Error message analysis in a production line

Abstract

To provide a method and system for reporting and analyzing error messages in a manufacturing production line.SOLUTION: The method comprises the steps of S201 receiving a plurality of error messages from one or more machines in a production line, each error message indicating a type of error, converting one or more error codes of the error messages into a readable format, the method includes a step S203 of assigning a descriptor to each error message, a step S205 of determining a stage in the production line to which each of the plurality of error messages relates, a step S207 of grouping the plurality of error messages relating to the same stage in the production line, a step S209 of organizing the group of error messages to be sequentially arranged to identify a primary cause of the plurality of error messages, and a step S211 of creating and displaying a report of the processed error messages.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to the field of error messages in manufacturing lines, and in particular to error messages relating to machine downtime in such production lines. [Background technology]

[0002] Machine stoppages, commonly known as downtime, are a problem on manufacturing lines that result in a decrease in factory output due to fewer products being produced.

[0003] Due to the nature of production lines, with numerous machines each performing many different tasks, it is often difficult to quickly determine the root cause of these production downtimes. For example, in the case of a production line that produces cigarettes, the production line may consist of a series of machines for creating cigarettes, a series of machines for packing the cigarettes into boxes, a series of machines for applying tax stamps to the boxes, a series of machines for packing multiple cigarette boxes together, and a series of machines for wrapping the packed cigarette packages. An error in a single machine in the line can trigger a series of error messages, as the initial error affects subsequent processes in the line. These error messages can appear so quickly that it is not clear what the root cause is or which messages are linked to each other, making it difficult to determine what actions need to be taken to resolve the error. This can lead to unnecessarily long downtime while attempts are made to determine the cause and restart the line.

[0004] This is not helped by the fact that the error messages are machine-specific and not easily readable by the production line workers who are often responsible for determining the problem and restarting the line. This is often a trial-and-error process for the workers, and some of their success may be based on past experience with the same error occurring previously. While workers can identify a specific solution to a particular error message, this information is typically not captured and similarly not shared with other workers so that they know what action to take when faced with the same error.

[0005] Additionally, across different production lines, there may be different machines or different models of machines, each with its own associated error messages. This means that insights into resolving a particular error message on one line are not transferable to resolving errors on another line. This means that a separate approach must be taken for each line.

[0006] There is a need for a unified approach to tracking error messages on a production line and eliminating the amount of time the line is down so that insights gained on a single line can be applied across multiple different production lines using different machines and / or machine models. Summary of the Invention

[0007] According to a first aspect, there is provided a method for reporting and analyzing error messages in a manufacturing production line, performed by an error analysis device, the method including: receiving a plurality of error messages from one or more machines in the production line, each error message associated with an error detected in its associated machine, and each error message including one or more error codes specific to its associated machine indicating a type of error; processing the plurality of error messages, assigning a descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a stage in the production line to which each of the plurality of error messages is associated; grouping multiple error messages associated with the same stage in the production line; and organizing the groups of error messages so that they are sequentially arranged to identify a root cause of the plurality of error messages; and generating and displaying a report of the processed error messages to enable a user to take action regarding the errors.

[0008] In this way, the error messages can be converted into a human-readable format so that they can be easily understood by a user. Additionally, by grouping messages related to the same stage in the production line and arranging them sequentially in chronological order, it may be possible to determine which error message is the primary cause of a series of error messages. When presented as a report, the descriptors in each error message may clearly indicate what the error message relates to, and by chronologically arranging the error messages based on when they were created, it may be possible to determine which error message is the primary cause of a subsequent error message.

[0009] An error message may indicate machine downtime. It may be assumed that the root cause of the error message is the root cause of the downtime, and that the first error message to occur is this root cause. By understanding the root cause of the error message, it may be possible to determine what actions are needed to address the downtime in order to get the production line up and running as quickly as possible.

[0010] A production line stage may be a particular step in the production of a product. For example, stages may include creating the product, packaging the product, and packing it up for shipment. This may be determined based on an indicator in the error message that indicates the stage to which the error message relates. Alternatively, or additionally, it may be based on knowledge of the machine on which the error message was received and which stage in the production line that machine is associated with.

[0011] An action that the user can take using the report may be to correct the error and restart the line, for example, this may be in real time, i.e., before the line is restarted following receipt of the error message.

[0012] Alternatively, the user action may be an action to be taken to correct the error when the same error message is received again, which may be at a later point in time. For example, generating a report may be to create a list of actions for the user to take when the error appears again, which may form an action plan of recommended corrective actions if the same error occurs again.

[0013] Preferably, each error message includes a timestamp. The timestamp may indicate the time the error message was triggered. In addition, the timestamp may also indicate the time the error was corrected. The sequential arrangement of the messages may be based on the timestamp. In another arrangement, the sequential arrangement of the messages may be based on the order in which the messages were received at the error analysis device.

[0014] The method may further include, prior to generating the report, displaying the processed error messages to a user and receiving user input directed to the displayed processed error messages, thereby enabling the user to modify the processed error messages. A user, such as a production line worker, may annotate the processed error messages with metadata. This may involve adding further details to indicate the cause of the error and / or to further classify the error.

[0015] In some cases, the user may be responsible for resolving the error, such as restarting a machine on a production line in situations where the error message is associated with downtime. The user may modify the processed error messages and add specific details to each processed error message. For example, the user may add a comment to the error message indicating the nature of the error (such as its cause). The user may also add information indicating what actions were taken to correct the error. This may include what actions were taken to restart the production line. This may include details of actions that were successful and / or unsuccessful.

[0016] In some cases, if the duration of the sequentially arranged error messages exceeds a threshold period, multiple processed error messages can be displayed to the user. The threshold may be a predetermined threshold. In this way, only downtimes that occurred during a specific period are displayed to the user for annotation. Short downtimes may be of less interest because they were quickly fixed, but for longer downtimes, it may be insightful to determine what actions the user took and what actions worked / did not work. The processing of error messages ensures that the sequentially arranged error messages relate to a single downtime. The duration may be the time from the start of the first error message to the fix of the last error message associated with its primary cause.

