Patent Application
20150026107
This invention relates to a system and method for the management of inputs from Operators operating within industrial processes, manufacturing systems and the manufacturing equipment comprising a part thereof, and for the collection and analysis of data derived from such inputs. The invention also relates to a system and method that analyses such input data and generates new parameters and instructions for the execution of the process steps relating to that industrial process or manufacturing system. More particularly, the invention relates to a system and method for on-site learning, storing, teaching and training manufacturing process know-how to skilled and semi-skilled operators. The invention also relates to a system and method for providing manufacturing process know-how to any person who may require it at any point.
The invention is addressed to the field of industrial processes and manufacturing systems, where industrial activities-executed by skilled and semi-skilled manufacturing equipment operators are captured, chronicled and analyzed in conjunction with the activities performed by the manufacturing system and status inputs received from the manufacturing system, the manufacturing equipment and the artifact being manufactured. The system comprises the creation of a knowledge-base of operational data relating to manufacturing systems and equipment, operator input, manufacturing performance parameters, artefact data, possible inputs resulting in manufacturing performance improvement in a given situation, analytic operations peformed upon any such data and their relationships, and the deployment of this knowledge to an operator or to any person to improve the performance of the manufacturing system.
A manufacturing system consists of multiple individual heterogenous manufacturing equipment including but not limited to machine tools and manufacturing equipment, metrology devices, sensors, actuators, auxiliary equipment etc. A manufacturing enterprise may comprise one or more manufacturing systems. Manufacturing system performance is determined by attributes including but not limited to: productivity, safety, quality, efficiency and maintenance.
Progressive sophistication and automation in the manufacturing sector calls for skilled operators to operate the manufacturing equipment and execute manual and semi-automated tasks, and they play a vital role in determining the efficiency of a manufacturing enterprise. The ‘skill’ of an operator in executing machine-related tasks (including but not limited to issuing commands to a machine, monitoring machine performance, obtaining desired output quality with optimal utilization of resources, ensuring safety of the machine, its surroundings and the operator/s, taking pro-active action to maintain the machine in good health etc.,) is a combination of acquired knowledge from training and work experience and intuitive insights. The aggregation of such skills of a set of operators in a given industrial processing or manufacturing set-up is referred to as tribal knowledge. In a number of manufacturing systems, the operator is given discretion to modify one or more process steps in the execution of a broad execution plan. With experienced operators, such discretion may be exercised to the benefit of one or more manufacturing performance parameters.
One prominent example of this situation, which by no means is construed as a limitation on the scope of the present invention, is that of high-speed milling. High-speed milling, especially when applied in aerospace or medical device manufacturing, involves manufacturing systems comprising equipment (“machine tools”) and tooling for the manufacture of highly accurate and precise parts in materials that are difficult to work with, like titanium, inconel, and aluminum. Planning the machining process (“process planning”) is a highly specialized task and is generally practiced by a skilled operator in a manufacturing facility. Executing a process plan for high-speed milling requires careful planning and a sound understanding of the milling process. While there are a few standard approaches on how to select the process parameters for a high speed milling operation, operators generally develop the process parameters and make a selection based on their observations of the manufacturing system, and their own knowledge and experience. The operator applies knowledge retained through observation and experience in developing the process plan to create the part. Developing an effective process plan involves selecting the appropriate tooling, and applying them to create the various part features at prescribed process parameters. In high speed milling, these parameters include spindle speed, path feedrate, axis feedrate, surface speed, depth of cut, width of cut, radial engagement, axial engagement, etc. The process parameters are also selected based on the type of machine tool the part is being made on and its capabilities. Thus the same part can be manufactured in a variety of ways using different tools and process parameters, and similarly, the same tool can be operated at different parameters to make a part. However, the knowledge applied by the operator in performing such an operation is highly contextual and incapable of being captured and analysed for future deployment. Additionally, there have been no scientific and reliable methods available in the art to capture, store and retrieve industrial/manufacturing tribal knowledge, particularly tribal knowledge related to manufacturing systems. As a result, hundreds of hours of training imparted by an enterprise to an operator to enhance his skill-level is lost when the operator retires or leaves the enterprise.
