Industrial Bottleneck Detection Using Clean Time-Stamped Data
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Solution Overview
Problem
Current industrial processes for bottleneck detection in manufacturing and supply chain environments are inefficient, relying on manual analysis and siloed data, which limits the ability to quickly identify and resolve bottlenecks, leading to increased costs and reduced productivity.
Innovation Solution
A computer-based Industrial Bottleneck Detection and Management System (IBDMS) that processes and analyzes time-stamped data to identify and prioritize bottlenecks in real-time, using data cleansing and multivariate analysis to provide clean data for statistical calculations and visualize bottlenecks, enabling rapid detection and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual data collection and analysis methods are used, then data accuracy can be maintained through human verification, but the detection speed and productivity are significantly reduced
Solution Approach 1:
The patent replaces manual mechanical data collection and analysis processes with an automated computer-based system that continuously collects, cleanses, and analyzes process data. The system uses automated algorithms to detect bottlenecks without human intervention, thereby maintaining detection accuracy while dramatically increasing detection speed and productivity.
Solution Approach 2:
The system enables self-service bottleneck detection by automatically monitoring process data, identifying bottlenecks, and generating reports without requiring manual analysis. The automated system serves itself by continuously processing data and alerting operators only when actual bottlenecks are detected, eliminating the need for constant manual verification.
2Productivity
If continuous real-time data analysis is implemented, then bottleneck detection speed is improved, but data processing complexity and computational requirements increase
Solution Approach 1:
The patent applies preliminary data cleansing and preprocessing steps before the main bottleneck detection analysis. By pre-processing the data to remove errors, handle missing values, and validate data quality, the system simplifies subsequent analytical operations and reduces computational complexity during real-time bottleneck detection.
Solution Approach 2:
The data processing system is divided into distinct modular components: data collection module, data cleansing module, bottleneck detection module, and reporting module. This segmentation allows each component to be optimized independently and processed in sequence, reducing overall system complexity while enabling real-time analysis.
3Reliability
If comprehensive data validation and cleansing are performed, then data quality is improved, but processing time and computational resources are consumed
Solution Approach 1:
Data validation and cleansing operations are performed as preliminary steps before bottleneck detection analysis. The system automatically validates data format, checks for missing values, identifies outliers, and cleanses problematic data points before they enter the main analysis pipeline, ensuring high data quality without significant time loss during critical detection phases.
Solution Approach 2:
The data cleansing process operates continuously in the background alongside data collection, rather than as a separate batch process. This allows the system to maintain continuous monitoring capability while progressively cleaning data, ensuring that data quality improvement does not interrupt or significantly delay bottleneck detection operations.
Data Source
AI summary
The present invention includes: (a) a method for improving data to be processed for bottleneck detection, by cleaning corrupt or outlier data; (b) a method for improved analysis of bottleneck data using a plurality of rules for categorization; and (c) a method for improved display and/or allowing improved user feedback for bottleneck data using multivariate analysis and display. These methods can be used alone, or preferably be combined in whole or in part together to improve performance of an industrial process. A system is also provided.