[0017] The duration may be the duration of only a single group of error messages, e.g., a group related only to the packer. Alternatively, the duration may be the duration of each of the sequentially arranged groups. For example, downtime in one stage may have an impact and cause downtime in another stage. For example, downtime in the packer may have an impact in the paracella and cause an error message.

[0018] Preferably, the threshold is greater than 15 minutes. In other arrangements, the threshold is preferably greater than 2 hours. In other arrangements, the threshold may be a period of time appropriate for a particular production line.

[0019] Alternatively, or additionally, if the primary cause of the error message is related to manual intervention that caused the generation of the error message, the processed error messages may be displayed to the user, allowing the user to modify the processed error messages to indicate reasons that may have caused the line downtime.

[0020] Preferably, the processing step further includes assigning to each of the plurality of error messages a descriptor indicating the type of problem that caused the generation of the error message. By having a descriptor indicating the type of problem, it is possible to easily ascertain which type of problem each error message relates to. The type of problem that caused the error message can be determined. In some arrangements, this can be determined by having a database of error messages and problem types. In this way, the problem type can be determined automatically. Alternatively, or additionally, the problem type may be entered by a user via user input.

[0021] The problem type may be the problem that directly caused the generation of the error message. For example, the problem may be that the machine ran out of input material, and an error message is generated to indicate this problem. The problem may have been caused by a root cause that could be in a step or process at an earlier point in the production line.

[0022] The processing step may further include classifying each of the plurality of error messages as being associated with or not associated with manual intervention that caused the generation of the error message. In this manner, it may be determined which error messages are the result of a machine on the assembly line not functioning properly or which operators caused the generation of the error message. This may be useful in helping identify error messages that were caused by intentional user action, such as shutting down the assembly line for maintenance and / or cleaning. This may be determined by a preset time when the line is specifically known to be in downtime. Alternatively, it may be by user input that modifies the classification of whether the plurality of error messages are associated with or not associated with manual intervention.

[0023] In some cases, if an error message is determined to be associated with manual intervention, the error message may be ignored. For example, they may be deleted and not used in the report. Alternatively, they may be clearly marked to distinguish them from other types of error messages in the report. In some cases, user input may include modifying the classification of multiple error messages as associated with manual intervention or not.

[0024] Preferably, each stage in the production line includes a series of processes, and the step of processing the plurality of error messages further includes determining the process to which each of the plurality of error messages relates.

[0025] Each stage in a production line consists of a series of processes that perform a particular part of the stage's function. Determining the particular process to which each error message relates can help determine further details about the nature of the error. This can further aid analysis at a later point in time, as the report can be used to pinpoint which processes are causing the most errors and indicate the nature of the errors to which each process is susceptible.

[0026] In some arrangements, the disposition may be determined by having a database of error messages and how they relate to a particular disposition. Alternatively, or additionally, the disposition may be determined based on the particular machine on which the error message was received. For example, it may be known which machine is associated with which disposition. In this manner, the disposition may be determined automatically. Alternatively, or additionally, the disposition may be entered by a user via user input.

[0027] The step of determining the stage may further include, for each error message of the plurality of error messages, identifying whether the error message is indirectly triggered by an error caused by a different stage with which the error message is associated, and assigning the error message to a group associated with that stage if the error message is triggered by an error caused by a different stage with which the error message is associated. Advantageously, this allows for re-categorization and assignment of error messages. This may be done by the error analysis device or by user input. For example, it may involve assigning the error message to another process or stage.

[0028] Preferably, for at least one error message of the plurality of error messages, the method further includes identifying a machine component associated with the error message and assigning a descriptor indicating the machine component to the error message. Identifying the specific machine component to which the error message is associated can further pinpoint the cause of the error message. This can be done for each error message. For example, if a root cause is identified, knowing the specific component of the machine assembly to which the error message is associated can provide guidance on where attention needs to be directed to address the error. This can reduce the amount of time taken to correct the error. If the error is related to downtime, this can help reduce the amount of time the line is stopped, thus increasing the line's production output. The descriptor can be in a human-readable format that allows a user to easily understand it. Additionally, analysis of this data over time can be used to indicate which machine components are responsible for the most errors. This can enable appropriate action to be taken to address these issues.

[0029] The processing step may further include identifying duplicate error messages in the plurality of error messages and deleting the identified duplicate error messages. In this way, the number of messages can be reduced to focus only on unique messages. This reduces the number of messages that need to be processed, thereby reducing the required computational resources. Duplicate error messages may be identified by the same error message being generated multiple times. In other arrangements, the duplicate error messages may be different error messages that are known to signal the same error.

[0030] Preferably, the step of assigning a standardized descriptor to each error message by converting one or more error codes into a readable format includes converting the error codes by using a reference source having details of the meaning of each error code for that machine. The reference source may include machine-specific documentation containing details of what each error code means for a particular machine, which can be used to convert the unique error codes into a human-readable format. The reference source may be stored in a database. The database may be a local database or a cloud database. This may be the same database in which processed error messages and reports are stored.

[0031] The report of processed error messages may include details of which errors are responsible for the most downtime on the manufacturing production line. The errors that caused the most downtime may be the identified primary cause that caused the most errors. This may be shown as the process that resulted in this error. This may be displayed by stage.

[0032] In some arrangements, the steps of the first aspect can be repeated multiple times to build a collection of processed error messages related to different problems. These collections of processed error messages can be output in a report. In this way, the report can show the most frequently occurring error messages / problems.

[0033] The report may further include details of actions that can be taken to resolve the error. This may be done by collecting details of how the error is resolved with user input. In this way, the report can act as a resource to help the user resolve the problem if it occurs again.

