Description:F O R M 2
THE PATENTS ACT, 1970
(39 of 1970)
The patent Rule, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

TITLE OF THE INVENTION
PRODUCTION CONTROL IN SHOP FLOOR

Name and address of the applicant:
Name: PROFIMAX DIGICONNECT PRIVATE LIMITED

Nationality: Indian

Address: 56-C Bharathi Park, 2nd Cross Road Saibaba Colony, Coimbatore- 641011.  
Preamble to the description
[0001] The following specification particularly describes the invention and the manner in which it is to be performed:
Description of the invention
Technical field of the invention
[0002] The present invention relates to digitization of shop floor. More particularly, the invention relates to a system for production control in a shop floor with a plurality of machines operated for manufacturing a product(s).
Background of the invention
[0003] Shop floor has a variety of machines like computerized numerical control (CNC) lathes, punch press, welding machines, robotic mechanism, plastic injection machine etc., of different makes and ages. When attempting to get data like production, operator efficiencies, energy consumption etc., this involves handling a variety of signals and protocols to analyze and get insights
[0004] Furthermore, the conventional automation systems require a lot of customization when the shop floor includes machines from different generations and industrial standards. There is no single solution that can accommodate variety of machines without requiring complex customization.
[0005] Hence, there is a need for a system for production control in a shop that is effective and accurate and tracking the working conditions of the machines as well as the products processed thereby. Furthermore, there is a need for a simple solution that can be adapted to variety of machines and harsh environments without requiring complex customizations.
Summary of the Invention
[0006] The present invention relates to a system for production control in a shop floor comprising at least one machine. The system comprises at least one identification (ID) member, at least one scanning unit, and an electronic control unit (ECU). An ID member is associated with each machine and at least one product to be processed at the machine. Each scanning unit is capable of reading each ID member. The ECU is communicatively connected to and controls each scanning unit and each machine.
[0007] The ECU receives a working status from the machine and associates the working status with at least one product that is at least partially processed by the machine. The ECU is configured to at least partially disable an operation of the machine if the working status received from the machine denotes that the machine is FAULTY.
[0008] In one embodiment, the ECU is configured to identify a time window from a time instance at which the working status is received from the machine and to associate the working status with at least one product that is in process by the machine during the time window.
[0009] In a preferred embodiment, at least one sensing device is associated with each machine and capable of sensing at least one parameter of the machine. More preferably, the working status includes the parameter of the machine. Most preferably, the parameter is at least one of a mechanical parameter and electrical parameter.
[0010] The present invention also relates to a method for production control in a shop floor comprising at least one machine. The method comprises associating at least one identification (ID) member with each machine and at least one product to be processed at the machine, reading, using at least one scanning unit, ID member of each product and the machine before initiating processing of the product at the machine, processing the product at the machine, and moving each product to a next process after the processing.
[0011] During the processing, a working status is received at an electronic control unit (ECU) from the machine and associated with at least one product that is at least partially processed by the machine, wherein an operation of the machine is at least partially disabled by the ECU if the working status received from the machine denotes that the machine is FAULTY.
[0012] In one embodiment, a time window is identified, using said ECU, from a time instance at which the working status is received from the machine. Furthermore, the working status is associated with at least one product that is in process by the machine during the time window.
[0013] In a preferred embodiment, the method further comprises sensing at least one parameter of the machine using at least one sensing device associated with each machine. More preferably, the working status includes the parameter of the machine. Most preferably, the parameter is at least one of a mechanical parameter and electrical parameter.
[0014] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the scope thereof, and the embodiments herein include all such modifications.
Brief description of the drawings

[0015] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.

[0016] Figure 1 illustrates a schematic block diagram of a system for production control in a shop floor, in accordance with an exemplary embodiment of the present invention.

[0017] Figure 2 illustrates a flow diagram of a method for production control in a shop floor, in accordance with an exemplary embodiment of the present invention.

