a first check on the actual quantity (C1) of the predetermined product turned out by the system, at a moment (t1) when the number (P) of emerging products equals a value (Pr) such as will result in a match (Pn=Pr+Cmax) between the nominal production target (Pn) for the predetermined product and the sum of the number (Pr) of products turned out plus the value (Cmax) indicating the maximum output capacity of the system, the actual quantity (C1) expressing the real number of products in the making in the system such number indicating the actual quantity (C1) being obtained by controlling and/or counting one or more countable parameters necessary for carrying out the tobacco manufacturing; comparing the value of the actual quantity (C1) registering at the first check with the value (Cmax) indicating the maximum output capacity of the system, in order to establish what action should be applied to the system on the basis of the comparison.

2) A method as in claim 1, comprising the further step of initiating a procedure for changeover to another brand of tobacco products in the event that the actual quantity (C1) of products registering at the moment of the first check is substantially equal to the value (Cmax) indicating the maximum output capacity of the system.

3) A method as in claim 1, comprising the further step of running at least a second check on the actual quantity (C2, C3 . . . ) of the predetermined product turned out, in the event that the value of the actual quantity (C1) of products registering at the moment of the first check is less than the value (Cmax) indicating the maximum output capacity of the system.

4) A method as in claim 3, wherein the second check on the actual quantity (C2) of the predetermined product turned out is run at a moment (t2) established according to the difference between the value (Cmax) indicating the maximum output capacity of the system and the value of the quantity (C1) measured at the moment (t1) of the first check.

5) A method as in claim 4, comprising the further steps of running a plurality of checks subsequent to the second check on the actual quantity (C3, C4 . . . ) of the predetermined product turned out, wherein each check from the second onwards will determine the moment of running the next check, according to the difference between the value (Ci-1) corresponding to the output quantity measured at the previous check and the value (Ci) corresponding to the quantity measured at the current moment.

6) A method as in claim 5, wherein the moments at which the checks are run depend on respective production thresholds programmed for one of the products turned out by a given machine of the system.

7) A method as in claim 6, wherein the production thresholds are referable to any one of the machines making up the system, and each threshold comprises a number of relative products equal to or constituting a multiple of the number of products constituting the end product.

8) A method as in claim 6, wherein the production thresholds are referable to the final machine of the system.

9) A method as in claim 8, wherein the procedure for changing over to another brand of tobacco product is initiated when, following the steps of running a plurality of successive checks on output quantities (C2, . . . Ci, . . . ) subsequent to the quantity (C1) measured at the moment (t1) of the first check, there is a match (Pn−P=Ci) between a value given by the production target (Pn) for at least one predetermined product among the products turned out by the machines less the number (P) of at least one of the products turned out by the corresponding machine of the system, and the value of the quantity (C1) measured at a corresponding moment (ti) of running the check.

10) A method as in claim 9, wherein the moments (t1, t2, . . . ti) of running the checks are dependent on the consumption thresholds for at least one of the wrapping materials or the addition and/or auxiliary materials used by at least one predetermined machine of the system.

11) A method as in claim 8, comprising the further step of establishing the production thresholds for at least one of the products, turned out by a given machine of the system, on the basis of a correction factor determined by statistical and/or experimental events.

12) A method as in claim 11, wherein the step of establishing the production threshold on the basis of a correction factor takes place following the last of a plurality of successive checks to measure the actual quantities of products turned out.

13) A method as in claim 1, wherein the moments at which the checks are run depend on respective production thresholds programmed for one of the products turned out by a given machine of the system.

14) A method as in claim 3, wherein the procedure for changing over to another brand of tobacco product is initiated when, following the steps of running a plurality of successive checks on output quantities (C2, . . . Ci, . . . ) subsequent to the quantity (C1) measured at the moment (t1) of the first check, there is a match (Pn−P=Ci) between a value given by the production target (Pn) for at least one predetermined product among the products turned out by the machines less the number (P) of at least one of the products turned out by the corresponding machine of the system, and the value of the quantity (C1) measured at a corresponding moment (ti) of running the check.

15) A method as in claim 1, wherein the moments (t1, t2, . . . ti) of running the checks are dependent on the consumption thresholds for at least one of the wrapping materials or the addition and/or auxiliary materials used by at least one predetermined machine of the system.

16) A method as in claim 6, comprising the further step of establishing the production thresholds for at least one of the products, turned out by a given machine of the system, on the basis of a correction factor determined by statistical and/or experimental events.

17) A method as in claim 2, wherein the moments at which the checks are run depend on respective production thresholds programmed for one of the products turned out by a given machine of the system.

18) A method as in claim 3, wherein the moments at which the checks are run depend on respective production thresholds programmed for one of the products turned out by a given machine of the system.

19) A method as in claim 4, wherein the moments at which the checks are run depend on respective production thresholds programmed for one of the products turned out by a given machine of the system.

20) A method as in claim 4, wherein the procedure for changing over to another brand of tobacco product is initiated when, following the steps of running a plurality of successive checks on output quantities (C2, . . . Ci, . . . ) subsequent to the quantity (C1) measured at the moment (t1) of the first check, there is a match (Pn−P=Ci) between a value given by the production target (Pn) for at least one predetermined product among the products turned out by the machines less the number (P) of at least one of the products turned out by the corresponding machine of the system, and the value of the quantity (C1) measured at a corresponding moment (ti) of running the check.