Mould Manufacturing Control System Automation
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Solution Overview
Problem
The manufacturing of lineal moulding is inefficient due to human error, manual labor, and paper-based processes, leading to resource mismanagement and reduced productivity in woodworking industries.
Innovation Solution
A system integrating a manufacturing application server with user computing devices and production devices, such as ripsaws and moulders, to automate order processing, optimize material yield, and provide real-time communication and status updates across the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual labor and paper-based processes are used for order management, then employees can handle orders, but human error increases and productivity decreases
Solution Approach 1:
The patent replaces manual paper-based order management with an automated computer system that receives orders, generates routing sheets, and transmits them to production devices. This substitution eliminates human error in order processing while maintaining full automation of the workflow, directly resolving the contradiction between reliability and productivity.
Solution Approach 2:
The system enables self-service automation where the computer automatically processes orders, determines routing instructions, and manages production scheduling without human intervention. This self-automating approach eliminates the need for manual order handling while ensuring accurate and efficient production management.
2Ease of operation
If multiple employees manually manage orders and rearrange queues, then order processing can be performed, but time consumption increases and efficiency decreases
Solution Approach 1:
The computer system performs preliminary automated actions by pre-determining routing sheets and production schedules before production begins. When order changes occur, the system automatically recalculates and redistributes routing instructions to relevant departments in advance, eliminating the need for manual queue rearrangement and saving significant time.
Solution Approach 2:
The patent introduces a computer system as an intermediary between order reception and production execution. This intermediary automatically processes order information, generates routing instructions, and coordinates with production devices, replacing manual employee interactions and dramatically reducing the time required for order management.
3Ease of manufacture
If employees manually inspect and manage work orders, then production can be controlled, but resource optimization is limited and waste increases
Solution Approach 1:
The computer system implements feedback by automatically tracking production status, monitoring material usage, and comparing actual results with planned production. This feedback loop enables real-time optimization of resource allocation and identifies opportunities to reduce material waste, while maintaining effective production control.
Solution Approach 2:
The system optimizes production parameters by automatically adjusting routing instructions, production schedules, and material allocation based on real-time data. This dynamic parameter optimization enables better resource utilization and reduces material waste while maintaining production control capability.
Data Source
AI summary
Embodiments of the invention provide methods, systems, computer programs and the like that provide for mould manufacturing control. Embodiments of the invention employ management communication and integration amongst a plurality of devices or process stations included in a lineal moulding manufacturing process. Once customer orders are received, the orders are analyzed by a manufacturing application server and used to create job instructions for producing the one or more orders. The job instructions are then transmitted to one or more production device(s). The production devices execute the job instructions and report back to the server. The server maintains status information for any jobs being performed and can provide real time information regarding the jobs to any of the production devices.