[0034] According to a further aspect, there is provided a data analysis device for reporting and analyzing error messages in a manufacturing production line, the data analysis device comprising: a receiving module configured to receive a plurality of error messages from one or more machines in the production line, each error message associated with an error detected in its associated machine, the error message including one or more error codes specific to its associated machine indicating a type of error; and a processing module configured to process the plurality of error messages, the processing comprising: assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; and determining a processing stage in the production line to which each of the plurality of error messages relates. a processing module that includes grouping multiple error messages associated with the same processing step in the production line and organizing the group of error messages so that they are sequentially arranged to identify a root cause of the multiple error messages; and a display module that is configured to create and display a report of the processed error messages so that a user can take action regarding the errors. Equipped with.

[0035] According to a further aspect, a computer program product is provided, the computer program product including instructions, when executed by a computer, that cause the computer to perform the steps of: receiving a plurality of error messages from one or more machines in a production line, each error message associated with an error detected in its associated machine, the error message including one or more error codes specific to the associated machine indicating a type of error; processing the plurality of error messages, including assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a processing stage in the production line to which each of the plurality of error messages is associated; grouping multiple error messages associated with the same processing stage in the production line; and organizing the groups of error messages so that they are sequentially arranged to identify a root cause of the plurality of error messages; and generating and displaying a report of the processed error messages to enable a user to take action regarding the errors.

[0036] According to a further aspect, a system is provided, the system comprising: a manufacturing production line having one or more machines for manufacturing a product; a data analysis device for reporting and analyzing error messages from the manufacturing production line, the system comprising: a receiving module configured to receive a plurality of error messages from one or more machines in the production line, each error message associated with an error detected in its associated machine, the error message including one or more error codes specific to the associated machine indicating a type of error; a processing module configured to process the plurality of error messages, the processing comprising: assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a processing stage in the production line to which each of the plurality of error messages is associated; grouping multiple error messages associated with the same processing stage in the production line; and organizing the groups of error messages so that they are sequentially arranged to identify a root cause of the plurality of error messages; and a display module configured to generate and display a report of the processed error messages to enable a user to take action regarding the errors.

[0037] Although it is mentioned above that the error message is related to downtime, this is not necessarily the case. For example, in other embodiments, the line may not need to be stopped and can continue despite the error message being triggered. In this example, the error message may indicate a problem with the line that needs to be corrected. In this way, the line can still operate, but at a reduced speed. These errors can be corrected using the methods described above. [Brief explanation of the drawings]

[0038] [Figure 1] 1 is a schematic diagram of an exemplary production line to which the present invention may be applied; [Figure 2] FIG. 2 is a flow diagram of an exemplary method for reporting and analyzing error messages in a manufacturing production line such as that shown in FIG. 1. [Figure 3] FIG. 10 shows a table of raw error messages received from the production line. [Figure 4] FIG. 10 illustrates a table of processed error messages processed in accordance with an aspect of the present invention. [Figure 5] FIG. 10 illustrates a user interface presented to a user to allow the user to correct an error message. [Figure 6] FIG. 1 illustrates an exemplary view of a series of tapes showing downtime in a production line. [Figure 7] FIG. 10 illustrates a further exemplary view of a series of tapes indicating downtime in a production line. [Figure 8A] FIG. 1 shows a table illustrating different processes for each of the stages in an exemplary tobacco production line. [Figure 8B] FIG. 1 shows a table illustrating different processes for each of the stages in an exemplary tobacco production line. [Figure 9] FIG. 10 illustrates an exemplary user interface displaying processed error messages and a tape-based analysis report. [Figure 10] FIG. 10 illustrates an exemplary user interface showing a report containing details of the most frequently recurring problems that lead to machine downtime. [Figure 11] FIG. 10 illustrates an example user interface showing a report providing details of the problem, actions to resolve the problem, and details of whether the problem was resolved. [Figure 12] FIG. 3 is a schematic diagram of an exemplary system for performing the method shown in FIG. 2. [Figure 13] 3 is a schematic diagram of an exemplary data processing device capable of performing the method shown in FIG. 2. DETAILED DESCRIPTION OF THE INVENTION

[0039] The embodiments disclosed herein relate to methods and devices for identifying, processing, and addressing error messages in production lines, particularly manufacturing production lines. One aim of the present invention is to improve the productivity of these production lines by analyzing error messages that are generated with the goal of reducing the amount of time the production line is down.

[0040] 1 shows an exemplary schematic diagram of a production line 10 according to the present invention. The production line involves a number of different stages 2a, 2b, 2c. At each stage 2a, 2b, 2c, a different step in the manufacture of a product is performed. In the example described herein, the product being manufactured is cigarettes. However, it will be understood that the invention described herein may not need to be limited to lines for the production of cigarettes and may be applicable to any type of production line.

[0041] As can be seen from Figure 1, the first stage 2a, Stage 1, is the maker. This is the stage where the cigarettes are formed. The second stage 2a, Stage 2, is the packer stage, where the cigarettes made in the first stage 2a are packed together in a box or the like. The third stage 2c, Stage 3, is the stage where the packed cigarettes are packaged in plastic wrapping or the like to prevent tampering, the so-called wrapper stage.

[0042] In some production lines, a single machine may perform the functions of each of states 2a, 2b, and 2c. For example, there may be a single machine that performs the maker state, a single different machine that performs the packer state, and a single different machine that performs the wrapper state. However, in other production lines, multiple different machines may be responsible for performing the functions of each of states 2a, 2b, and 2c, or the same machine may be responsible for performing all of states 2a, 2b, and 2c.

[0043] As can be seen from Figure 1, each of stages 2a, 2b, and 2c is made up of a number of different processes. Stage 2a is made up of processes 4a and 4b. Typical processes that a manufacturer may perform may include feeding tobacco paper into the machine, applying filters to the tobacco, or cutting the formed tobacco.

