F0RM2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)
1. Title of the invention. - AN IMPROVED AUTOMATED SYSTEM AND
METHOD FOR SCHEDULING, TRACKING AND MONITORING REAL-TIME MANUFACTURING OF PARTS IN JOBBING SHOP OR TOOL ROOM
2. Applicant(s)
(a) NAME : LARSEN & TOUBRO LIMITED
(b) NATIONALITY : An Indian Company.
(c)ADDRESS: L & T House, Ballard Estate, Mumbai 400 001,
State of Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed:

TECHNICAL FIELD OF THE INVENTION
The present invention relates to an automated system using RFID for Scheduling and monitoring/tracking real-time manufacturing of parts and part assemblies. More particularly, the invention is concerned about job scheduling during various operations involved in manufacturing of parts by optimizing the resource utilization.
BACKGROUND AND THE PRIOR ART
In the past each machine and item was individually monitored and the progress was manually noted in order, which was a hectic task. By the time, operator finished his inspection and returns, the status of operations on different machines were changed.
Traditionally, parts undergo a series of processing steps in the manufacturing shops. In the process of manufacturing the parts may required to be moved to various destinations (like another manufacturing location or a supplier's premises etc) in order to be completed, for example with the help of RFID reader/tags. The steps through which item of assembly typically pass along a typical distribution chain are often fixed, and are similar for many industries. These steps may typically include manufacturing, logistics to a storage facility or warehouse, storage in the warehouse, transportation to a distributor, storage at the distributor, and transportation to the end user. These steps are viewed as necessary by many industries.
One of the major challenges faced in the jobbing shop or tool room is tracking the progress of a particular product tool.
So-called RFID tags (passive) (for radio frequency identification) are also known from the prior art. Such tags can be read out in non contact process with the aid of electromagnetic waves. They typically require no energy storing means, since while being read out they are supplied with energy from outside, likewise by means of electromagnetic waves.The RFID readers then detect the tag's emitted RF signal when the signal is within the range of the reader's emitted RF field (or receive range), and the readers receive and process the RF signal emitted by the tags. Thus, the reader detects the presence of an RFID tag by detecting its RF signal, and processes the received data Passive

US 11/856,869 discloses a item tracking system which makes use RFID technology for automatically monitoring the taking and returning operations of items from one or more storage locations inside a working area which allows to have an "on line" status of each tool as well as the using history of each tool, furthermore, the system "knows" which item has been taken or stored from which storage area by which worker and when and synchronize and compile the information of all storage locations in one database and system for administering, reporting and sending alarms in order to have total tool control, accountability, tools service control (maintenance, calibration, repairs, and/or replacement), and administration of usage for the tools controlled by the system.
However, this system fails to support sufficient software systems that manage, track, and schedule and allow maintenance of the tools/tool parts. The system only locates the physical location of items that are currently under process. It only tracks the movement, the repairs or replacements required. Further from this prior art use of scheduling engine for scheduling process of tools/tool parts to be manufactured was not known. Tracking work in progress (WIP) by capturing the current statuses of operations by graphical veiw was not present.
US 6.839,604 B2 discloses a method for automatically tracking compliance in a manufacturing process involving successive manufacturing operations comprising selecting an object; associating an identifier with said object, said identifier comprising a memory; performing a first manufacturing operation relating to the object; following the successful completion of said first manufacturing operation, writing an associated compliance data item to the memory; performing one or more manufacturing operations relating to the object ;and following the successful completion of each said further manufacturing operation or any package thereof, writing an associative compliance data item to the memory.
However the rework and touchup conditions were not known along with the scheduling and detailed operational tracking.
US 6,747,560 B2 discloses a system for determining movement of an item bearing an RF1D label. The system includes an RF1D reader for receiving RFID label identification information from an RFID label associated with the item, and a computer for determining location information for the RFID label and the item, and for comparing the determined

