Guided Tool Workflow With Real-Time Validation for Workpiece Operations
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Solution Overview
Problem
Current industrial application management systems are inefficient and costly due to poor record keeping, ineffective training, and inadequate monitoring, leading to errors and costly events such as Loss of Primary Containment (LOPC) in facilities like refineries and chemical plants.
Innovation Solution
A workflow management system that includes a guidance device communicatively coupled to tools and sensors, which collects and uploads identification, industrial application, and workpiece state data, performs data analytics, and provides workflow instructions to users, enabling real-time monitoring and error detection, thereby improving data accuracy and reducing adverse events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual record-keeping and monitoring methods are used in industrial applications, then operational flexibility is maintained, but data accuracy and reliability deteriorate leading to costly errors and LOPC events
Solution Approach 1:
The system continuously collects data from sensors and tools, uploads it to a service for analysis, and uses the results to generate workflow instructions that are fed back to workers through guidance devices. This closed-loop feedback mechanism ensures data accuracy and enables real-time error detection and correction, directly resolving the reliability issue.
Solution Approach 2:
A service acts as an intermediary between the field devices (sensors, tools, guidance devices) and the central system. This intermediary handles data aggregation, validation, and analysis, reducing the complexity burden on individual components while maintaining high data accuracy through centralized quality control.
2Reliability
If comprehensive data collection and monitoring systems are implemented, then error detection capability is improved, but overhead and paperwork increase
Solution Approach 1:
The system automatically performs data collection, validation, and analysis without requiring manual intervention. Sensors and tools self-report their status and performance data, which is then automatically processed by the service to generate workflow instructions, eliminating the need for manual paperwork and reducing overhead significantly.
Solution Approach 2:
Manual record-keeping and monitoring activities are replaced by an automated electronic system that collects, transmits, and analyzes data automatically. This substitution of mechanical/manual processes with automated electronic systems reduces overhead while enhancing error detection capabilities.
3Manufacturing precision
If real-time data upload and validation is performed for every operation, then quality control is improved, but productivity is reduced due to additional verification steps
Solution Approach 1:
The system performs validation and analysis on a selective basis rather than uniformly for all operations. The service intelligently determines which data points require detailed validation based on risk assessment and historical patterns, applying partial verification to low-risk operations and excessive verification to high-risk operations, thus balancing quality control with productivity.
4Loss of information
If multiple data points are collected and validated at each workflow step, then loss of information is reduced, but device complexity increases
Solution Approach 1:
The system merges data collection, validation, storage, and analysis functions into a unified service architecture. Multiple data points from various sensors and tools are combined into a single data stream that is processed centrally, reducing the complexity at individual device levels while ensuring complete data capture and validation.
Data Source
AI summary
According to at least one aspect of the present disclosure a method of managing workflow for an industrial application is provided. The method comprises providing a guidance device configured to be communicatively coupled to a tool configured to be used on a workpiece, obtaining identification data pertaining to the workpiece being used in the industrial application, obtaining industrial application state data pertaining to at least one state of the industrial application, obtaining workpiece state data, operating the tool on the workpiece, obtaining tool operation data, uploading to a service, via the guidance device, at least one of the identification data, the industrial application state data, and the tool operation data, and validating the industrial application state data.