[0044] Stage 2b consists of operations 4c and 4d. Typical operations that the packer may perform include feeding a foil wrapper into the machine, bending and forming a blank box, or gluing blanks to form a box.

[0045] Stage 2c consists of operations 4e and 4f. Typical operations that the wrapper may perform include feeding the pack into the machine, applying a film to the pack, or sealing the pack.

[0046] These steps and processes are merely representative of an exemplary production line, and there may be other steps and processes besides those shown. Additional steps and processes may be located between, before, or after the steps and processes shown in Figure 1. Figures 8A and 8B provide further details in this regard, and table 800 shows exemplary steps 801 and associated processes 803 in an exemplary tobacco production line.

[0047] The steps of the production line shown in FIG. 1 flow from left to right, such that products undergo processes 4a and 4b in stage 2a, then processes 4c and 4d in stage 2b, and then processes 4e and 4f in stage 2c. Because each process may depend on the output of the previous process, a problem in a single process in the line can lead to other problems occurring in other processes in the line. A problem in one process may cause problems not only in processes further downstream in the line, but also in processes upstream in the line. This can result in many different error messages being displayed as each process is affected. This can be confusing for production line operators, as the large number of error messages may make it impossible to quickly pinpoint the cause of the error. Additionally, when reviewing line downtime at a later point in time, such as for performance analysis, it may not be clear what caused the problem from the numerous error messages. One object of the present invention is to solve these problems.

[0048] 2 illustrates an exemplary method 200 for reporting and analyzing error messages in a manufacturing production line. The method begins at step 201 with receiving a plurality of error messages from one or more machines in the production line, each error message relating to an error detected in its associated machine, the error message including one or more error codes specific to its associated machine that indicate the type of error.

[0049] The error messages are then processed in steps 203 to 209. Step 203 involves assigning a descriptor to each error message by converting the error message's one or more error codes into a readable format.

[0050] In step 205, the stage in the production line to which each of the plurality of error messages is associated is determined.

[0051] Next, step 207 involves grouping multiple error messages relating to the same stage in the production line.

[0052] In step 209, the group of error messages is organized so that they are arranged sequentially to identify the root cause of multiple error messages.

[0053] Finally, in step 211, a report of the processed error messages is generated and displayed so that the user can take action regarding the errors.

[0054] Figure 12 shows a schematic diagram of a system 1200 in which the method 200 of Figure 2 can be implemented. The system includes an error analysis device 1201, a production line 1213, and a database 1211.

[0055] 1. The database 1211 may be an external database as shown, or may be, for example, a cloud database, a local database, or a data warehouse. Alternatively, the database 1211 may be part of the error analysis device 1201.

[0056] The error analysis device 1201 includes a receiving module 1203, a processing module 1205, and a display module 1207. The receiving module 1203 is responsible for receiving error messages from the production line 1213, as described in step 201 of Figure 2. It is also responsible for receiving data stored in a database 1211 and / or receiving user input from operators on the production line.

[0057] The processing module 1205 is responsible for processing error messages from the production line as described above and for performing steps 203-209 as shown in FIG.

[0058] The display module 1205 is responsible for displaying the processed error messages from the production line as described above and for performing step 209 as shown in Figure 2. The display module 1205 may actually assist in the display of the processed error messages or may be responsible for sending the processed error messages and reports for display elsewhere.

[0059] Further details regarding the processing performed by the error analysis device and the method illustrated in FIG. 2 are described in further detail below.

[0060] As outlined in connection with FIG. 1 , when an error exists on a production line, an error message may be triggered. Typically, these may be displayed on a user interface of a machine on the production line, such as a human-machine interface (HMI) of a programmable logic controller (PLC), so that an operator can view the error. Alternatively, a production line operator may have a handheld computer, such as a mobile data computer (MDC), on which they can view the error message that has been triggered. As outlined above, a large number of these raw error messages may be triggered, making it difficult for a user to determine what action to take to resolve the problem on the production line.

[0061] Figure 3 shows a table 300 that includes a number of error messages 315a-g, with each error message 315a-g occupying a different row in the table 300. The error messages 315a-g shown in Figure 3 are raw error messages received from machines on a production line that may traditionally be shown to a user on a user interface associated with the machine or on the user's associated handheld terminal.

[0062] Each error message 315a-g includes details of the factory 301 and work center 303 where the error message originated, indicating the production line where the error message occurred. Also provided is a machine ID 305, indicating the source machine 307. In this example, the source machine 307 indicates that the message in table 301 is from the manufacturer (e.g., stage 2a in FIG. 1). An error reason code 309 is also provided with each error message. The reason code 309 is a series of numbers that indicates the type of error that occurred. Each error message also includes a breakdown start date 311 and a breakdown end date 313, indicating the period during which the error that caused the error message to be generated occurred.

[0063] As can be seen from table 300, the raw error messages 315a-g are difficult to interpret in their current form. For example, a production line operator has no way of knowing what an error message relates to without deep familiarity with what each error code 309 means. With such a large number of error messages 315a-g generated from the many different machines on the production line, it would be difficult for a production line operator to become familiar with the meaning of each error message 315a-g. Additionally, these error messages 315a-g in the form shown in table 300 would be even less insightful for a user not directly working on the line who is viewing the error messages 315a-g for the purpose of analyzing the error messages to determine the cause of downtime on the line.

[0064] To alleviate these problems, error messages are processed to provide a richer form of data. Figure 4 shows a table 400 of processed error messages 415a-c.

[0065] Each processed error message 415a-c includes a start time 401 and an end time 403, indicating when the error started and when it was fixed, based on data from the raw error messages in columns 311 and 313 of Figure 3.