Detailed description of the invention

[0018] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention.
[0019] Figure 1 illustrates a schematic block diagram of a system (10) for production control in a shop floor (1), in accordance with an exemplary embodiment of the present invention. The system (10) comprises comprises at least one identification (ID) member (20), at least one scanning unit (30), at least one data storage unit (60), and an electronic control unit (ECU) (40). Each ID member (20) is associated with a corresponding machine (2) in the shop floor (1) or at least one product (4) to be processed at the machine (2), and each scanning unit (30) is capable of reading each ID member (20). The system (10) further comprises an electronic control unit (ECU) (40) communicatively connected to and controlling each scanning unit (30) and each machine (2).
[0020] In one embodiment, each component of the system (10) is connected to a network (3) for communicating with other components of the system (10) and/or with any external devices. In one example, the network (3) is any conventional wireless network, e.g., WiFi, Bluetooth, etc., wherein the components of the system (10) are wirelessly connected to the network (3). In another example, the network (3) is a wired network e.g., wired local area network, communication bus, etc., wherein the components of the system (10) are connected to the network (3) through any conventional communication cable.
[0021] In one embodiment, the machine (2) includes, but not limited to, computerized numerical control (CNC) lathes, punch press, welding machines, drilling machines, robotic mechanism, plastic injection machines or any other convention machines capable of processing the product (4) for altering a physical, mechanical and/or chemical properties of the product (4).
[0022] The ECU (40) receives a working status from the machine (2) and associates the working status with at least one product that is at least partially processed by the machine (2). The working status can include but not limited to “IN OPERTAION” and “FAULTY”.
[0023] In one embodiment, the ECU (40) is configured to identify a time window from a time instance at which the working status is received from the machine (2) and to associate the working status with at least one product that is in process by the machine (2) during the time window.
[0024] In one embodiment, each scanning unit (30) is configured to read the ID member (20) associated with the product (4) before the product (4) is moved or conveyed for processing by the machine (2). Each scanning unit (30) communicates the read data to the ECU (40), wherein the ECU (40) updates a status of the product (4) as UNDER PRORCESS.
[0025] In one example, an operator operates the scanning unit (30) to read the ID member (20) associated with the product (4) before positioning the product (4) for processing by the machine (2). In another example, the scanning unit (30) automatically reads the ID member (20) associated with the product (4) when the product (4) is manually or automatically positioned for processing by the machine (2).
[0026] In one example, by default, each machine (2) is disabled from processing the product (4), wherein the ECU (40) enables each machine (2) only after the scanning unit (30) associated with the machine (2) automatically reads the ID member (20) of a product and ECU (40) verifies that the working status of the product (4) is IN OPERATION with respect to any previous operation to be carried out for the product (4). In another example, an operator operates the scanning unit (30) to read the ID member (20) of the product (4) and the scanning unit (30) automatically reads the ID member (20) associated with the product (4) when the product (4) is manually or automatically positioned for processing by the machine (2). In one example, a plurality of units of the product (4) is loaded into a machine for processing. In such cases, a container, such as basket, bin, bag and the like, is attached with an ID member, wherein all the units in the plurality of units of the product (4) are identified by the same ID member.
[0027] In one example, the ID member (20) can include but not limited to any conventional codes such as alphanumeric code, radio frequency ID (RFID), barcode, QR code, and the like, and the scanning unit (30) can include but not limited to an imaging sensor, barcode reader, QR code reader and RFID reader. In one example, the ID member (20) is in the form of a tag, sticker, label, token, badge, and the like, which is attached, welded, embedded, etched, linked, fastened, glued or engraved on an external portion of each product and/or each machine (2).
[0028] In one embodiment, the system (10) further comprises at least one sensing device (50) associated with each machine (2) and capable of sensing at least one parameter of the machine (2). More preferably, the working status includes the parameter of at least one component in the machine (2). Most preferably, the parameter is at least one of a mechanical parameter and electrical parameter.
[0029] In one embodiment, the system (10) further comprises at least one categorizing unit (not shown), preferably in the form of a mechanical device, such as robotic arm, associated with at least one machine (2) and capable of dividing a set of products based on the corresponding working status.
[0030] In one embodiment, the system (10) further comprises at least one output unit (not shown), preferably in the form of a display screen, such as touchscreen, capable of displaying a report including the working status of at least one machine and/or at least one product.
[0031] In one embodiment, the ECU (40) is configured to at least partially disable an operation of the machine (2) if the working status received from the machine (2) denotes that the machine (2) is FAULTY. The operation of the machine (2) can include but not limited to welding, cutting, soldering, shaping, clamping, drilling, attaching, glueing, or any other conventional processing of the product (4). For example, if the working status received from a drilling machine denotes that the drilling machine is FAULTY, the ECU (40) disables the drilling machine from drilling the product (4).
[0032] In one embodiment, the ECU (40) is configured to enable the at least partially disabled operation of the machine (2) after ECU (40) receives the working status denoting that the machine (2) is IN OPERATION. In one embodiment, the ECU (40) is configured to change or further update the working status of any product (associated with the working status FAULTY) from FAULTY to IN OPERATION only after the product (4) is re-processed by the machine (2) whose disabled operation is enabled. For example, when the faulty drilling machine is serviced and the working status of the drilling machine changes from FAULTY to IN OPERATION, the ECU (40) enables the disabled operation of the drilling machine. Furthermore, the working status of any product associated with the working status FAULTY is changed from FAULTY to IN OPERATION by the ECU (40), after the ECU determines that the product (4) has been re-processed by the drilling machine.
