Production Equipment Control Using Dynamic Risk-Based Item Switching
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Solution Overview
Problem
In highly automated production processes, the lack of human oversight leads to the potential production of non-usable products due to ignored risks, necessitating improved control mechanisms to adjust processes based on risk assessments without human intervention.
Innovation Solution
A control system that determines risk values for products and components, automatically adjusting process control data to switch from one processing mode to another with lower risk, using a risk evaluator module to detect changes exceeding predefined thresholds, and initiating the production of items with the lowest risk values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high degree of automation is implemented in production processes, then productivity and efficiency are improved, but the ability to assess and respond to risks is reduced due to lack of human operators
Solution Approach 1:
The control system performs self-assessment of risks by automatically determining risk values for products and components using sensor data and process parameters, eliminating the need for human operators to assess risks while maintaining continuous monitoring and adaptation of the production process
Solution Approach 2:
The system implements continuous feedback loops where sensor data from the production process is fed into the control system, which determines risk values and automatically adjusts process parameters in real-time to maintain safe and efficient operation without human intervention
2Speed
If automated control systems are used without human oversight, then operational speed is improved, but the detection of potential risks and ability to prevent waste is reduced
Solution Approach 1:
The control system performs preliminary risk assessment by determining risk values for products and components before production issues occur, allowing the system to proactively adjust process parameters to prevent potential problems rather than reacting to them after they manifest
Solution Approach 2:
The system replaces human mechanical assessment and decision-making with automated electronic risk evaluation algorithms that continuously analyze sensor data and process parameters to detect and respond to risks at speeds impossible for human operators
3Reliability
If risk-based automatic control is implemented, then the production of non-usable products is prevented, but the complexity of the control system increases
Solution Approach 1:
The control system segments risk assessment into distinct components by determining individual risk values for specific products and components separately, allowing the system to target adjustments to specific process parameters affecting only the at-risk elements rather than overhauling the entire production system
Data Source
AI summary
A control system and control method for controlling a process performed by production equipment. The control system has a first interface configured to obtain, from a data provisioning module, production control data for operating the production equipment wherein the production control data relates to operating instructions configured to control the production equipment to automatically process a plurality of physical items and their respective components. It further includes a risk evaluator module configured to determine for each item a total risk value based on partial risk values associated with the respective components, and further configured to detect a change in the determined total risk values. It further includes a control unit configured to: initiate, via a second interface, execution of the operating instructions for manufacturing a particular item having the lowest total risk value during a first operating time interval; initiate termination of the execution of the operating instructions for processing the particular item if the change in the determined total risk values results in an alternative item having the lowest total risk value; and initiate, via the second interface, execution of the operating instructions for processing the alternative item during a second operating time interval.