[0066] Column 405 contains a description 405 "MDC Message (English)" that describes the cause of the error in the local language. In this case, the description is written in English, but this could be in any language, which may depend on where the machine is running.

[0067] Each message is also classified as either a direct error or an indirect error, as shown in column 407. A direct error is an error that is the primary cause of the problem. An indirect error is an error that is indirectly caused by a previous direct error. For example, as can be seen in Figure 4, the message in row 415c is an indirect error caused by the direct error in row 415b. The error in row 415b is related to a rear paper break in the printer of the cigarette paper / transport process and is the first error related to this problem. The error in row 415c is the same as the error in row 415b, but at a later time. This may be because, after error 415b, the line was restarted without resolving the cause of the first error, resulting in the same error occurring again, as shown by error 415c.

[0068] Column 409 contains the reason for each error, which is determined by converting the error code in column 309 into a descriptor shown in column 409. When processed in this manner, rather than a reason code such as 1.1.1103 shown in column 309, for example, each error has a user-understandable meaning such as "internal machine down" shown in column 409.

[0069] Each error message is also assigned to a process step in the production line, as shown in column 411. This may be, for example, process 4a or 4b shown in Figure 1. In the case shown in Figure 4, the process step for each error message is "Cigarette Paper / Transport".

[0070] Each error message is also assigned a problem type, as shown in column 413. This may be the particular problem that caused the error message to be generated. For example, in the example shown in Figure 4, the problem type for the error in row 415a is "Machine / Reject Limit," and the problem type for the errors in rows 415b and 415c is "Material / Damage."

[0071] The part of the machine where this problem occurred is also assigned in column 414, labeled "machine assembly." This is the specific part of the process where the problem occurred. For example, this could be the specific part of the machine performing the process where the error occurred. As shown in FIG. 4, example parts of the machine could include the "cutting" or "printing" parts of the machine assembly.

[0072] The processing of the raw error messages shown in table 300 of FIG. 3 to arrive at the processed error messages shown in table 400 of FIG. 4 may be performed automatically by the error analysis device 1201.

[0073] The error analysis device 1201 can enter a "reason" in column 409 based on the "reason code" in column 309. This may involve the error analysis device referencing a database of stored reason codes with associated meanings. For example, in the example shown in Figures 3 and 4, the database may have an entry indicating that reason code 1.2.1103 relates to an "internal machine stop." The database is populated using documentation such as user manuals supplied by the machine manufacturer, which typically include details of what each error code relates to. Alternatively, or additionally, it may be populated from PLC codes used on the production line.

[0074] The assignment of the process step 411, problem type 413, machine assembly 414, and "MDC message (English)" descriptor 405 by the error analysis device 1201 can be done using the reason code 309, source machine 307, and machine ID 305. By knowing the machine that sent the error message, the source machine 307 and machine ID 305 data in the raw error message can allow the data analysis device to pinpoint the process on the production line that caused the error message to be generated. This, in combination with the reason code 309, provides details of the problem type 413 that the error is associated with and can be used to determine further details regarding the cause of the generation of the error message, providing further details as the "MDC message (English)" descriptor 405.

[0075] Columns 401 and 403, which indicate time values, may be automatically populated from columns 311 and 313. At this stage, duplicate error messages may also be removed, as the same error message may be received multiple times. By reducing these multiple entries, the number of entries in table 400 can be kept to a more manageable level.

[0076] Additionally, by splitting and enhancing the columns shown in FIG. 3 into columns as shown in FIG. 4, it is possible to extract additional details from the error message that are not readily available by simply looking at the raw error message as shown in table 300 of FIG. 3.

[0077] The processing of error messages 315a-315g may be further enhanced by user input. By allowing production line workers to add metadata to error messages, additional insight may be gained from the user that may not be available from the data analysis device alone. Figure 5 shows an example of a user interface 500 displayed to a worker by the error analysis device on an input display panel. This may, for example, be displayed on one of the machines on the production line or on a handheld computing device operated by the worker.

[0078] The user interface 500 includes a summary of problems that occurred during a worker's shift. The tape 501 shows a series of downtimes 503, 505 and the timescales on which they occurred. The downtimes are separated by the time the production line was running.

[0079] As can be seen, downtime 503 is downtime that occurred approximately one hour into the worker's shift. Downtime 505 is further downtime that occurred approximately two hours later. Between downtime 503 and downtime 505 is a period of time during which the production line is operational. Also shown along tape 501 are several other downtimes.

[0080] Located below tape 501 is a table 509 of error messages associated with the downtime indicated on tape 501. Table 509 includes column 511 with a description of the failure, column 513 which is the OEE class, column 515 with the reason for the error message, column 517 with the step, sub-step, and sub-reason for the error, and columns 519 and 521 for the start time and duration of the problem.

[0081] When displayed to the user, each of the columns of table 509 may be populated by data analysis device 1201 as described above with respect to Figure 4. For example, the reason in column 513 may be populated from the details in column 409 of table 400, the process 517 may be populated from the process in column 411, and the time values ​​in columns 519 and 521 may be populated using the values ​​in columns 401 and 403.

[0082] Displaying these values ​​in this manner allows the error analysis device 1201 to obtain data from the operator to gain further insight into the causes of downtime.

[0083] A user can enter data into the user interface using a control panel 507 located between the tape 501 and the table 509 in the user interface 500. The control panel 507 includes the controls "New," "Classify," "Split," and "Delete." "New" allows an operator to add missing errors that occurred that were not picked up by the error analysis device. "Classify" allows an operator to modify parameters in the table 509 to categorize errors. In particular, categorizing can be adding details in column 517 about the cause of downtime that resulted in the error and the actions taken to correct them. "Split" can allow a user to edit an error message and split it into multiple different errors. For example, downtime on the tape 501 can be attributed to multiple different causes. Using the "Split" control, a user can split an error message in the table 509 related to downtime into multiple different entries, each related to its cause. "Delete" allows a user to delete unwanted error messages, such as duplicate messages and / or messages unrelated to the downtime.

