Factory management monitoring system and method

Abstract

To provide a factory management and monitoring system and method for can production lines.SOLUTION: A factory management and monitoring system includes: a processing unit 10 configured to receive data from a plurality of sensors 44, 45 and 46 configured to monitor one or more factories or machines included in the factories so as to analyze the received data, and to generate a user interface including the received data or information resulting from analysis of the received data; and a display 22 configured to display the user interface.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] <Cross - Reference to Related Applications> This application claims priority to U.S. Provisional Patent Application No. 62 / 669,472, filed on May 10, 2018, with the title "FACTORY MANAGEMENT AND MONITORING SYSTEMS AND METHODS", the content of which is incorporated herein by reference.

[0002] <Technical Field> The disclosed concepts generally relate to factory management monitoring systems and methods, and more particularly, to factory management monitoring systems and methods for a can manufacturing line.

Background Art

[0003] Various cans are manufactured for various purposes, such as containers for food and beverages. The amount of cans produced annually in a single factory is enormous. In a can manufacturing factory, efficiency is an important issue. Due to downtime of the production line or when the operating rate is less than optimal, the amount of cans produced in the factory decreases. Considering the amount of cans produced on a can manufacturing line, even a slight decrease in efficiency can have a significant impact on the amount of cans produced on the can manufacturing line. However, it has been difficult to even identify that the can manufacturing line is operating at less than optimal efficiency or to predict the reasons why production is less than optimal. Also, it is difficult to predict the failures that cause downtime of the production line. There is room for improvement in can manufacturing factories.

Summary of the Invention

[0004] These needs and other needs are met by embodiments of the disclosed concepts. In such embodiments, a factory management monitoring system includes a processing unit configured to collect data from sensors associated with machines located in one or more factories and generate a user interface for displaying the collected data.

[0005] In one aspect of the disclosed concept, a factory management monitoring system includes a processing unit and a display. The processing unit receives data from a plurality of sensors configured to monitor one or more factories or machines included in those factories, analyzes the received data, and is configured to generate a user interface including the received data or information obtained as a result of the analysis of the received data. The display is configured to display the user interface.

[0006] In another aspect of the disclosed concept, a method for managing and monitoring a factory includes receiving data from a plurality of sensors configured to monitor one or more factories or machines included in those factories, analyzing the received data, generating a user interface including the received data or information obtained as a result of the analysis of the received data, and displaying the user interface.

[0007] In another aspect of the disclosed concept, a non-transitory computer-readable medium storing one or more programs including commands is provided. When the programs are executed by a computer, the computer executes a factory management monitoring method. This method includes receiving data from a plurality of sensors configured to monitor one or more factories or machines included in a factory, analyzing the received data, generating a user interface including the received data or information obtained as a result of the analysis of the received data, and displaying the user interface.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0009] As used herein, terms related to directions, such as left, right, front, back, up, down, and their derivatives, are related to the orientation of the elements shown in the drawings and are not intended to limit the scope of the claims unless explicitly stated herein.

[0010] As used herein, the description that two or more parts are "coupled" together shall mean that the parts are connected directly or through one or more intermediate parts.

[0011] As used herein, the term "processor" shall mean a controller, microprocessor, microcontroller, microcomputer, central processing unit, or any suitable processing device or apparatus connected to analog and / or digital devices capable of storing, retrieving, and processing data.

[0012] The disclosed concept relates to a factory management monitoring system and method. Based on an exemplary embodiment of the disclosed concept, the factory management monitoring system is utilized in the production of cans.

[0013] An exemplary can manufacturing factory includes a can manufacturing line having machines with names close to their functions, such as a cupper, a body maker, a washer, a coat oven, a base coater, a decorator, an internal spray machine, a necker, a light tester, a palletizer, etc. The can manufacturing line may include other intermediate machines such as other machines and conveying machines. Various sensors are arranged throughout the can manufacturing line to monitor various parameters of the can manufacturing line. The sensors can monitor various characteristics of the machines on the can manufacturing line. For example, the sensors can monitor the operating speeds of the cupper and the body maker on the can manufacturing line. However, it is contemplated that the sensors can monitor a number of different characteristics of each machine on the manufacturing line, the overall characteristics of the manufacturing line itself, the characteristics of the products being produced on the manufacturing line, the position of the products on the manufacturing line, or other types of characteristics without departing from the scope of the disclosed concept.