Attempts through traditional methods such as videography, interviews/surveys and other documentation have not been successful in capturing tribal knowledge. One significant reason for their failure is the lack of a well-founded system and method to first identify specific tribal knowledge. Even if there are (hypothetical) methods to capture tribal knowledge, there are even fewer methods to store it and make it available when needed. Again, with regard to the specific manufacturing systems surrounding the area of high speed milling, the state of the art involves using one or a combination of the following techniques:
The above techniques are very limited in their appeal because:
There is therefore a long unfulfilled need for a scientific and reliable system and method to (i) capture and store industrial process and operational machine data including operator input and environmental factors, (ii) analyse such data in order to identify elements of tribal knowledge therein and (iii) deploy such tribal knowledge, especially in a manufacturing system.
The inventors have invented a system and method to (i) capture and store industrial process and operational machine data including operator input and environmental factors, (ii) analyse such data in order to identify elements of tribal knowledge therein and (iii) deploy such tribal knowledge, especially in a manufacturing system. Such a system could be utilized for the purposes of (i) making it available at the right time in the form of training and for analytics and knowledge sharing, and (ii) building a data warehouse of such captured data for the purposes of further analytics.
The main object of this invention is to (i) capture and store industrial process and operational machine data including operator input and environmental factors, (ii) analyse such data in order to identify elements of tribal knowledge therein and (iii) deploy such tribal knowledge, especially in an industrial process.
Another object of this invention is to provide for a system that executes technical operations and overrides that boost the efficiency of industrial processes;
Yet another object of this invention is to provide for a chronicled knowledge base of every transformation undergone by the industrial process and/or manufacturing system and the artefacts pertaining thereto from the date of installation, including sequence logs of the causative antecedent factors for every transformation
Yet another object of this invention is to analyse the above-referenced knowledge bases and deploy the knowledge base and analytics derived therefrom in an industrial process and/or manufacturing system.
Yet another object of this invention is to provide for a system that identifies and qualifies specific transformation patterns based on their causal antecedents and classifies them according to their (relative and absolute) resource intensiveness (such as consumption of power, raw material, time, output quality etc.,) and desired parameters that determine its performance;
Another object of this invention is to provide for a system that computes complex cause-effect linear and non-linear relationships of known inputs with other perceptible factors of the industrial processes resulting in realistic and scientific forecasts.
Another object of this invention is to apply the captured tribal knowledge towards the identification of key performance attributes of industrial processes and equipment not envisaged by the manufacturer or the end-user.
Another object of this invention is to provide for real time evaluation and analysis, of an operator's action/input in terms of conformance to/deviation from a given plan.
Another object of this invention is to develop and maintain a warehouse of indexed data starting from the date of installation of this invention on a perpetual basis comprising every transformation including (but not limited to): material removal; rate of material removal; surface properties; mechanical wear; heat conducted, absorbed, dissipated, radiated in unit time; Electric including static charge inducted/discharged; mass; volume; dimensions; artifact quality; vibration in components; process execution capabilities; position, velocity, and acceleration of equipment components and sub-components during process execution; consumption rate of consumables and resources; time lapsed between process steps; order of execution of process steps; commands executed by process equipment.
A further object of this invention is to assess the capability and suitability of operators for a given job work in a manufacturing process and to rank and re-rank them on an ongoing basis either non-intrusively or otherwise, against parameters (including but not limited to) job-protocols; discipline to process compliance; efficiency of resource and consumable consumption; adherence to delivery deadlines; output quality and quantity; material handling efficiency; maintenance and functional life of manufacturing system.