[0084] A user may be able to modify each of the elements in table 500. By selecting the downtime displayed on tape 501, the user may then be able to modify the values ​​in table 509 by selecting control 509. Alternatively, the user may be restricted to only being able to modify certain columns in the table. For example, time values ​​519, 521 may be locked so that they cannot be modified by the operator, while the processing column 517 may be user-editable.

[0085] Before the user is presented with the interface 500 shown in FIG. 5, the error messages are arranged in chronological order based on the time the error messages first occurred. This may be based on the values ​​in tables 401 and 403 of FIG. 4. This step may be necessary due to the fact that the error messages may be received at the error analysis device 1201 in an order that does not correspond to the order in which the errors occurred, which may make it difficult for the user and the error analysis device to identify the errors. This may make it possible to identify the root cause of the error messages. Arranging the error messages in chronological order makes it possible to arrange the error messages in a tape, such as tape 501 shown in FIG. 5.

[0086] FIG. 6 shows three additional example tapes, 601, 603, and 605. The tapes shown in FIG. 6, compared to the tape shown in FIG. 5, are based on error messages further processed as described in connection with FIG. 4. The tapes in FIG. 6 show downtime plotted against the time during which the downtime occurred. Tapes 601, 603, and 605 are arranged in different stages, so that each different stage has its own associated tape that is offset from each other on the vertical axis. However, because the tapes for each stage are plotted against the same time axis, the impact of downtime between different stages can be easily seen. As shown in FIG. 6, tape 601 relates to error messages generated in the packer, tape 603 relates to error messages generated in the parachute, and tape 605 relates to error messages generated in the wrapper. Key 609 is located above the track showing the breakdown reasons from columns 405 and 511 of tables 400 and 500. The gaps between downtimes indicate the periods during which the machine was operational.

[0087] By organizing the error messages into a tape, it is possible to easily visualize the primary cause of downtime and subsequent problems. In the tape shown in FIG. 6, it is clear that error 607 is the root cause of the subsequent downtime shown in tape 600. Error 607 is caused by an error in the packer due to an empty tobacco vane ("Tobacco Vane Empty"). As can be seen, each error message on each tape is an indirect result of this initial error 607. This had the effect of causing downtime not only in the packing stage, but also in the parachute and wrapper stages. As shown in FIG. 6, a single error, such as an empty tobacco vane, can cause multiple cascading errors, resulting in a line shutdown for more than 20 minutes. Reducing this downtime is desirable because it can have a significant impact on the product line's output. Processing the data in this manner provides this insight, allowing for mitigation of this error in the future.

[0088] The error analysis device may create tapes such that each tape is associated with a single primary cause. For example, the error analysis device may determine the length of each tape, i.e., when the tape should end, based on the amount of time that has elapsed since the error was detected. For example, if a certain amount of time has passed between subsequent error messages, it may be determined that the subsequent error messages are no longer associated with the same primary cause, and as a result, the tape may be displayed to end and a new tape may be started. However, alternatively, tapes representing an entire worker shift (as shown in FIG. 5) or one or more production runs may also be used. In this manner, each tape need not be specifically associated with a single primary case.

[0089] Although the error messages are located within the tape, the user does not need to view each error message individually as in the past; instead, the error messages are presented to the user on the tape and can be viewed as they relate to the tape, as shown in Figures 5 and 6.

[0090] By using the tape shown in FIG. 6, it is not necessary to present every single tape to the operator. The operator can be presented only with tapes whose length exceeds a certain threshold or when it is determined that the root cause was a user-initiated action. In the case of a short tape, it is clear that the downtime was quickly corrected, and therefore no additional insight from the production line operator is required. However, in the case of a long tape where multiple error messages are displayed and the operator is unable to quickly restart the production line, insight into the problems that occurred and the actions the user took to correct them is required. This also applies when the user initiated the downtime through their own action, and details about why this action was taken are required. In addition, an additional benefit of displaying the tape is that it allows the user to reassign error messages if they feel that the classification of all error messages in the tape does not relate to the same root cause.

[0091] The tapes may be stored in a database for use in generating downtime reports and subsequent analysis. Both tapes annotated by production line operators (those that exceed a duration threshold and / or are operator-caused) and tapes that are determined to be too short to present to operators may be stored to provide a complete picture of line performance. However, in some arrangements, certain tapes may be excluded from storage in the database.

[0092] 7 shows a further example of a series of tapes 700. Shown are a packer tape 701, a parachute tape 703, a tax stamper tape 707, and a wrapper tape 709. However, during the span of these tapes, the production line was in standby mode and not intentionally operating. The error analysis device 1201 can be programmed with details of when the production line is not intentionally operating so that it can ignore tapes that may be generated during pre-planned downtime.

[0093] After processing the error messages, the error analysis device can present the data from each of the stored tapes in a user interface 900 shown in Figure 9. This can be displayed in real time to an operator on the production line, or in real time and at a later time to an operator analyzing the line remotely.

[0094] Interface 900 includes user selectable areas 901 that allow selection of each of the different stages (maker, packer, tax stamper, paraphernalia, and wrapper). Selecting one of the stages in user selectable area 901 can display processed data related to downtime for the selected stage in user interface 900.

[0095] The interface further includes a process stage bar graph 903 that shows the total aggregate time that the selected stage of the process experienced downtime. Key 921 also indicates whether the cause of the downtime was a direct or indirect cause.

[0096] A bar graph showing problem types 905 is also displayed within interface 900. Graph 905 shows the problems experienced by the currently selected stage and the aggregate time the problems were experienced. Further details regarding the portion of the process where the error occurred are provided in graph 907. Graph 907 shows the problems experienced by that particular stage "assembly" (i.e., a particular device component) and the aggregate time the problems were experienced.

