Process line changeover

Abstract

Methods for changing over a production line from a first product to a second product are described herein. One method involves assigning a changeover code to the first product and the second product and determining a cleaning type for the changeover. A second method involves receiving a plurality of batch production orders for a plurality of products. A cleaning type is determined for different sequences of the batch production orders and a sequence is selected that reduces an amount of time required to clean the production line during the changeover. A third method involves transferring a product to a filling station prior to receiving a quality control test result. The product is held at the filling station until the test result is received. If the product passes the quality control test, the product is dispensed by the filling station; otherwise, if the product fails the quality control test, the product is isolated.

Description

Technical Field

[0001] This disclosure relates to batch processing as a whole, and specifically to production line changeover in the coating manufacturing process in the specific implementation scheme. Background Technology

[0002] A production line change occurs when the product manufactured on a production line changes. For example, in the paint manufacturing process, a change of production line may be necessary when the color, hue, or gloss of the paint being produced is altered. Production line changeovers directly impact the entire production value chain. Example Implementation Plan Overview

[0003] The following is a simplified overview of the example embodiments to provide a basic understanding of some aspects of them. This overview is not a comprehensive summary of the example embodiments. It is not intended to identify key or essential elements of the example embodiments, nor is it intended to define the scope of the appended claims. The sole purpose of this overview is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that follows.

[0004] According to an example implementation, this document discloses a method for determining the type of cleaning to be performed for a production line changeover. A first (or current) product has a first code corresponding to the attributes of that first product, and a second (or next) product has a second code corresponding to that second product. A lookup is performed to obtain the appropriate cleaning type for the combination "first product followed by second product", and the appropriate cleaning type is performed.

[0005] Based on an example implementation, this paper discloses a method for scheduling production batches based on cleaning type. Multiple batches are provided, and cleaning types (and therefore times) are determined for different sequences within the batches. Sequences that reduce cleaning time are selected.

[0006] According to an example implementation, this document discloses a method for accelerating the filling process after batch completion. While the product is being tested, it is moved to the filling station. If the product is approved, it is allocated; otherwise, it is isolated and / or otherwise disposed of. Attached Figure Description

[0007] The accompanying drawings, which are incorporated herein and form part of this specification, illustrate exemplary embodiments.

[0008] Figure 1 This is a block diagram of a system employing an automatic cleanup component, based on an example implementation.

[0009] Figure 2 This is a table that illustrates examples of formal digital line-changing codes.

[0010] Figure 3This is a table that illustrates the example cleaning type.

[0011] Figure 4 This is an example of a system that can be used to accelerate filling inspection.

[0012] Figure 5 An example of a paint production line is shown.

[0013] Figure 6 This is a block diagram illustrating an example of a paint production line.

[0014] Figure 7 This is a block diagram illustrating an example of a method for selecting a cleaning type.

[0015] Figure 8 This is a block diagram illustrating a method for scheduling batch jobs to reduce cleaning time.

[0016] Figure 8 This is a block diagram illustrating a method for accelerating filling inspection.

[0017] Figure 10 It is a computer system on which example implementation schemes can be implemented. Description of the example implementation plan

[0018] This description provides examples that are not intended to limit the scope of the appended claims. The accompanying drawings generally indicate features of these examples, and it should be understood and appreciated that similar reference numerals are used to refer to the same elements. References in the specification to “one embodiment,” “an embodiment,” or “an example embodiment” mean that the particular feature, structure, or characteristic described is included in at least one embodiment described herein, and not that such feature, structure, or characteristic is present in all embodiments described herein.

[0019] The example embodiments herein describe a method for changing production lines for a process. Although the description herein describes a method for implementing a coating manufacturing process, those skilled in the art will readily understand that the features described herein can be applied to any manufacturing process that employs liquid, dry materials and / or gases in the production of a product, and therefore, this disclosure should not be construed as limited to coating manufacturing.