[0033] In many real-time scenario, operators in a shop floor are low skilled or unqualified to operate the machines and verify the product (4)s. Such operators are only taught to operate few buttons on an oeprations panel of the machines, e.g., start/stop button, emergency alert button, load/unload button. Most of the operations carried out in the shop floor rely on automation systems. When there is a fault/alarm displayed the operators are at a loss to interpret and leave the machines, walk around and search for supervisors resulting in loss of productivity. The Supervisors or maintenance engineers are mostly occupied with other tasks and until their attention is got and they come over, machines are idling wasting time and money.
[0034] The ECU (40) is provided with a user-friendly rotary dial with Icons/figures for selecting one of a plurality of input commends and displays information in a language fluent to the operator, wherein the operator can operate a dial to search for a reason and press an enter key. In one embodiment, the rotary dial is integrated with a display screen e.g. LED, LCD and touch screen, for displaying the information. The ECU (40) is configured to identify one or more relevant persons-in-charge for that particular machine and directly sends a notification e.g., an SMS, email or instant message. In one example, such persons-in-charge carry a user device e.g., mobile phone, handheld computing device, etc., installed with a dedicated software application through which the notification is sent. Thereby, reducing the down time of a machine due to a distance between the operator and the person-in-charge. Furthermore, the rotary dial allows the system to be applied for harsh environments, wherein the operator with dirty or greasy hands can easily operate the rotatry dial without spoiling a function of the system.
[0035] In one example, a machine in a shop floor may stop working for a variety of reasons, namely for want of material, finished part inspection, part program change, offset correction, scrap cleaning, fixture issue, etc. Under such conditions, different actions are required by other people in the shop floor rather than the operator. But operator shift target is to produce so a predefined number of units as set under idle conditions without considering real-time deviations and the cost of producing the parts is quoted by a manufacturer. As the machine down time reasons are entered for every stop and recorded by the present invention, the manufacturer will get access to historical records and can more accurately estimate and quote, resulting in better profits.
[0036] In some examples, a night shift operator increases a feed rate of a machine more than a permitted rate with a supervisor not present, and it becomes impossible to pin point to the operator and the operator would have left by the time poor quality parts are found the following day. By over speeding the operator makes the planned parts much earlier and goes for sleep, does other things. This results in abusing that machine as well as other machines that are involved in further processing the poor quality parts, and thus reducing life of the machines as well. The present invention can detect over speeding as a faulty status of that particular machine and records the operation time and the operator involved, and shuts down the machine and prevents operation of the machine any further until a supervisor finds the reason and approves operation of the machine.
[0037] In some examples, each operator and supervisor are provided with an ID member to record the operators involved in operating any machine and the supervisors who approve such operations. In some examples, ID members of supervisors are assigned with more access rights as compared to the ID members of operators. For example, overspeeding can be approved by the supervisors under certain conditions, so that the machines continue operation at overspeed. In some examples, a manual override operation is provided in the ECU (40), wherein the supervisors are provided with the access to such manual override operation.
[0038] Figure 2 illustrates a flow diagram of a method (100) for production control in a shop floor, in accordance with an exemplary embodiment of the present invention. The method (100) comprises associating at least one identification (ID) member with each machine and at least one product to be processed at the machine (110) and reading, using at least one scanning unit, ID member of each product and the machine before initating processing of the product (4) at the machine (120). The method (100) further comprises processing the product (4) at the machine (130), and moving each product to a next process after the processing (140).
[0039] During the processing, receiving, at an electronic control unit (ECU), a working status from the machine, and associating the working status with at least one product that is at least partially processed by the machine. An operation of the machine is at least partially disabled by said ECU if the working status received from the machine denotes that the machine is FAULTY.
[0040] In one embodiment, the method (100) further comprises identifying, using the ECU, a time window from a time instance at which the working status is received from the machine, and associating the working status with at least one product that is in process by the machine during the time window.
[0041] In one embodiment, the method (100) further comprises sensing at least one parameter of the machine using at least one sensing device associated with each machine, wherein the working status includes the parameter of the machine. Preferably, the parameter is at least one of a mechanical parameter and electrical parameter.
[0042] Since the current working status of each machine is associated with the corresponding product being processed by the machine, the present invention enables close monitoring and accurate tracking of the product (4)ion process. Furthermore, each machine is disabled based on the corresponding working status, and thus the present invention controls further production of any faulty products. Thereby, the present invention facilitates increasing profitable run time of each machine in the shop floor and reducing costly down time, which in turn results in increased productivity. , Claims:CLAIMS
We claim:
1. A system (10) for production control in a shop floor (1) comprising at least one machine (2), the system (10) comprising:
a) at least one identification (ID) member (20) associated with each machine (2) or at least one product to be processed at said machine (2);
b) at least one scanning unit (30) capable of reading each ID member (20);
c) an electronic control unit (ECU) (40) communicatively connected to and controlling each scanning unit (30) and each machine (2),
characterized in that:
- said ECU (40) receives a working status from said machine (2) and associates said working status with at least one product that is at least partially processed by said machine (2), wherein said ECU (40) is configured to at least partially disable an operation of said machine (2) if the working status received from said machine (2) denotes that said machine (2) is FAULTY.