[0097] The processed error messages from which the data shown in graphs 903, 905, and 907 was collected are shown in table 909. The details of the error messages shown in table 909 include their descriptors and the duration of the error. The duration is further separated into two additional columns: direct cause duration and indirect cause duration. This allows the total overall time to be displayed at the bottom of the table, in addition to the total time for each of the direct and indirect causes.

[0098] A further tab 925 also allows the user to toggle between viewing internal or external machine outages, where an internal machine outage is one where the downtime is caused by the machine itself stopping, whereas an external machine outage is one where an operator commands a stop (e.g. by pressing a stop button) or a different machine (upstream or downstream) stops.

[0099] Towards the bottom of the user interface 900 are a series of tabs 911 that allow the user to switch between viewing data for different production lines. In FIG. 9, line MP57 is shown on the display. By selecting different tabs 911, the user interface can switch between viewing data for different production lines. Located below the series of tabs 911 is a bar graph 923 that shows the duration of the currently selected error over multiple days.

[0100] The user interface functions as part of a report, allowing for detailed analysis of error messages and downtime across several different production lines. For example, as shown in FIG. 9, the "Pucker" stage is selected. Thus, graph 903 shows the top six processes within the packer that experienced downtime, the duration of these downtimes, and whether they were direct or indirect causes. In this case, the tobacco / feeding process is responsible for the greatest direct cause of downtime. Selecting the tobacco / feeding process 913 in graph 903 displays the top causes of problems associated with this issue in graph 905, with the causes causing this error highlighted (915). Graph 907 then shows where within the process these errors most frequently occur, with the most frequently highlighted areas 917 being the hopper and the tobacco quality detection area, which detects missing filters and loose ends. The error messages corresponding to these values ​​are also highlighted (919) in table 909. From this user interface, it is possible to quickly determine which parts of the production line are causing the most downtime and the exact cause. For example, it may be determined that a "direct" stop of tobacco supply is triggered by the presence of material and the reaching of a control limit of a material sensor on the hopper and tobacco quality detection area.

[0101] A downtime analysis performed using the interface 900 can generate a set of problem statements, as shown in FIG. 10 . FIG. 10 shows a table 1000 containing details of the most recurring problems resulting in machine downtime identified through the user interface 900. This report can be output to the user for review and editing. Table 1000 shows problem statements for maker 1001 and packer 1003 for production line "MP59." Problem statements for other production lines can also be included in the same table 1000, or separate tables can be created for each production line. Table 1000 includes columns for processing step 1007, assembly 1009, MDC message 1011, duration of each downtime 1013, number of downtime events associated with each error 1015, and whether the error is chronic. For each stage, the problems are each ordered based on the number of events shown in column 1015 that occurred. This report can be used to identify recurring problems on the line, identify the causes of the greatest downtime, and develop a plan to correct them.

[0102] FIG. 11 shows a portion of a problem setting plan report, providing details of the problem, actions to resolve the problem, and details of whether the problem was resolved. As can be seen, interface 1100 includes a section corresponding to error 1101 from problem statement interface 1000 shown in FIG. 10. In this example, the production line (1105) shown is MP86, and the stage shown is the tax stamper. As in interface 1000, columns related to processing 1007, assembly 1009, and assembly 1011 are shown. User input section 1103 of interface 1100 is intended to provide a "daily direction setting" for the worker. This includes actions the worker should take to resolve the error when it occurs. Section 1103 includes columns for action 1107, responsible party 1109, due date 1111, check date 1113, status 1115, and action efficiency 1117. Action 1107 is the action the worker should take; in the example shown, the action is to continue monitoring the error. As shown in column 1109, the person responsible for this is an electrician and this should be completed by 12 / 02 / 2020. Column 1113 for the date checked shows that this was checked on 12 / 02 / 2020 and the issue was resolved from column 1115 for the status.

[0103] The reports shown in the user interfaces of FIGS. 10 and 11 can be reviewed at recurring points in time as a basis for prioritizing corrective actions required for the production line under analysis. For example, they can be reviewed after 24 hours of production to set actions that need to be addressed within the next 24 hours. Additionally, as issues are resolved, they are also collected in the report and stored in a database. This creates a library of historical resolved issues that can be used if the same issue is encountered again in the future. Because the nature of the process means that error descriptions are generalized rather than machine-specific, an approach to resolving errors taken on one production line can be implemented across multiple production lines with different machine versions, providing faster error resolution.

[0104] It will be understood that any of the methods described herein, and any particular steps of the methods, may be implemented by a computer or data processing device. Such implementation may take the form of a processor executing instructions stored on one or more non-transitory computer-readable media, which, when executed, cause the processor to perform any one or more steps of any of the methods described herein. Individual steps of the methods may be performed by different processors, all collectively operating in accordance with computer-readable instructions stored on one or more storage media. One or more processors may be components of the error analysis device 1200. A schematic diagram of such a data processing device 1300 is shown in FIG. 13. The data processing device includes a processor 1303 and a memory 1301.

[0105] Processor 1303 may be operatively coupled to memory 1301 through a storage interface. The storage interface is any component capable of providing access to memory to processor 1303. The storage interface may include, for example, an Advanced Technology Attachment (ATA) adapter, a Serial ATA (SATA) adapter, a Small Computer System Interface (SCSI) adapter, a RAID controller, a SAN adapter, a network adapter, and / or any component that provides processor 805 with access to a storage device.

[0106] Memory 1301 may include, but is not limited to, random access memory (RAM), such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and non-volatile RAM (NVRAM). The above memory types are exemplary only and thus not limiting as to the types of memory that may be used to store computer programs.

[0107] Having described aspects of the present disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of the aspects of the present disclosure, as defined in the appended claims. Because various changes can be made in the structures, products, and methods described above without departing from the scope of the aspects of the present disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.