location with the preferred location to determine that the RFID label and the item have moved.
However this system fails to support sufficient software systems that manage, track, and schedule and allow maintenance of the tools/tool parts. The system only locates the physical location of items that are currently under process. It only tracks the movement. Further from this prior art use of scheduling engine for scheduling process of tools/tool parts to be manufactured was not known.
US 5,785,181 discloses A permanently attached identification device which is a button sized RFID tag having a unique number. The RFID tag is applied to the garment on the first visit and the identification number is then read. Information related to the garment (such as owner name, dates, reason for cleaning, etc.) is input to a computer along with the identification number. Each time the garment is deposited with a dry cleaner the RFID tag is automatically read by a tag reader near the garment conveyor, and information related to (he current visit is input to (he computer. The comparer maintains a history record related to each garment that is keyed to the identification number in the RFID tag.
However the conventional systems described above include RFID tags of various elongated shapes, which are not always compatible with the various assets that arc to be tracked. Specifically, difficulties are encountered with large RFID tags are to be attached to small devices and therefore make using the smalt device awkward and cumbersome. the RFID tags are passive until illuminated by the radio reader, in order to exchange data. All of this communication between the tag's transponder and the sensor is performed using radio frequency energy of some kind. When multiple RFID tags are involved, anti-collision protocols are employed in order to multiplex or provide multiple accesses to the readers by the multiple tags.
US 7,053,775 discloses a method and apparatus for tracking items automatically is described. A passive RFID (Radio Frequency Identification) tag is used with a material tracking system capable of real-time pinpoint location and identification of thousands of items in production and storage areas. Passive RFID tags are attached to the item to be tracked, remote sensing antennas are placed at each remote location to be monitored, interrogators with several antenna inputs are connected to the sensing antennas to multiplex the antenna signals, and a host computer communicates with the interrogators to determine item locations to an exacting measure.

However in one of the conventional systems mentioned above, the RFID tags are passive until illuminated by the radio reader, in order to exchange data. All of this communication between the tag's transponder and the sensor is performed using radio frequency energy of some kind. When multiple RFID tags are involved, anti-collision protocols are employed in order to multiplex or provide multiple accesses to the readers by the multiple tags.
US 7,443,282 disclose a system and method, including software and hardware, for providing an accurate, real-time, and synchronized view of supply chain information. The system utilizes various RFID technologies (like an RFID tag, an RFID reader, and an RFID middleware software) to collect and manage data in real time. It then implements a synchronization mechanism to synchronize supply chain data from various data sources within and across a company in near real time fashion to allow different types of enterprise users, both interna! and externa), to access the synchronized information and take synchronized action within an appropriate timeframe.
The conventional system uses infinite number of modules (hardware and software) making the system complex to make and work upon.
Tool rooms and precision manufacturing shops across the globe have faced a common set of challenges-competition, product development cycle, changing priorities, high capital costs, changing customer needs, capacity utilization, bottlenecks, high volumes of process intensive unique parts, imbalance and fluctuating inflow, complex make-buy decisions, resource downtime, inefficiency, rejection, rework. However The conventional system uses infinite number of modules (hardware and software) making the system complex to make and work upon.
In this scenario it has become imperative that tool rooms manage their operations in a manner that allows them to provide their customer cost-effective, technology driven quality solution in a timely manner.
Thus there is a need to make an improved system which can overcome the entire above prior art shortcomings. Thus to implement a system, which is user friendly as much less efforts are made to convey the current tool room/fitting shop status to the system and simplifies the work of employee to a greater extend.