2. The system (10) as claimed in claim 1, wherein said ECU (40) is configured to identify a time window from a time instance at which said working status is received from said machine (2) and to associate said working status with at least one product that is in process by said machine (2) during said time window.
3. The system (10) as claimed in claim 1, further comprising at least one sensing device (50) associated with each machine (2) and capable of sensing at least one parameter of said machine (2).
4. The system (10) as claimed in claim 1, wherein said working status includes said parameter of said machine (2).
5. The system (10) as claimed in claim 3, wherein said parameter is at least one of a mechanical parameter and electrical parameter.
6. The system (10) as claimed in claim 1, wherein said ECU (40) is configured to enable the at least partially disabled operation of the machine (2) receiving, from the machine (2), the working status denoting that the machine (2) is IN OPERATION.
7. The system (10) as claimed in claim 6, wherein the ECU (40) is configured to change the working status of the product (4) from FAULTY to IN OPERATION only after the product (4) is re-processed by the machine (2).
8. The system (10) as claimed in claim 1, wehrein the ECU (40) includes a rotary dial for selecting one of a plurality of input commands and a display screen integrated to the rotary dial.
9. A method (100) for production control in a shop floor comprising at least one machine, the method (100) comprising:
a) associating at least one identification (ID) member with each machine and at least one product to be processed at said machine (110);
b) reading, using at least one scanning unit, ID member of each product and said machine before initating process of said product at said machine (120);
c) processing said product at said machine (130);
d) moving each product to a next process after said processing (140),
characterized in that, during said processing,:
- receiving, at an electronic control unit (ECU), a working status from said machine; and
- associating said working status with at least one product that is at least partially processed by said machine, wherein an operation of said machine is at least partially disabled by said ECU if the working status received from said machine denotes that said machine is FAULTY.

10. The method (100) as claimed in claim 9, further comprising:
identifying, using said ECU, a time window from a time instance at which said working status is received from said machine; and
associating said working status with at least one product that is in process by said machine during said time window.