Industrial Printer Productivity Tracking With Downtime Reporting
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Solution Overview
Problem
Existing industrial printers lack effective methods to track production line productivity, leading to inefficiencies and increased operating costs due to unforeseen downtime and incorrect labeling, which can result in discarded products and reduced facility productivity.
Innovation Solution
A method and system that utilizes existing industrial printers to monitor print operations and report productivity metrics, including event codes for downtime, using sensors and a processor to generate reports on a display device, allowing for real-time monitoring and analysis of production line performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If industrial printers are used to mark products on production lines, then product identification and tracking are improved, but the ability to monitor overall production line productivity deteriorates due to lack of integrated tracking capabilities
Solution Approach 1:
The industrial printer is enhanced with additional sensors (encoders, proximity sensors, temperature sensors) and a processor that enables it to perform both its original marking function and new productivity tracking functions. The printer now serves as a multi-functional device that marks products while simultaneously monitoring print operations, detecting downtime events, and generating productivity reports.
Solution Approach 2:
The patent combines the productivity tracking system with the existing printer infrastructure by integrating sensors, processors, and reporting capabilities into the printer itself. This merges the marking function with the monitoring function into a single unified system, eliminating the need for separate tracking devices.
2Reliability
If traditional separate systems are used to track production line productivity, then dedicated monitoring capability is improved, but device complexity and operating costs increase
Solution Approach 1:
The printer is transformed into a multi-functional device that performs both product marking and productivity tracking. By integrating encoders, proximity sensors, temperature sensors, and a processor into the printer, it gains the capability to monitor print operations, detect downtime events, and generate reports without requiring separate dedicated tracking systems.
Solution Approach 2:
The printer monitors its own operational status using integrated sensors and encoders to detect downtime events, print operation counts, and environmental conditions. The system automatically generates productivity reports based on its own operational data, eliminating the need for external monitoring systems.
3Productivity
If real-time productivity monitoring is implemented, then production transparency and throughput are improved, but data collection and processing requirements increase
Solution Approach 1:
The system extracts only the essential productivity data needed for monitoring—print operation counts, downtime events, and target comparisons—from the vast amount of sensor data generated by the printer. The processor filters and processes this data to generate concise productivity reports that highlight key performance metrics without overwhelming detail.
Solution Approach 2:
The system continuously monitors print operations and compares actual productivity against target values, providing real-time feedback through generated reports. This feedback mechanism enables immediate identification of productivity deviations and facilitates quick corrective actions to maintain optimal production levels.
Data Source
AI summary
A method implemented on a processor for operating an industrial printer comprises obtaining first data that indicates a representative industrial printer used on a production line at a facility and a product to be output by the production line; obtaining second data that indicates a target start time and a target number of the product and a target duration for producing the target number of the product; and upon a condition precedent, determining a line report that indicates productivity of the production line based on the count of print operations and the second data.