Beacon-Based Manufacturing Monitoring for Real-Time Floor Control

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Solution Overview

Problem

In manufacturing environments, supervisors face delays in accessing critical information needed to manage production processes efficiently, as they often need to leave the production floor to retrieve data, leading to potential issues like increased costs, production downtime, and quality control problems.

Innovation Solution

A system utilizing beacon technology and proximity-based reporting software that allows supervisors to monitor and control manufacturing environments using mobile devices, providing real-time access to a corporate knowledge base, enabling them to adjust processes without leaving their location.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If supervisors leave the production environment to access the corporate knowledge base, then they can obtain necessary information, but this causes unacceptable delays in decision-making

Engineering Contradiction:

ImproveAccess to corporate knowledge baseVSAvoidDecision-making delay

Core Design Contradiction:

Loss of informationVSLoss of time

Solution Approach 1:

A mobile computing device with proximity-based computing capabilities serves as an intermediary between supervisors and the corporate knowledge base. The device automatically retrieves and displays relevant information from the knowledge base based on the supervisor's proximity to workstations, eliminating the need to physically leave the production floor while providing timely access to necessary data for decision-making

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical system of physical movement (supervisors leaving and returning to the production floor) with an electronic information delivery system. The mobile device receives identifying information from beacons and automatically fetches relevant data from the corporate knowledge base, substituting physical travel with digital information transmission to eliminate decision-making delays

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If supervisors remain on the production floor to maintain visibility, then they can monitor activities, but they cannot access the corporate knowledge base efficiently

Engineering Contradiction:

ImproveMonitoring capabilityVSAvoidAccess to corporate knowledge base

Core Design Contradiction:

Ease of operationVSLoss of information

Solution Approach 1:

The mobile computing device performs multiple functions simultaneously: it acts as both a monitoring tool (displaying production activities) and an information access terminal (retrieving data from the corporate knowledge base). The proximity-based system automatically provides both real-time production visibility and access to corporate information without requiring supervisors to switch between different locations or devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If the facility is enclosed in steel or other metals to create a secure environment, then protection is provided, but significant electromagnetic interference is generated

Engineering Contradiction:

ImproveElectromagnetic interferenceVSAvoidWireless communication reliability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent employs Bluetooth Low Energy (BLE) beacons that transmit short-lived, low-energy identifying information signals. These brief, intermittent transmissions are sufficient for proximity detection and information retrieval, requiring minimal electromagnetic energy and thus performing reliably even in the presence of the facility's metal-induced electromagnetic interference

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables supervisors to quickly obtain relevant information and make decisions, reducing delays and improving production efficiency, while maintaining visibility of the manufacturing environment, thus enhancing productivity and reducing operational risks.

Implementation Method 1

beacon technology and proximity-based reporting and control software... beacons positioned around the production environment that are configured to work with software operating on a computer such as a mobile computing device... beacons may broadcast identifying information to the mobile device

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Data Source

PatentUS11809145B2System and method for monitoring and controlling a manufacturing environment

Publication Date: 2023.11.07 THE LAKE CO LLC

AI summary

A system for monitoring and controlling a manufacturing environment is disclosed. Aspects discussed include beacons broadcasting identifying information for aspects of the manufacturing environment such as workstations, manufactured items, machines, equipment, and people. The identifying information may be used to generate reports about the operation of these and possibly other aspects, as well as provide control options for changing the manufacturing environment. Employees may move about the environment to visually monitor activities taking place, while the system may automatically query for additional information about the tools, equipment, people encountered in the environment. Control options for changing aspects of the manufacturing processes may also be automatically displayed as well.