Event-Based Manufacturing Information System for Waste and Delay Tracking
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Solution Overview
Problem
Current manufacturing systems fail to adequately document and analyze factors causing machine delays and productivity issues, and lack integration with financial reporting systems to provide accurate accounting data, leading to inefficiencies and waste in production processes.
Innovation Solution
An event-based manufacturing information system that includes sensors for detecting events like waste, machine delays, or quality issues, a data logger for recording event parameters, a database for storing data, and a reporting system for generating productivity reports, allowing for real-time tracking and analysis of production issues and financial impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional manufacturing systems are used, then machine operations continue without interruption, but productivity losses from waste and delays are not adequately documented or analyzed
Solution Approach 1:
The patent introduces an intermediary manufacturing information system that acts as a mediator between the manufacturing process and financial reporting systems. This system captures event data from sensors, logs it in a database, and translates it into accounting data, thereby documenting productivity losses without requiring direct integration between existing manufacturing and financial systems.
Solution Approach 2:
The system enables self-service by automatically capturing event data through sensors and logging it without requiring manual intervention. The manufacturing information system autonomously monitors the process, records waste and delay events, and generates accounting data, eliminating the need for manual documentation of productivity losses.
2Measurement precision
If manual tracking of production issues is used, then system complexity is minimized, but accuracy and timeliness of productivity data are insufficient
Solution Approach 1:
The patent replaces manual mechanical tracking methods with automated sensor-based detection systems. Sensors automatically detect events such as machine delays, waste generation, and quality issues, converting physical process states into digital event data that is logged and analyzed, thereby improving measurement precision through automation.
Solution Approach 2:
The system implements feedback by continuously monitoring the manufacturing process through sensors, comparing actual performance against expected parameters, and automatically logging deviations as events. This closed-loop approach ensures accurate and timely detection of productivity issues, with the feedback mechanism driving continuous improvement in measurement precision.
3Loss of substance
If production processes continue without material validation, then operational simplicity is maintained, but waste from incorrect raw materials increases
Solution Approach 1:
The patent applies preliminary action by validating raw materials before they are introduced into the manufacturing process. The system checks material identifiers against required specifications in advance, preventing incorrect materials from entering the process and thereby avoiding waste generation downstream without requiring complex continuous monitoring during production.
Solution Approach 2:
The manufacturing information system serves as an intermediary between raw material delivery and the production process. It validates materials through identifier verification and batch tracking, acting as a gatekeeper that prevents incorrect materials from being used while maintaining operational simplicity through automated verification procedures.
4Loss of information
If integration with financial reporting systems is not implemented, then system simplicity is preserved, but accounting data accuracy for productivity analysis deteriorates
Solution Approach 1:
The patent introduces a manufacturing information system as an intermediary layer between manufacturing operations and financial reporting systems. This intermediary captures event data, processes it into accounting-relevant information, and interfaces with financial systems, thereby improving accounting data accuracy without requiring direct complex integration between manufacturing and financial infrastructure.
Solution Approach 2:
The system transforms manufacturing event parameters into financial accounting parameters through automated data processing. Event data such as machine delays and waste quantities are converted into cost categories and accounting metrics that align with financial reporting requirements, enabling accurate productivity analysis through parameter transformation rather than direct system integration.
Data Source
AI summary
Providing quality management and intelligent manufacturing with labels and smart tags in event-based product manufacturing. Some of the disclosed embodiments include a system, method, and computer-readable media for storing, during a process, data associated with a material. Also disclosed are a method of collecting, storing, and reporting machine productivity, waste, and delay information on an event basis in a manufacturing system, a method of capturing and storing material history, a method of automating tracking of positions of components used in a process and correlating portions of a component with production problems, an improved inventory management system, and a method of tracking and recording actions of specific operators of a process performed by a machine. The embodiments are operable in an intelligent manufacturing system including a process for converting raw materials to a product, a process control system including one or more sensors capable of generating an alarm in response to an event that results in one of waste, machine delay, or decrease product quality, a data logger associated with the process control system for obtaining event parameters associated with the event, a database on a server for recording event parameters obtained by the data logger, and a reporting system cooperatively associated with the database for reporting productivity parameters regarding the process derived at least in part from the event parameters.