[0020] This document describes an automated cleaning component that performs cleaning steps based on a cleaning type definition. The batch process includes a recipe (or process recipe) and a code referred to herein as a Formal Digital Changeover Code (“FDCC”). The batch process is monitored, and upon determining that a changeover has been initiated, the controller identifies the recipe for the current batch process and the recipe for the next batch process, along with their associated recipe digital changeover codes. Based on the formal digital changeover codes, the cleaning type and associated steps are retrieved from a database. The changeover steps are communicated to the filling machine computer, equipment PLC, and operator interface.

[0021] A scheduling tool is described in the example implementation described herein. It receives orders for batches to be produced. This scheduling tool provides visibility and control over orders in the manufacturing process. The scheduling tool schedules filling orders based on cleaning type to reduce the time spent cleaning equipment. An example of this is scheduling several consecutive "no-clean" transitions, then allowing the schedule to provide a single "simple clean" or "full clean." This helps maintain the cleanliness of the filling machine and prevents unexpected filling inspection failures. In a specific implementation, the scheduling tool automatically sorts orders before processing each batch to minimize cleaning time.

[0022] An accelerated filling check is described in the example implementation herein, which supplies product to the filling line prior to approval of a quality filling check. The accelerated filling check is activated based on an approved formulation digital changeover code conversion and the incoming formulation is not on an exclusion list. This exclusion list includes formulations whose viscosity measurements may change prior to filling. The accelerated filling check integrates quality laboratory testing into the filling line operation. If the accelerated filling check is approved at the start of the changeover, an interlock is activated at the end of the filling line. Product is not permitted to be released from the production line until the quality check passes, or, in the event of non-conformity, the product produced in that batch can be isolated. Additionally, in the event of non-conformity, feed to the filling machine is also shut off to prevent further filling of the non-conforming product.

[0023] Figure 1 This is a block diagram of a system 100 employing an automated cleaning component according to an example embodiment. The system includes tanks for receiving materials and producing products. As will be readily understood by those skilled in the art, this is a very simplified example, as other embodiments may include multiple tanks for mixing, heating, cooling, and / or any other processes that may be employed in the manufacture of the product.

[0024] Control logic unit 104 controls the operation within tank 102 and performs the functionality described herein. As used herein, "logic unit" includes, but is not limited to, hardware, firmware, software, and / or combinations of each, to perform one or more functions or actions, and / or cause functions or actions from another component. For example, depending on the desired application or requirement, a logic unit may include a software-controlled microprocessor, discrete logic units (such as application-specific integrated circuits (ASICs)), programmable / programmable logic devices, instruction-containing memory devices, or combinational logic units embodied in hardware. A logic unit may also be implemented entirely in software embodied on a tangible, non-transitory computer-readable medium, which performs the described functionality when executed by one or more processors. Control logic unit 104 is coupled to database 106.

[0025] During operation, the control logic unit 104 receives data representing various batches, including formulations or batch processes used to manufacture products. Each batch can be for a different product, thus the same equipment can be used for multiple different products. For example, a paint manufacturing facility can produce a variety of different paints. These paints can have different colors, shades, or gloss levels. Figure 2 These are examples of the different properties that coatings can have.

[0026] According to the example implementation, when the production line changes, control logic unit 104 determines the FDCC code of the current batch and the FDCC code of the next batch. Control logic unit 104 uses database 106 to determine the cleaning type used for the line change. Figure 3 Examples of different cleaning types and their steps are illustrated. In the illustrated examples, cleaning types include no evacuation (ND), no cleaning (NW), simple cleaning (W1), manual cleaning (MW), and full cleaning (W2). The example implementation described herein is characterized by not performing full cleaning at every line changeover, which can save time and thus increase throughput.

[0027] In an example implementation, control logic unit 104 is operable to obtain data representing several batches of several products. Some products may have multiple batches. Control logic unit 104 determines the cleaning type (and therefore the cleaning time) for different batches and sequences the batches to reduce the time required for cleaning the production line (e.g., tank 102), thereby improving the efficiency of the production line.