[0014] FIG. 1 is a schematic diagram of a factory management system according to an exemplary embodiment of the disclosed concept. FIG. 2 is a schematic diagram of the factory management system, and a typical factory 40A is shown in more detail based on an exemplary embodiment of the disclosed concept.

[0015] The factory management monitoring system includes a processing unit 10 and a client device 20. The factory management monitoring system further includes several factories 40A, 40B, 40C. Each of the factories 40A, 40B, 40C includes a can manufacturing line that includes several machines such as a copper 41, a body maker 42, a necker 43 (shown in FIG. 2), etc. Each of the factories 40A, 40B, 40C also includes several sensors 44, 45, 46 (shown in FIG. 2). Each of the sensors 44, 45, 46 is associated with a corresponding machine such as a copper 41, a body maker 42, a necker 43, etc. It will be understood that FIG. 2 shows an example of several machines in the can manufacturing line and the sensors associated therewith. However, it will also be understood that each of the factories 40A, 40B, 40C may include additional machines such as, but not limited to, a washer, a coat oven, a base coater, a decorator, an internal spray machine, a light tester, a palletizer, etc., without departing from the scope of the disclosed concept. Also, it will be understood that the factories 40A, 40B, 40C may include multiple machines of the same type without departing from the scope of the disclosed concept. The sensors 44, 45, 46 are configured to monitor various characteristics of the machines on the can manufacturing line associated with them. For example, sensor 41 may monitor the operating speed of the copper 41 associated with it, and sensor 45 may monitor the operating speed of the body maker 42 on the can manufacturing line associated with it. However, it is contemplated that the sensors 44, 45, 46 may monitor a number of different characteristics of the machines they are associated with in the manufacturing line. Also, it will be understood that sensors may be provided to monitor the overall characteristics of the manufacturing line itself, the characteristics of the products produced on the manufacturing line, the position of the products on the manufacturing line, or other types of characteristics without departing from the scope of the disclosed concept. The disclosed concept is not limited to the number of machines and sensors shown in FIG. 2, and it will be understood that additional machines and sensors may be provided in each of the factories 40A, 40B, 40C without departing from the scope of the disclosed concept. Also, it will be understood that any number of factories 40A, 40B, 40C may be provided without departing from the scope of the disclosed concept.

[0016] The processing unit 10 is configured to receive the outputs of sensors 44, 45, 46 (e.g., but not limited to, the monitored characteristics of the machines to which they are related, etc.). The processing unit 10 can receive the outputs of sensors 44, 45, 46 via a network 30 (e.g., but not limited to, the Internet) or any other suitable communication link.

[0017] In some exemplary embodiments, the client device 20 includes a display 22 and an input device 24. The display 22 can be any suitable type of display, such as, but not limited to, an LCD, an LED, or other suitable type of display. The input device 24 can be any suitable type of device for receiving input from a user. For example, but not limited to, the input device 24 can be a keyboard and / or a mouse, a touch screen, or any other suitable type of device for receiving input from a user. The client device 20 can be a computer or other type of processing device. It will be understood by those skilled in the art that the client device 20 can be incorporated into the processing unit 10 or vice versa without departing from the scope of the disclosed concepts.

[0018] The processing unit 10 may be a computer, a server, or another type of processing device. In some exemplary embodiments, the processing unit 10 and the client device 20 communicate with each other via a network connection or other suitable type of connection. The processing unit 10 is configured to collect data from various sensors 44, 45, 46 and generate a user interface for displaying the data. The user interface may be displayed on the processing unit 10 itself in an exemplary embodiment where the processing unit 10 includes a display, or may be displayed on the display 22 of the client device 20 by communicating with the client device 20. The data may be collected from the sensors via a network 30 such as the Internet or another type of network. Any suitable method for communicating the data from the sensors 44, 45, 46 to the processing unit 10 may be employed without departing from the scope of the disclosed concept, including any method using an intermediate collection point or repository. Also, the processing unit 10 is considered to be able to collect data from sensors 44, 45, 46 located in a plurality of factories 40A, 40B, 40C. As described above, FIGS. 1 and 2 illustrate exemplary factories 40A, 40B, 40C, but it will be understood that without departing from the scope of the disclosed concept, the processing unit 10 may collect data from any number of machines and sensors associated with factories. The processing unit 10 may be located remotely from one or more factories 40A, 40B, 40C where the sensors 44, 45, 46 are located.

