Predictive Batch Operation Timing for Multi-Unit Operator Control
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Solution Overview
Problem
Industrial processes with sequential operations face challenges in providing timely information to operators, leading to operator delays, equipment damage, and lost product due to fragmented, inaccurate, or non-existent time-based data for planning and execution.
Innovation Solution
An apparatus and method for predictive time-based control of batch or sequential operations using historical timing data to generate graphical displays, such as consolidated Gantt-style charts, that predict important sequence phases and interactions across multiple units, along with a merged 'to do' list for operators, enhancing planning and reducing mental effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional monitoring systems are used for batch or sequential operations, then equipment can be monitored, but timing information is fragmented, inaccurate, or non-existent leading to operator delays and errors
Solution Approach 1:
The patent consolidates timing information from multiple sequential operations into a single unified graphical display (Gantt-style chart). This merging of fragmented timing data from different process units and operations provides operators with comprehensive, accurate timing information in one view, eliminating the information loss and delays caused by scattered or missing timing data across multiple monitoring systems
Solution Approach 2:
The system performs preliminary analysis of historical batch data to predict future timing information for sequential operations. By pre-calculating and displaying predicted timing data before operations commence, operators receive advance timing information needed for effective planning, preventing delays caused by waiting for real-time data during critical operation phases
2Productivity
If operators manage multiple sequential operations manually, then flexibility is maintained, but operator workload and mental effort increase leading to errors and reduced efficiency
Solution Approach 1:
The graphical display system acts as an intermediary between complex sequential operations and operators. It automatically processes and synthesizes timing data from multiple process units, presenting simplified, intuitive visual information that reduces operator workload while maintaining comprehensive monitoring capability. This intermediary layer handles the complexity of coordinating multiple operations, allowing operators to manage broader scopes of responsibility with reduced mental effort
Solution Approach 2:
The patent replaces manual operator coordination of multiple sequential operations with an automated computer-based system that generates and displays predictive timing information. This substitution of mechanical/manual processes with automated information processing increases operator efficiency by eliminating the need for operators to manually track and coordinate timing across multiple operations, reducing errors while expanding their effective scope of responsibility
3Measurement precision
If historical data is not utilized, then system simplicity is maintained, but predictive timing information cannot be generated reducing planning capability
Solution Approach 1:
The system implements feedback by analyzing historical batch data to generate predictive timing information for future operations. Historical timing data from completed sequential operations is fed back into the system to refine and improve the accuracy of predictions for upcoming operations. This feedback loop continuously enhances timing prediction accuracy while the automated processing manages the complexity of historical data analysis, providing progressively more precise timing information for operator planning
Data Source
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AI summary
A method includes identifying (504) multiple planned sequences of operations (104a-104n) involving industrial equipment. The planned sequences of operations include one or more sequences of operations currently being performed using the industrial equipment and/or one or more sequences of operations to be performed using the industrial equipment. The method also includes identifying (506) information associated with prior executions of the sequences of operations. The information includes timing information associated with the prior executions of the sequences of operations. The method further includes generating (508) timing predictions for operations in the planned sequences of operations using the identified information. In addition, the method includes generating (512) an interface (400) for presentation to an operator. The interface identifies the planned sequences of operations and the timing predictions for the operations in the planned sequences of operations.