[0028] Figure 4 This is an example of a system 400 that can be used to accelerate filling inspection. After a batch is completed, the product begins to move from tank 102 to filling station 108. This allows changeovers to begin earlier and reduces the amount of time between batches. Interlock device 110 prevents the product from being distributed before testing is complete.

[0029] A sample of the product undergoes quality control (QC) 112 testing. If the product passes the test, control logic unit 104 releases the interlock and allows the product to be distributed. However, if the product fails the test, it is isolated and disposed of.

[0030] Figure 5 An example of a paint production line 500 is shown. Raw materials (represented by 502) and production orders (represented by 504) are received at the batch / manufacturing facility (represented by 506).

[0031] After a batch is completed, a line changeover begins, as indicated by 508. Line changeover 508 can employ any of the methods described herein to reduce changeover time and / or time between batches.

[0032] Quality control tests are performed on the product, as indicated by 512. In an implementation employing the accelerated filling inspection described herein, the product can be moved to the filling station (indicated by 510) while the test is being performed. If the product passes quality control test 512, it is released and moved to packaging 514, then to stacking / warehouse 516 and / or shipment 518. If the product fails quality control test 512, it is isolated and not distributed at filling station 510.

[0033] Figure 6 This is a block diagram illustrating an example of a paint production line. Note that in some embodiments, some of the illustrated features may not be present, and other embodiments may have additional features.

[0034] Solvent 602, desiccant 604, and plasticizer 606 are provided to dilution tank 626. Additives (other than desiccant 604) 608, binders (oils and / or resins) 610, and pigments and fillers 612 are provided to feed hopper 614 and then to weighing tank 616.

[0035] Additive 608, binder 610, and pigment 612 are transferred to mixing device 618 and tank 620. From tank 620, additive 608, binder 610, and pigment 612 are ground (indicated by 622) and then reach tank 624. In the example embodiment, the mixing and grinding process is performed more than once.

[0036] Additive 608, binder 610, and pigment 612 are mixed with solvent 602, desiccant 604, and plasticizer 606 in dilution tank 626. The batch is then sieved by screening machine 628 to remove sludge from the product. The product is then sent to filling station 630, labeling machine 632, and moved to packaging 636 by conveyor belt 634. From packaging 636, the product is moved to storage 638 and / or shipped.

[0037] During line changeover, any of tanks 616, 620, 624, and 626 can be cleaned based on the cleaning type determined using the methods described herein. In the example implementation, accelerated filling inspection can be employed, and as described herein, product can be moved from dilution tank 626 to filling station 630 while performing quality control tests.

[0038] In view of the aforementioned structural and functional features, refer to Figures 7 to 9 This will help to better understand the method based on the example implementation. Although, for the purpose of simplifying the explanation, Figures 7 to 10 The methods described herein are shown and described as being executed sequentially, but it should be understood and appreciated that the example implementations are not limited to the illustrated order, as some aspects may occur in a different order and / or simultaneously with other aspects shown and described herein. Furthermore, not all illustrated features may be necessary. The methods described herein are suitably adapted for implementation in logical components such as hardware, software stored on a computer-readable medium when executed by at least one processor, or combinations thereof.

[0039] Figure 7 This is a block diagram illustrating an example of method 700 for selecting a cleaning type. Method 700 can be... Figure 1 and Figure 4 The control logic component 104 is implemented in the middle.

[0040] At 702, the first (or current batch) is in progress and the first product is being produced. For example, a paint with the first color, hue, and gloss.

[0041] At point 704, after the first batch is confirmed, a line change occurs. Part of the line change process involves cleaning the equipment (e.g., before starting the second batch) Figure 1 and Figure 4 (In tank 102) to prevent contamination.

[0042] At 706, the first (current) batch and the second (next) batch of FDCCs are obtained. Figure 2 An example of FDCC code is shown below. The code depends on the product being manufactured.

[0043] At point 708, the cleaning type used for this line change is determined. In the example implementation, the cleaning types for different combinations of FDCC codes are stored in a database. The appropriate cleaning type is then performed before starting the second (next) batch. Figure 3 Examples of the different cleaning types and steps involved are provided in the document.