[0019] The processing unit 10 is configured to generate a user interface for displaying the data collected from sensors 44, 45, 46. The user interface may be displayed on the same device as the processing unit 10, or may be displayed on a device remote from the processing unit 10, such as the display 22 of the client device 20. For example, but not limited to, the processing unit 10 may be disposed in a server or other computing device located at a certain place. The user can access and interact with the user interface via the client device 20 that is located at another place and connected to the processing unit 10 via a network. The processing unit 10 is also configured to analyze the data collected from sensors 44, 45, 46. For example, but not limited to, the processing unit 10 may compare the data including one or more characteristics of the relevant machine collected from sensors 44, 45, 46 with a threshold value, and set an alarm state when these characteristics exceed the threshold value. The alarm state may be displayed on the user interface to alert the user of the state. For example, but not limited to, the sensors related to a washer in a factory may monitor the characteristics of the washer, such as the burner temperature of the washer. The processing unit 10 may analyze the temperature and set an alarm state when the temperature exceeds a predetermined threshold temperature. When the temperature exceeds the predetermined threshold, the processing unit 10 can display a warning on the user interface to alert the user who is viewing the user interface on the processing unit 10 or the client device 20 of the alarm state. This is an exemplary alarm state, and it will be understood that there may be any number of different types of alarm states without departing from the scope of the disclosed concept. For example, without departing from the scope of the disclosed concept, the processing unit 10 may set an alarm state based on the output of one sensor, a combination of the outputs of multiple sensors, a combination of the outputs of multiple sensors across multiple factories, etc.

[0020] Without departing from the scope of the disclosed concepts, it is contemplated that the processing unit 10 may analyze the data collected from sensors 44, 45, 46 in various ways and derive any information regarding the operation of one or more factories 40A, 40B, 40C. Also, without departing from the scope of the disclosed concepts, it is contemplated that the displayed user interface may include any data collected by sensors 44, 45, 46 or any information obtained as a result of the analysis by the processing unit 10. Further, it is contemplated that the displayed user interface may include any data in a format suitable for viewing by the user, such as graphs, numerical representations, or other suitable ways of displaying data.

[0021] In some exemplary embodiments of the disclosed concepts, the processing unit 10 may analyze the data collected from sensors 44, 45, 46 using artificial intelligence or machine learning techniques. For example, but not limited to, the processing unit 10 may use artificial intelligence or machine learning techniques to predict machine failures or maintenance, material usage, optimize a machine or a factory, or perform other suitable uses based on the collected data. As an example, the processing unit 10 may analyze data collected from various factories using artificial intelligence techniques to identify an optimal operating pattern based on specific goals such as efficiency or output capacity. It will be understood by those skilled in the art that the processing unit 10 may analyze the data collected from sensors 44, 45, 46 or other sensors using any number of artificial intelligence or machine learning techniques without departing from the scope of the disclosed concepts. Also, in some exemplary embodiments, it will be understood that based on such analysis, the processing unit 10 may control the machines of one or more factories.

[0022] The user interface is configured to be interactive. For example, but not limited to, the user may interact with various areas of the user interface to change the arrangement or format of the displayed information. The input device 24 of the client device 20, or in some exemplary embodiments the input device of the processing unit 10, may be used to input commands to interact with the user interface. For example, but not limited to, the user interface may include an overall view of the factory that displays the entire manufacturing line and data related to the entire manufacturing line. The user may interact with the user interface (e.g., via the input device 24) to cause the user interface to display a specific machine on the manufacturing line (e.g., a capper, a body maker, a necker, etc.) and data related to the specific machine. The user interface may include displays related to a group of factories, a selected factory, a selected machine, or a specific product, and it is contemplated that the user can interact with the user interface to switch between these types of displays. Also, it is contemplated that the user can interact with the user interface to customize the displayed data.