A further object of this invention is to analyse the captured tribal knowledge base in identifying the type of knowledge to be communicated to an operator based on assessing the immediate needs of the operator. A further object of this invention is to communicate such identified tribal knowledge to the operator using an appropriate communications interface in real-time.
A further object of this invention is to develop a knowledge database of accumulated tribal knowledge for future reference and analysis by an operator or other person.
A further object of this invention is to analyse a database of performance attributes of a given manufacturing system, component within an manufacturing system or combination of manufacturing systems in order to provide analytics of use to any person interested in the maintenance, operation or optimization towards improvement of manufacturing performance parameters of such manufacturing systems or steps or components thereof.
According to this invention there is therefore provided a system, and method to enable data capture in an industrial process, analysis of such captured data for the purposes of tribal knowledge identification and deployment of such tribal knowledge.
The system consists of the following elements:
The method by which the system captures data for a given iteration of a operation, analyses the captured data for the purpose of tribal knowledge identification and deploys the data is described as follows:
The invention provides for a system of data collection, data analysis and tribal knowledge identification, and deployment of tribal knowledge in a manufacturing system. The invention includes the system, devices, apparatus and methods of the invention. The invention relates to the management of manufacturing system sensor inputs according to instructions sent by the system. The system collects and analyses including operational machine data, inputs from the operator unit and environmental factors. The analysis of the collected data allows the system to generate new parameters and instructions for the execution of the broad execution plan.
The invention seeks to perform certain steps within ‘real-time’. For the purposes of this invention, the delineation of time and process intervals and the explanation of the term ‘real-time’ is as follows:
The broad execution plan is a list of instruction that lays out the prescribed process steps for performing one or a series of transformations upon an artifact. The broad execution plan may be reduced into a recorded medium, such as paper or instructions on a visual display unit, orally instructed to the operator or merely internalized within the operator's memory. The broad execution plan is divided into a number of process steps or operations. The operator has the discretion to modify the manner in which a process step is performed as well as to alter their sequence, dispense with certain process steps and/or add new process steps within the broad execution plan.
A process step is a defined task that a machine tool, system or operator has to perform in order to work a transformation upon an artefact.
A function is said to be performed by the invention or any part thereof in real-time when the said function is performed before the commencement of the process step subsequent to the one for which data pertaining to that function has been collected.
The manufacturing system sensor inputs capture operational data through inputs from devices such as computerised numeric controller (CNC), numeric controller (NC) and programmable logic controller (PLC) accelerometers, gyroscopes, thermistors, thermocouples, vibration sensors, optical gauges, eddy current sensors, capacitive sensors, power meters and energy meters.
The operational data to be captured by the system includes data relating to all or any of the following operational parameters: acceleration, vibration, temperature, position, energy usage, current drawn, voltage, power factor, magnetic field, distance, position, capacitance; and data reported by a CNC and/or PLC controller including: axes positions, axes feedrate, surface speed, path feedrate, axes acceleration, axes jerk, spindle speed, axis loads, spindle loads, program block being executed, program line being executed, current macro variables in CNC memory, alarms, messages, other notifications.
The environmental factors that may be captured include date, time, manufacturing system characteristics (such as age, make, model, etc), Maintenance status, Operator status, and state of operation.
The artefact is a physical object that is transformed by the manufacturing system.
The system provides for operator sensor inputs that capture data inputted by a manufacturing equipment operator over the course of the execution of the manufacturing equipment operation.
The metrology equipment used for the capture of data by the system includes gage blocks, coordinate measurement machines (stationary and portable), go/no-go gages, capacitance probes, laser-based systems, interferometry, microscopy, profilometry, air gages, LVDT probes and articulating arms.
The broad execution plan is communicated to the operator using appropriate means before the commencement of the operation. Such means may include video display units, audio players, written instructions and oral instructions. The operator is made aware of the overall method of the operation of the manufacturing equipment.
The display unit of the system used to communicate instructions to the operator includes video monitors, video screens and the like.
