Data processing: generic control systems or specific application – Generic control system – apparatus or process – Having operator control interface
Reexamination Certificate
2000-01-06
2002-06-04
Grant, William (Department: 2121)
Data processing: generic control systems or specific application
Generic control system, apparatus or process
Having operator control interface
C340S870030, C705S014270
Reexamination Certificate
active
06400997
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention is related to apparatus and methods for factory automation and tracking. In particular, the present invention is directed to a factory automation apparatus which includes a plurality of portable tablets and an automation server in wireless communication, and the software for implementing a paperless factory automation system with that apparatus.
BACKGROUND OF THE INVENTION
Facilities which machine custom parts are traditionally managed with a variety of paper systems. For example, time records are kept on time cards which need to be gathered and analyzed. Component drawings for a given job are created on large sheets of paper and provide the necessary dimensional and manufacturing requirements for the job. Other examples include manufacturing orders, manufacturing instructions statistical process control (SPC) data sheets and yellow tag or discrepant component data sheets. Each of these paper systems require manpower to gather and analyze the data and physical space to store and archive the various papers.
Additionally, the nature of the paper system is susceptible to lost information, incorrect information, and information recorded in disparate documents which are not readily available to the person needing the information. Papers can be misplaced or information transcribed incorrectly. Paper systems also significantly delay responses to customer inquires because the manager must determine who is working on the job, either seek out that person or check a job board for status and sometimes determine additional information, such as why a job is suspended. The potential also exists that the information located on the job board is not current.
Therefore, a need exists for a system that can move beyond the traditional paper management systems and allow employees to enter all types of data into an easily accessible system that collects, processes and stores the data in a central location which is also easily accessible from various locations within or remote from the facility. The system needs to collect and compile employee data, such as time records, location and current assignments; and job information, such as schedules, current status and supporting documentation. The system also needs to enable managers the capability to instantly view the employee and job information so that the manager can respond to customer inquires and can quickly reallocate resources to meet scheduling requirements.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus and method for a paperless factory automation system. The apparatus of the paperless factory automation system includes a plurality of portable tablets used by operators, a central automation server in wireless communication with the tablets. The method collects, processes and stores information for a plurality of jobs being performed by a plurality of operators in a facility.
The factory floor tablet automation system collects, stores and processes manufacturing data generated throughout a facility during manufacturing, and makes the manufacturing data accessible from various locations throughout the facility. The factory floor tablet automation system includes a server computer, multiple portable tablet devices, and one or more transceivers. The server computer has a processor unit and storage device, and maintains a plurality of databases including a job assignment database, an operator assignment database, a job description database, a drawing repository, a process control database, and a time keeping database. Each of the multiple portable tablet devices has a processor unit, a memory device, a display screen, an input/output device and a tablet antenna. The transceivers are located throughout the facility and each transceiver is connected to the server computer. The plurality of portable tablet devices is in wireless communication with the server computer through the transceivers and the tablet antennas. A job is assigned to an operator in the facility and one of the portable tablet devices is allocated to the operator. The operator accesses and receives information from the server computer and the storage device through the allocated portable tablet device. The server computer receives, stores and processes information from the operator through the allocated portable tablet device for tracking the status of the job and for tracking time allocation of the operator.
The factory floor tablet automation system can also include a command center which has a processor unit, a display device, and an input device. The command center communicates with the server computer, and is used to populate and retrieve data from the databases stored on the central server, and to determine job status and operator time allocation. A bar code printer and a bar code reader can be connected to the command center. The bar code reader communicates with the server computer, and the command center prints a job bar code for each job using the bar code printer. The operator acknowledges receipt of the job by scanning the job bar code with the bar code reader and inputting an operator identifier. The server computer associates the job with the operator that scanned the job bar code.
The factory floor tablet automation system can also include a discrepant material report station having a processor unit, a display device, and an input device. The discrepant material report station communicates with the server computer. Discrepant material reports that identify discrepant materials or parts discovered during processing of a discrepant job are sent to the discrepant material report station. The discrepant material report station tracks proposed dispositions of the discrepant material identified in each of the discrepant material reports, and tracks the approval of the proposed dispositions. The discrepant material report station can present the user with a list of proposed dispositions for the discrepant material including a rework disposition. When the rework disposition is selected, the discrepant material report station enables the user to view scheduled operations, to add operations, to delete operations, to resequence operations, and to associate sketches or resources with operations for further processing of the discrepant material.
The factory floor tablet automation system can also include a statistical process control (SPC) parameter setup station having a processor unit, a display device, and an input device. The SPC station communicates with the server computer. The SPC station enables a user to add an SPC data entry point by positioning an SPC icon for the SPC data entry point on a sketch associated with an job and associating a quality characteristic of the job with the SPC data entry point. A portable tablet device displays the SPC icon for the SPC data entry point when the sketch is displayed on the portable tablet device. The operator can enter SPC data for the quality characteristic of the SPC job by selecting the SPC icon of the SPC data entry point on the portable tablet device.
A method for factory floor automation which includes collecting, processing, storing and accessing information for a plurality of jobs being performed by a plurality of operators in a facility. Job information is stored for the plurality of jobs on a central computer having a processor unit and a storage device. One of a plurality of portable computing devices is allocated to one of the operators. Each of the portable computing devices includes a processor unit, a memory device, a display device, an input/output device and an antenna, and each of the portable computing devices communicates wirelessly with the central computer. At least one of the jobs is assigned to an assigned operator. An assigned portable computing device is associated with the assigned job by knowing the operator assigned to the job and the portable computing device allocated to the assigned operator. The job information for the job is made accessible to the assigned operator through the assigned computing device. Manufacturing
Bose McKinney & Evans LLP
Gain, Jr. Edward F.
Grant William
Rapp, III Roy
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