[0023] In some exemplary embodiments of the disclosed concepts, a user can interact with a user interface to control various metrics of factories 40A, 40B, 40C or factory machinery. For example, processing unit 10 may communicate with the controllers of various machines in factories 40A, 40B, 40C. In some exemplary embodiments, a user can interact with a user interface to process alarm signals sent from processing unit 10 to one or more machines (e.g., but not limited to, capper 41, body maker 42, or necker 43) located in one or more of factories 40A, 40B, 40C to alert an operator remotely located at one of factories 40A, 40B, 40C, stop the machine, or adjust a set of parameters that would adjust the operation of the machine in a particular manner. This is conditional upon the user having access to a security level authenticated according to a particular protocol. The protocol includes, but is not limited to, interacting with personnel near the machine and the person responsible for machine operation through user input confirmation before a change is executed.

[0024] Figures 3 through 6 are examples of user interfaces presented based on exemplary embodiments of the disclosed concepts. A user can switch between the various examples shown in Figures 3 through 6 by interacting with the user interface via input device 24 or other suitable input device. Figure 3 is a screenshot of a factory overview screen based on an exemplary embodiment of the disclosed concepts. As shown in Figure 3, data collected from sensors associated with various machines within the factory is presented. The necker speed (cans per minute) is an example of a necker metric, collected from one or more sensors associated with the necker and presented on the user interface. From the user interface, a user can easily view not only the necker speed (cans per minute), but also various other metrics of the necker, metrics of other machines, or other metrics of the factory operation collected from other sensors.

[0025] Figure 4 is a screenshot of a body maker overview screen based on an exemplary embodiment of the disclosed concept. In this example, a plurality of body maker metrics are shown in the user interface. The body maker may be located in one factory or in multiple factories.

[0026] Figure 5 is a screenshot of a copper overview screen based on an exemplary embodiment of the disclosed concept. In this example, copper metrics are displayed in the user interface. For example, various metrics of the copper components, in addition to the copper speed and the total number of cups made during the copper's service life, are shown in the user interface. In the user interface of this example, the user can easily observe remotely many aspects of the copper's operation and status at the client device 20 or the processing unit 10.

[0027] Figure 6 is a screenshot of a necker overview screen based on an exemplary embodiment of the disclosed concept. In this example, necker metrics are shown in the user interface. Similar to the previous example, the necker speed, the total number of units made during the necker's service life, and various metrics of the necker components are shown. In this example of the user interface, the user can easily observe remotely many aspects of the necker's operation and status at the client device 20 or the processing unit 10.

[0028] The examples shown in FIGS. 4 through 6 are examples of user interfaces and data types associated with one or more factory machines that can be displayed on the user interface. It will be understood that the user interface may show information related to different types of machines, or different types of information, without departing from the scope of the disclosed concepts. By interacting with the user interface and viewing the information shown on the user interface, the user can observe the operation and status of a single machine, multiple machines, a single factory, multiple factories, or any combination thereof. In this way, the user can interact with the user interface to customize what is displayed and display appropriate data when evaluating the operation and / or status of the machine and / or factory. The user can use such information to perform optimization and / or maintenance of the machine and / or factory, generate material orders, or perform other actions related to the machine and / or factory. In some exemplary embodiments of the disclosed concepts, such actions are performed via commands issued through the user interface to control one or more machines. Further, as described above, the user interface can display the alarm state determined by the processing unit 10. Through these alarm states, the user can recognize the alarm state and take corrective measures. In some exemplary embodiments of the disclosed concepts, such corrective measures may be taken via commands issued through the user interface.

[0029] The processing unit 10 is considered to be able to restrict the information included in the user interface based on the rights of the user. For example, one type of user may be able to access one set of data via the user interface, while another type of user may be able to access another set of data via the user interface.