The operator inputs commands to the machine tool using an input interface which may include keyboards, touch screens and buttons.
The data collection unit collects the data from the operation of the manufacturing equipment. The collected data includes operational data from the manufacturing equipment sensor inputs, data inputs from the manufacturing equipment operator retrieved from the operator sensor outputs, data relating to the artefact retrieved from the metrology equipment and data relating to the broad execution plan. The data collected by the data collection unit is transmitted via a first data transmission unit. The collected data transmitted through the first data transmission unit is then sent to a server. The transmitted data is stored on a first data storage unit located on the server. This storage unit is intended for short term storage. The analysis unit is located on the server. The analysis unit is a specific set of programs that performs retrieval and selects operational parameters from the captured data. The operational parameters selected are manufacturing performance parameters including productivity, efficiency, utilization, failure rate, rejection rate, first-time quality, overall equipment effectiveness, operating cost, product cost, production efficiency, rejection rate, rejection rate parts per million, rework rate, availability, in-cycle time, cycle time, available time, repair time, planned downtime, unplanned downtime, total downtime. The long term storage of the transmitted data is achieved by means of a second data storage unit, which may also be the historical data repository unit located on the server. In addition to the transmitted data, the historical data repository unit also contain:
The evaluation unit located on the server compares the operational parameters selected by the analysis unit such as operational data, operator input data and artifact data against the corresponding historical data stored in the historical data repository. The first logic unit is located on the server. The first logic unit determines whether the operator input of the transmitted data deviates from the corresponding historical data of the same or similar machine tool and the broad execution plan. The second logic unit is also located on the server. The second logic unit determines whether the operational data and artefact data of the transmitted data deviate from the corresponding historical data of the same or similar machine tool and the broad execution plan. A third logic unit, also located on the server, determines relationships between the deviations determined from operator input and deviations determined from the operational data and artefact data. The learning unit is located on the server and determines whether the relationships so determined by the third logic unit result in improvements in operational parameters of the manufacturing tool, manufacturing performance parameters and/or the artifact. The fourth logic unit, also located on the server, compares operator input data against historical operator data. The compared sets of data pertain to data from the same or similar manufacturing tool that has resulted in improvements in operational parameters of the machine tool, manufacturing performance parameters and/or the artefact. The fifth logic unit present on the server determines the alternative operator inputs that would result in improvements in the manufacturing performance parameters. The teaching unit is also located on the server. The teaching unit creates recommendations based on alternative operator inputs that would improve the parameters relating to manufacturing performance. The second data storage unit located on the server stores the improvements determined by the logic unit. These determinations relate to improvements in operational parameters of the machine tool, manufacturing performance parameters and/or the artefact including the transmitted data at the time of operation of the machine tool. The second storage data unit also stores the recommendations which correspond to improvements in manufacturing performance parameters achieved as a result of alternative operator input. The system includes a second data transmission unit to transmit the recommendations regarding alternative operator inputs to machine tool operator or any other person. The recommendations are designed to result in improvements in the manufacturing performance parameters.
In addition to the above, there may be an embodiment where the server is remotely located in relation to the location of the manufacturing system. The remotely located server is located in a different location and is not within the physical proximity of the manufacturing system.
There may also be an embodiment in which the second data storage unit is the same as the historical data repository unit.
The transmission of recommendations from the second data transmission unit as mentioned above can be made to one or a plurality of persons including the machine tool operator. The machine tool operators receive the recommendations in real time so that they may be applied during the course of the execution of the machine tool operation.