[0044] Figure 8 This is a block diagram illustrating an example of a method 800 for scheduling batch jobs to reduce cleaning time. Method 800 can be derived from... Figure 1 and Figure 4 The control logic component 104 is implemented in the middle.

[0045] At point 802, multiple batches corresponding to a product are received. Some products may have multiple batches. These multiple products have corresponding formulas or processes for transforming materials into finished products. These batches may correspond to any desired time period, such as, for example, daily production or shifts.

[0046] At position 804, you obtain codes for multiple products, such as FDCC codes. These codes correspond to product characteristics. For example, in... Figure 2 The image shows an example of FDCC codes used for coatings. The codes correspond to the product's color, hue, and gloss level.

[0047] At point 806, the cleaning type for different combinations of multiple batches is determined. Then, the cleaning type for different sequences of multiple batches is determined. Figure 3 Examples of cleaning types used in paint production and examples of actions for each type of cleaning are shown.

[0048] At point 808, a sequence that reduces the total cleaning time for multiple batches is selected. Production then begins, processing each batch according to the selected sequence.

[0049] Figure 9 This is a block diagram illustrating an example of a method 900 for accelerating filling inspection. Method 700 can be derived from... Figure 1 and Figure 4 The control logic component 104 is implemented in the middle.

[0050] At position 902, after batch completion, the product is moved from the can to the filling station. Once the product has been moved to the filling station, the changeover can begin. This saves time compared to keeping the product in the can until testing is complete, allowing the production line more time to process the batch.

[0051] At point 904, quality control testing begins. Interlocking devices at the filling station prevent product distribution before testing is complete. At point 906, it is determined whether the product has passed the quality control test.

[0052] If the product passes the quality control test at 906 (Yes), the interlock device is released at 908 and the product is distributed. If the product fails the quality control test at 906 (No), the product is isolated and / or disposed of at 910 without being distributed.

[0053] Figure 10 This is a block diagram illustrating a computer system 1000 on which an example implementation scheme can be carried out. The computer system 1000 can be used to implement... Figure 1 and Figure 4 The control logic unit 104 described herein and / or implemented therein are respectively in Figure 7 , Figure 8 , Figure 9 Any or all of the methods described in methods 700, 800, and 900.

[0054] Computer system 1000 includes a bus 1002 or other communication mechanism for conveying information, and a processor 1004 coupled to the bus 1002 to process information. Computer system 1000 also includes main memory 1006, such as random access memory (RAM) or other dynamic storage device coupled to the bus 1002, for storing information and instructions to be executed by the processor 1004. Main memory 1006 can also be used to store temporary variables or other intermediate information during the execution of instructions to be executed by the processor 1004. Computer system 1000 also includes read-only memory (ROM) 1008 or other static storage device coupled to the bus 1002 for storing static information and instructions for the processor 1004. Storage device 1010, such as a magnetic disk or optical disk, is provided and coupled to the bus 1002 for storing information and instructions.

[0055] Computer system 1000 may be coupled via bus 1002 to display 1012, such as a cathode ray tube (CRT) or liquid crystal display (LCD), to display information to the computer user. Input device 1014 (such as a keyboard including alphanumeric and other keys) is coupled to bus 1002 to transmit information and command selections to processor 1004. Another type of user input device is cursor control device 1016, such as a mouse, trackball, or cursor arrow keys, to transmit directional information and command selections to processor 1004 and control cursor movement on display 1012. This input device typically has two degrees of freedom on two axes (a first axis (e.g., x) and a second axis (e.g., y)), allowing the device to specify a position in a plane. In an example embodiment, input device 1014 is a touchscreen.

[0056] One aspect of the example implementation involves using computer system 1000 for process line changeover. According to one implementation, computer system 1000 provides process line changeover in response to processor 1004 executing one or more sequences of one or more instructions contained in main memory 1006. Such instructions may be read into main memory 1006 from another computer-readable medium, such as storage device 1010. Executing the sequence of instructions contained in main memory 1006 causes processor 1004 to perform the process steps described herein. One or more processors in a multiprocessor arrangement may also be used to execute the sequence of instructions contained in main memory 1006. In alternative implementations, hardware wiring circuitry may be used in place of or in combination with software instructions to implement the example implementation. Therefore, the implementations described herein are not limited to any particular combination of hardware circuitry and software.