[0108] As will be appreciated based on the foregoing specification, the above-described embodiments of the present disclosure may be implemented using computer programming or engineering techniques, including computer software, firmware, hardware, or any combination or subset thereof. Any such resulting program having computer readable code means may be embodied or provided in one or more computer readable mediums, thereby creating a computer program product, i.e., an article of manufacture, in accordance with the contemplated embodiments of the present disclosure.

[0109] In the above description, errors are attributed to downtime on the production line, however, errors may not necessarily be associated with downtime and the above devices and processes may be implemented to reduce errors that cause inefficiencies but not necessarily downtime.

[0110] The error analysis module shown in Figure 12 has four different modules, but is not necessarily limited to such. The actions performed by each module can be processed together or separately.

[0111] FIG. 3 above shows exemplary raw error messages that are processed using an error analysis device to arrive at the processed error messages of FIG. 4. However, the error messages shown in FIG. 3 are merely examples. Error messages that can be processed by the error analysis device are not limited to the structure shown; the same processing steps can be applied to error messages having different formats. Furthermore, the specific details regarding reasons, processing stages, problem types, and machine assemblies discussed above are merely examples of how these columns may be populated from raw error messages. Other methods are also contemplated.

Claims

1. 1. A method for reporting and analyzing error messages in a manufacturing production line, performed by an error analysis device, comprising: receiving a plurality of error messages from one or more machines in the production line, each error message relating to an error detected at its associated machine, each error message including one or more error codes specific to its associated machine indicating a type of error; processing the plurality of error messages, assigning a descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a stage in the production line to which each of the plurality of error messages relates; grouping the plurality of error messages relating to the same stage in the production line; and Organizing the groups of error messages so that they are arranged sequentially to identify a root cause of the plurality of error messages; and generating and displaying a report of the processed error messages so that a user can take action regarding the errors; A method comprising:

2. Before generating the report, displaying the processed error messages to a user; and 10. The method of claim 1, further comprising: receiving user input directed to the displayed processed plurality of error messages, thereby enabling the user to modify the processed plurality of error messages.

3. The method of claim 2 , wherein the processed error messages are displayed to the user if the duration of the sequentially arranged error messages exceeds a threshold period.

4. 4. The method of claim 1, wherein the processing step further comprises assigning to each of the plurality of error messages a descriptor indicating a type of problem that caused generation of the error message.

5. 5. The method of claim 1, wherein the processing step further comprises classifying each of the plurality of error messages as being related to a manual intervention that caused the generation of the error message.

6. The method of claim 5 when dependent on claim 2, wherein the user input includes modifying the classification of the plurality of error messages as associated with manual intervention or not.

7. 7. The method of claim 1, wherein each stage in the production line includes a series of processes, and wherein the step of processing the plurality of error messages further includes determining the process to which each of the plurality of error messages is associated.

8. The method of any one of claims 1 to 7, wherein each error message includes a timestamp, said timestamp indicating when said error message was triggered.

9. 9. The method of claim 1, further comprising, for at least one error message of the plurality of error messages, identifying a component of a machine to which the error message relates, and assigning the error message a descriptor indicating the component of the machine.

10. 10. The method of claim 1, wherein the processing step further comprises: identifying duplicate error messages in the plurality of error messages; and deleting the identified duplicate error messages.

11. 11. A method according to any one of claims 1 to 10, wherein the step of assigning a standardised descriptor to each error message by converting the one or more error codes into a readable format comprises converting the error codes by using a reference source having details of the meaning of each error code for the machine.

12. A method according to any preceding claim, wherein the report of the processed error messages includes details of which errors are responsible for the most downtime of the manufacturing production line.

13. 1. A data analysis device for reporting and analyzing error messages in a manufacturing production line, comprising: a receiving module configured to receive a plurality of error messages from one or more machines in the production line, each error message relating to an error detected at its associated machine, the error message including one or more error codes specific to its associated machine indicating a type of error; a processing module configured to process the plurality of error messages, said processing comprising: assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a process stage in the production line to which each of the plurality of error messages is associated; grouping the plurality of error messages associated with the same processing step in the production line; and Organizing the groups of error messages so that they are arranged sequentially to identify a root cause of the plurality of error messages; a processing module including: a display module configured to generate and display a report of the processed error messages so that a user can take action regarding the errors; A data analysis device comprising:

14. A computer program product, the computer being configured to, when the program is executed by a computer, receiving a plurality of error messages from one or more machines in a production line, each error message relating to an error detected at its associated machine, said error message including one or more error codes specific to its associated machine indicating a type of error; processing the plurality of error messages, assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a process stage in the production line to which each of the plurality of error messages is associated; grouping the plurality of error messages associated with the same processing step in the production line; and Organizing the groups of error messages so that they are arranged sequentially to identify a root cause of the plurality of error messages; and generating and displaying a report of the processed error messages so that a user can take action regarding the errors; 1. A computer program product comprising instructions for causing a computer to perform the steps of:

15. 1. A system comprising: a manufacturing production line comprising one or more machines for manufacturing a product; a data analysis device for reporting and analyzing error messages from the manufacturing production line, a receiving module configured to receive a plurality of error messages from one or more machines in the production line, each error message relating to an error detected at its associated machine, the error message including one or more error codes specific to its associated machine indicating a type of error; a processing module configured to process the plurality of error messages, said processing comprising: assigning a standardized descriptor to each error message by converting the one or more error codes of the error message into a readable format; determining a process stage in the production line to which each of the plurality of error messages is associated; grouping the plurality of error messages associated with the same processing step in the production line; and Organizing the groups of error messages so that they are arranged sequentially to identify a root cause of the plurality of error messages; a processing module including: a display module configured to generate and display a report of the processed error messages so that a user can take action regarding the errors; a data analysis device comprising: A system comprising:

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