The method by which data collection, data analysis and tribal knowledge identification, and deployment of such tribal knowledge is implemented is by first collecting operational data from the manufacturing system sensor inputs, machine tool operator, metrology equipment and the broad execution plan. The collected data is then transmitted through a first data transmission unit to the server. The data is then stored in the first data storage unit. The transmitted data is then analysed by the analysis unit which determines the manufacturing performance parameters for manufacturing the artefact. The data culled by the analysis unit includes any deviations in operational parameters owing to alternative operator input. The transmitted data is then compared with historical data by the evaluation unit. The evaluation unit compares the operational data, operator input data and artefact data of the transmitted data against corresponding historical data already present in the historical data repository. The evaluation unit detects variations in transmitted data as against historical data. The first logic unit then detects deviations in the operator input data. This determination is arrived at by comparison with the corresponding historical data relating to the same or similar manufacturing tool. The deviation is also determined using the broad execution plan. A second logic unit then determines deviations in operational data and artefact data. This determination is arrived at by comparison with the corresponding historical data relating to the same or similar manufacturing tool. A third logic unit then identifies and analyses relationships between determined deviations in operator input data against determined deviations in operational data and artefact data. A learning unit then determines improvements in operational parameters of the machine tool, manufacturing performance and/or the artefact. The learning unit determines these improvements through the relationships determined by the above-mentioned third logic unit. The learning unit stores the improvements in operational parameters for use in subsequent execution plans. A second storage data unit then stores the transmitted data captured at the time of operation and the determined data. The determined data includes improvements in operational parameters of the machine tool, manufacturing performance and/or the artefact. A fourth logic unit is used for the comparison of data inputs made by the operator against previously made historical operator input data. The compared data inputs pertain to the same or similar machine tool where the data inputs resulted in improvements in operational parameters of the machine tool, manufacturing performance and/or the artefact. A fifth logic unit determines whether alternative operator inputs such as deviations from the broad execution plan, i.e., tribal knowledge, would result in improvements in the operational parameters of the machine tool and/or the artefact. The teaching unit is used in the dispensation of the collected tribal knowledge to other operators. The teaching unit makes recommendations to the operators, regarding alternative operator inputs that would improve the operational parameters of the machine tool and/or artefact. The above mentioned recommendations generated by the teaching unit are stored in the previously disclosed second data storage unit. The recommendations generated by the teaching unit are then transmitted to the machine tool operator in real time. The fifteenth aspect of the invention relates to the means by which the data collecting unit collects the operational data from the manufacturing system sensor inputs, the data inputted in the operator sensor units by the machine tool operator, the data about the artefact produced that is retrieved from the metrology equipment and the data pertaining to the broad execution plan. The data collection unit operates in real time. In one aspect of the invention, the server referred to is remotely located in relation to the location of the manufacturing system and is not within the physical proximity of the manufacturing system. In another aspect of the invention, the second data storage unit is the same as the historical data repository unit mentioned above. A further aspect of the invention provides for the transmission of recommendations made by the afore-mentioned learning unit to multiple persons. The learning unit transmits the recommendations based on alternative operator input to the machine tool operator or to any other person so that they may also achieve improvements in the operational parameters of the machine tool and/or the artefact. Another aspect of the invention relates to the transmission of the recommendations in real time. The machine tool operators receive the recommendations in real time so that they may be applied during the course of the execution of the machine equipment process step.
The following working embodiment illustrates the use of the invention in the context of a specific manufacturing system, involving high speed milling. The steps by which operational data is collected, processed for identifying tribal knowledge and deployed along with relevant algorithms within the manufacturing system are outlined below:
A. Data Collection
Override on the machine tool to 125% just at the start of machining as tribal knowledge
A sample algorithm is provided below to illustrate the calculation of manufacturing performance parameters for Cycle Time and Average Path Feedrate
A sample algorithm is provided below to illustrate the comparison of transmitted operational data with historical data and the marking of such data as tribal knowledge
A sample algorithm is provided below to illustrate the identification of tribal knowledge and the teaching of the same to the Operator.
| Number | Date | Country | Kind |
|---|---|---|---|
| 3571/CHE/2011 | Mar 2012 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IN2013/000162 | 3/18/2013 | WO | 00 |