[0057] As used herein, the term "computer-readable medium" refers to any medium that participates in providing instructions to processor 704 for execution. Such media can take many forms, including but not limited to non-volatile media. Non-volatile media include, for example, optical discs or magnetic disks, such as storage device 710. Common forms of computer-readable media include, for example, RAM, PROM, EPROM, FLASHPROM, CD, DVD, SSD, or any other storage chip or tape, or other media from which a computer can read.

[0058] Computer system 1000 also includes a communication interface 1018 coupled to bus 1002. Communication interface 1018 provides bidirectional data communication coupling with network link 1020, which connects to local network 1022. For example, communication interface 1018 may be an Integrated Services Digital Network (ISDN) card or a modem to provide data communication connectivity with a corresponding type of telephone line. As another example, communication interface 1018 may be a Local Area Network (LAN) card to provide data communication connectivity with a compatible LAN. A wireless link may also be implemented. In any such implementation, communication interface 1018 transmits and receives electrical, electromagnetic, or optical signals carrying data streams representing various types of information.

[0059] Network link 1020 typically provides data communication to other data devices via one or more networks. For example, network link 1020 may provide connectivity to host computer 1024 or data equipment operated by Internet Service Provider (ISP) 1026 via local network 1022. ISP 1026, in turn, provides data communication via a global packet data communication network (now commonly referred to as "the Internet" 1028). Both local network 1022 and Internet 1028 use electrical, electromagnetic, or optical signals carrying digital data to and from computer system 1000, which are exemplary forms of carrier waves for transmitting information.

[0060] The foregoing description is of an exemplary embodiment. Of course, for the purposes of describing exemplary embodiments, it is impossible to describe every conceivable combination of components or methods; however, those skilled in the art will recognize that many other combinations and permutations of the exemplary embodiments are possible. Therefore, it is intended to cover all such changes, modifications, and variations that fall within the substance and scope of any claims filed herein, thereby interpreting the priority of this application in accordance with the scope of the claims to which it is fairly, legally, and justly enjoyed.

Claims

1. A method, the method comprising: Assign a line-changing code to the coating based on its characteristics; The first coating with the first characteristic is produced in the production line; A second coating having the second property is produced in the production line; as well as A production line changeover is performed after the production of the first coating and before the production of the second coating, the production line changeover including: The type of cleaning to be performed on the production line is determined based on a set of rules used to compare the first characteristic with the second characteristic. The production line is selectively cleaned using the determined cleaning type.

2. The method according to claim 1, wherein the cleaning type is selected from the group consisting of no draining, no cleaning, simple cleaning, complete cleaning and manual cleaning.

3. The method of claim 2, wherein the selected cleaning type is non-drainage.

4. The method of claim 2, wherein the selected cleaning type is no cleaning.

5. The method of claim 2, wherein the selected cleaning type is simple cleaning.

6. The method of claim 2, wherein the selected cleaning type is a complete cleaning.

7. The method of claim 2, wherein the selected cleaning type is manual cleaning.

8. The method of claim 1, wherein the characteristic includes color.

9. The method of claim 1, wherein the characteristics include color and hue.

10. The method of claim 1, wherein the characteristics include color, hue, and gloss.

11. The method according to claim 1, further comprising: Producing third-party coatings with third-party properties; The second cleaning type to be performed on the production line is determined based on a set of rules used to compare the first characteristic with the third characteristic; The third cleaning type to be performed on the production line is determined based on a set of rules used to compare the second characteristic with the third characteristic. Determine the line change time for the first cleaning type; Determine the line change time for the second cleaning type; Determine the line change time for the third cleaning type; The production of the first coating, the second coating, and the third coating is scheduled in the order that minimizes the total changeover time for producing the first coating, the second coating, and the third coating.

