Historical Data Visualization for Production Delay Analysis
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Solution Overview
Problem
Highly automated production systems with high product variability face challenges in quickly identifying delays and optimizing performance due to complex interactions between autonomous sub-areas and lack of sufficient analytical tools to understand process performance.
Innovation Solution
A production system with a mass memory for storing time-indexed status data and an electronic computer unit for graphical representation of historical data, allowing for the analysis of past production processes to identify delays and bottlenecks, including the use of a Graphical Performance Analyzer (GPA) for visualizing historical trends and causalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If digital camera recordings are used to analyze production situations, then visual information about system sections is obtained, but sufficient information about internal machine states, release and sensor signals, and production data connections is lacking
Solution Approach 1:
The patent combines multiple data sources (camera recordings, machine state sensors, release signals, sensor signals, and production data) into a single integrated display device. This merging allows simultaneous visualization of visual system state and internal operational data, eliminating the information gap without requiring separate complex analysis tools for each data type.
Solution Approach 2:
The display device serves multiple functions: it displays camera recordings for visual monitoring, machine states for operational status, release signals for process control, sensor signals for real-time monitoring, and production data for performance analysis. This multi-functionality provides comprehensive information in one interface without increasing overall system complexity.
2Loss of information
If detailed tabular records of cycle times and errors are used for analysis, then product-related cost information is obtained, but clear causalities and quantitative relationships are difficult to identify
Solution Approach 1:
The patent transitions from two-dimensional tabular data to a multi-dimensional visual display that shows causal relationships spatially and temporally. The display device presents machine states, signals, and production data in an integrated visual format that reveals quantitative relationships and causalities through graphical representation rather than numerical tables, making patterns and relationships immediately visible.
3Productivity
If intermediate buffers are made larger to prevent waiting in autonomous sub-areas, then system continuity is improved, but device complexity and space requirements increase
Solution Approach 1:
The display device provides real-time feedback on buffer filling levels and system state, allowing operators to monitor buffer status and make informed decisions. This feedback mechanism enables optimized buffer management where buffers can be kept smaller while maintaining system continuity through active monitoring and responsive control based on displayed information.
4Measurement precision
If more sensors and control elements are added to monitor all machine states, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges data from multiple sensors and control elements into a single integrated display interface. Rather than requiring separate monitoring systems for each machine state, the display device consolidates all sensor data, release signals, and production information into one coherent visualization, achieving comprehensive monitoring without proportionally increasing system complexity.
Data Source
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AI summary
Production installation (P) for the automated manufacture of parts (T), particularly a pallet circulating installation for the manufacture of reinforced concrete elements and/or an installation for manufacturing reinforcement elements, having an electronic control computer (L) which is connected to sensors and control elements in the production installation (P) and controls the production sequence, wherein at least one display device (A) is provided for the schematic graphical representation of the production installation (P) and the current state data therefor (Dakt), wherein a mass memory (S) is provided which can be used to store the state data (D) for the production installation (P) in time-indexed fashion over a period which goes beyond the production time for a part (T), and wherein also an electronic computer unit (R) and a display device (A') are provided which can be used to retrieve and graphically display the historical state data (Dhist) stored in the mass memory (S), together with a schematic graphical representation of the production installation (P).