[0030] The processing unit 10 may also be configured to generate and / or display a report based on the data collected from sensors 44, 45, 46, or on the information obtained as a result of the analysis of the data collected from sensors 44, 45, 46. The report may be, for example, but not limited to, selected information indicating an overview of the operation and / or performance of a manufacturing line or a particular machine on the manufacturing line. The user can generate a selected report by interacting with the user interface.

[0031] Figures 7A and 7B are aggregated exemplary body maker reports based on an exemplary embodiment of the disclosed concept. Figures 8A through C are examples of exemplary single body maker reports based on an exemplary embodiment of the disclosed concept. Figures 9A - C are examples of single copper reports based on an exemplary embodiment of the disclosed concept. Figures 10A - D are examples of single necker reports based on an exemplary embodiment of the disclosed concept. In these examples of reports, various information collected from sensors may be aggregated. The report may be displayed on a user interface or output so as to be viewable on other devices or media. For example, the report may be output in any suitable file format (e.g., but not limited to, PDF), thereby making it viewable on different devices. Also, the report may be printed so as to be viewable offline.

[0032] By observing the user interface, interacting with the user interface, and / or generating reports via the user interface, a user can easily obtain various ranges of information regarding a factory or multiple factories, or information regarding specific machines on the manufacturing lines of a factory. Such information may be utilized for observing and improving the efficiency of the factory. For example, a user may use the user interface to observe the production status of manufacturing lines in different factories. If the manufacturing line of a certain factory is performing below that of another factory, the user can use the user interface to display and compare the metrics of specific machines on the manufacturing line. The user can identify the specific machines or other aspects causing performance problems and appropriately address those problems. The collected data may also be stored and analyzed using machine learning or other techniques for use in predicting failures, predicting and optimizing maintenance, or other ways to improve the efficiency of one or more factories.

[0033] In some exemplary embodiments of the disclosed concepts, the processing unit 10 may be used to enhance the automation of one or more factories. For example, but not limited to, the processing unit 10 may operate based on the data collected and analyzed. For example, but not limited to, the processing unit 10 may determine that machine maintenance is necessary or will be necessary soon based on the data collected and analyzed. The processing unit 10 may place or initiate a purchase order for materials or parts required for machine maintenance. Also, the processing unit 10 may place or initiate a purchase order for materials based on the production volume of one or more factories. For example, the processing unit may determine based on the data collected and analyzed that the factory needs to replenish the inventory of aluminum or other materials required for can production, and automatically place a purchase order for the materials required for production in anticipation, or initiate it. The purchase order for additional materials is an example of additional actions that the processing unit 10 can perform based on the data collected and analyzed. It is considered that various different actions, such as, but not limited to, controlling or adjusting the machine, sending an alarm, a warning, or a notification, or other appropriate actions related to the monitoring or management of the factory, may be performed by the processing unit 10. Also, it is considered that a user interface may be used by the user to set or adjust additional actions that the processing unit automatically performs in response to the data collected and analyzed.

[0034] The disclosed concepts are described in relation to can production, but the management monitoring systems and methods according to various exemplary embodiments of the disclosed concepts can be employed in factories that adopt similar manufacturing processes or substantially different manufacturing processes without departing from the scope of the disclosed concepts.

[0035] One or more aspects of the disclosed concepts may also be embodied as computer-readable code on a tangible, non-transitory computer-readable recording medium. A computer-readable recording medium is any data storage device that can store data readable by a computer system. Non-limiting examples of computer-readable recording media include read-only memory (ROM), non-volatile random access memory (RAM), CD-ROMs, magnetic tapes, floppy disks, disk storage devices, and optical data storage devices.

[0036] Although specific embodiments of the disclosed concepts have been described in detail, those skilled in the art will recognize that various modifications and alternatives to those details can be developed in light of the overall teachings of the disclosure. Accordingly, the specific configurations disclosed are intended to be illustrative only and not to limit the scope of the disclosed concepts with respect to the full scope of the appended claims and all their equivalents.