12. The method according to claim 1, further comprising: Producing at least one additional coating with a third property; Multiple types of additional cleaning to be performed are determined by comparing the characteristics of the at least one additional coating with the first characteristic, the second characteristic, and comparing the characteristics of the at least one additional coating with each other; Determine the line changeover time between the first cleaning type and the multiple different cleaning types; The production of the first coating, the second coating, and the at least one additional coating is scheduled in order to minimize the total changeover time for producing the first coating, the second coating, and the at least one additional coating.

13. The method according to claim 1, further comprising: Before testing the second coating, the filling line is filled with the second coating; The second coating is held in the filling line until the test is completed; as well as After approval based on the test, the second coating is released from the filling line.

14. An apparatus comprising: A can in which materials are processed to produce a product; A control logic component, which is coupled to the tank and operable to control operations within the tank; and A database, which is coupled to the control logic component; The control logic unit is operable to determine the line changeover from a first batch process for producing a first product to a second batch process for producing a second product. The control logic unit is operable to determine the first line change code of the first product and the second line change code of the second product; The control logic unit is operable to determine the cleaning type from the database based on the first line change code and the second line change code; and The control logic unit is operable to cause the tank to be cleaned according to the cleaning code.

15. The apparatus of claim 14, wherein the first product and the second product are identical.

16. The apparatus of claim 14, wherein the cleaning type is selected from the group consisting of no draining, no cleaning, simple cleaning, complete cleaning, and manual cleaning.

17. An apparatus, the apparatus further comprising: A can in which materials are processed to produce a product; A control logic component, which is coupled to the tank and operable to control operations within the tank; and A database, which is coupled to the control logic component; The control logic unit is operable to receive multiple batch production requests, the multiple batch production requests including: a first batch, the first batch having a first formula for producing a first product having a first changeover code; a second batch, the second batch having a second formula for producing a second product having a second changeover code; and a third batch, the third batch having a third... The control logic unit is operable to use the database to determine a first cleaning type based on a first sequence of the first and second line change codes, a second cleaning type based on a sequence of the second and third line change codes, a third cleaning type based on a third sequence of the third and first line change codes, a fourth cleaning type based on a sequence of the second and first line change codes, a fifth cleaning type based on a sequence of the third and second line change codes, and a sixth cleaning type based on a sequence of the third and first line change codes; and The control logic unit is operable to selectively schedule the production of the first batch, the second batch, and the third batch based on a sequence selected from the first sequence, the second sequence, the third sequence, the fourth sequence, and the fifth sequence, the sequence being based on the first cleaning type, the second cleaning type, the third cleaning type, the fourth cleaning type, the fifth cleaning type, and the sixth cleaning type, thereby reducing the total changeover time for producing the first product, the second product, and the third product.

18. The apparatus according to claim 17, The first product is a first coating having a first color, a first hue, and a first gloss, and the first line change code is based on the first color, the first hue, and the first gloss. The second product is a second coating having a second color, a second hue, and a second gloss level; the second line change code is based on the second color, the second hue, and the second gloss level; and The third product is a third coating having a third color, a third hue, and a third gloss, and the third line change code is based on the third color, the third hue, and the third gloss.

19. An apparatus comprising: A can in which materials are processed to produce a product; A control logic component, which is coupled to the tank and operable to control operations within the tank; and A filling station, the filling station including an interlocking device coupled to the can; The control logic unit is operable to transfer the first product from the tank to the filling station before receiving the quality control test results of the first product produced in the first batch. The control logic unit is operable to receive data representing the test results of the first product; and The control logic unit is operable to release the interlocking device and allow the distribution of the first product when it is determined that the data indicating the test result indicates that the first product is satisfactory.

20. The apparatus of claim 19, further comprising: The control logic unit is operable to transfer the second product from the tank to the filling station before receiving the quality control test results of the second product produced in the second batch; and The control logic component is operable to prevent the distribution of the first product when it is determined that the data indicating the test results indicates that the second product is unsatisfactory.

Images