Claims

1. A factory management monitoring system, comprising: a processing unit configured to receive data from a plurality of sensors configured to monitor a plurality of machines of a can production line of a plant, to analyze the received data, and to generate a user interface comprising the received data or information resulting from the analysis of the received data; a display configured to display the user interface; It is equipped with The plurality of machines includes a copper, a necker, and a bodymaker; the user interface includes a plurality of views including a first view, a second view, a third view, and a fourth view; the first view includes information related to the copper; the second view includes information related to the Necker; the third view includes information related to the bodymaker; The fourth view is an overall plant view that displays the entire can production line and data related to the entire can production line.

2. 2. The factory management monitoring system of claim 1, wherein the can production line is a can body production line or a can end production line.

3. The factory management monitoring system of claim 1 , wherein the processing unit is located remotely from the factory.

4. 2. The factory management monitoring system of claim 1, wherein the processing unit is configured to compare at least a portion of the received data with a predetermined threshold and generate an alarm if at least a portion of the received data exceeds the predetermined threshold.

5. The factory management monitoring system of claim 1 , wherein the processing unit is configured to output one or more commands for controlling at least one of the plurality of machines.

6. The factory management monitoring system of claim 1 , wherein the processing unit is configured to generate material or work orders based on the received data.

7. The factory management monitoring system of claim 1 , wherein said display is located remotely from said processing unit.

8. The factory management monitoring system of claim 1 , wherein the processing unit is configured to generate one or more reports including the received data or information resulting from analysis of the received data.

9. The factory management monitoring system of claim 1 , further comprising an input device configured to receive input from a user, said user interface being interactively responsive to input received via said input device.

10. The factory control monitoring system of claim 9 , wherein the processing unit is configured to switch between the multiple views based on input received via the input device.

11. 2. The factory management monitoring system of claim 1, wherein the received data or information obtained as a result of analysis of the received data includes one or more of the following: copper speed, total cup count, an index of one or more components of the copper, necker speed, total number of units produced by the necker, an index of one or more components of the necker, and an index of the bodymaker.

12. receiving, at a processing unit, data from a plurality of sensors configured to monitor a plurality of machines in a can production line of a plant; analyzing the received data; generating a user interface comprising the received data or information resulting from an analysis of the received data; displaying the user interface; Contains The plurality of machines includes a copper, a necker, and a bodymaker; the user interface includes a plurality of views including a first view, a second view, a third view, and a fourth view; the first view includes information related to the copper; the second view includes information related to the Necker; the third view includes information related to the bodymaker; The fourth view is an overall plant view that displays the entire can production line and data related to the entire can production line.

13. comparing, in the processing unit, at least a portion of the received data with a predetermined threshold; generating an alarm at the user interface if at least a portion of the received data exceeds a predefined threshold; The factory management monitoring method of claim 12 further comprising:

14. 13. The method of claim 12, further comprising outputting, by said processing unit, one or more commands for controlling at least one of said plurality of machines.

15. 13. The method of claim 12 further comprising the step of generating material or work orders based on the received data.

16. 13. A method as claimed in claim 12, further comprising the step of generating, at said processing unit, one or more reports including said received data or information resulting from analysis of said received data.

17. 13. The factory management monitoring method of claim 12, wherein the received data or information obtained as a result of analysis of the received data includes one or more of the following: copper speed, total cup count, an indication of one or more components of the copper, necker speed, total number of units produced by the necker, an indication of one or more components of the necker, and an indication of the bodymaker.

18. A non-transitory computer readable medium storing one or more programs including instructions that, when executed by a computer, cause the computer to perform a factory management monitoring method, the method comprising: receiving data at a processing unit from a plurality of sensors configured to monitor a plurality of machines in a can production line of a plant; analyzing the received data; generating a user interface comprising the received data or information resulting from an analysis of the received data; displaying the user interface; Contains The plurality of machines includes a copper, a necker, and a bodymaker; the user interface includes a plurality of views including a first view, a second view, a third view, and a fourth view; the first view includes information related to the copper; the second view includes information related to the Necker; the third view includes information related to the bodymaker; The fourth view is a plant-wide view that displays the entire can production line and data related to the entire can production line.

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