OBJECTS OF THE INVENTION
The basic object of the invention is to overcome the disadvantages of the prior art.
One object is to provide improved method and system for tracking, monitoring, and managing parts and assemblies during manufacturing.
Another object of the present invention is to provide schedule tracking and monitoring status of multiple jobs on the shop floor during the manufacturing cycle.
The present invention takes in to account all the manufacturing constraints and delivers more realistic schedules. The system uses a powerful "decision support" tool that can handle resource utilization, management of bottleneck resources, inventory management and is also capable to compare different schedules against production objectives. The system can be of great help for tracking work in progress for companies involved in manufacturing and for manufacturing identifiable parts.
SUMMARY OF THE INVENTION
According to one aspect for the present invention there is provision of an automated system for scheduling and/or monitoring/tracking a work in progress (WIP) of real time manufacturing of parts, sub assemblies and final assembly, the said system comprising:
RFID module for collecting, validating and transferring data based on the user inputs; a middleware forming an interface between RFID module and the database; wherein said database comprises access controlled software adapted to integrate and generate performance monitoring reports in analytical and graphical formats ; and scheduling engine adapted for scheduling the process steps while a real time manufacturing process is on.
According to another aspect for the present invention there is provided a method for scheduling and/or monitoring/tracking a work in progress (WIP) on real time basis manufacturing of parts, said method steps comprising RFID Tags and readers using set of status codes through user input to determine the current status;
User data from readers being validated, filtered and transferred to the Database through middleware interface;
providing initial and master inputs , validation for any status change from the RFJD module with the help of a software application present in the database;

providing information/data to the scheduling engine from the database;
providing the output of the scheduling engine to the graphical view and report generation
application to easily locate the parts, subassemblies and final assemblies in the
manufacturing setup;
providing scheduling and tracking/recording/monitoring of work in progress by capturing
the current statuses of operations
viewing the steps with the current statuses of operation of each step with the help of
graphical view; and
changing the status to indicate the status of operation within the selected step;
DETAILED DESCRIPTION OF THE INVENTION
In the present invention an Automated system using RFID has been developed for
scheduling, monitoring and tracking on real-time basis in job shop / tool room
environment. Using a Scheduling engine to schedule the parts by optimizing the
resources.
System Overview
The system comprises of are mentioned and described below: -
1. RFID Module(Work In Progress tracking system)
2. Interface application comprising of the
a) Real-time work in progress tracking system.
Middleware software validating, filtering, mediating and transferring information based on RFID events to database.
b) Database and integrator application server.
c) Access controlled software application to integrate reports, scheduling engine and graphical view of work in progress.
d) Scheduling Engine (available in commercial scheduling system)
e) Graphical monitoring to provide graphical view of the work in
progress (WIP) in terms of status, physical location Retailed information
of orders execution and resource utilization in terms of graphical
representation.
The system has RFID module (mentioned in 1 above) that comprises of RFID card readers that have been mounted on each and every machine. Further the RFID module

comprises plurality of RFID tags, namely the employer tag and the item tag. The RF1D tags and the RFID reader comprise of an unique id.
The RFID card reader has a keypad with numeric keys, a Function key and an Enter key. The custom designed reader has a 16x2 alphanumeric display. Each Reader has a unique id. Twelve pre defined status codes are available on the RFID readers. The operator/employee enters the status code and the step number of a particular operation. Information related to the employee, item, operation, changed status of operation and time gets stored in the central system database.
RFID tags are assigned to the items to be manufactured and to the shop floor personnel with an unique id.
And Middleware (as mentioned in point no. Id) is used as an interface between the RFID system and the database.
Scheduling Engine (2d above) requires initial inputs Bill Of Materials, Operations and their Routes, expected Processing time for each operation, target date of completion that are provided through a software application (2c above) for providing master inputs and administrative functions .The output of the scheduling engine is stored in the database which is fed to a graphical view to facilitate quick view of work in progress of the steps under observation.
An access controlled software application (2c above) also has been developed for the system, which integrates reports, scheduling engine and graphical view of Work in Progress. Reports help in monitoring the real-time status of tools under processing and other tools that are scheduled according to the resource loading on the shop floor. Using multi detection technique of RFID readers, registration of physical location of item is possible by simply flashing the item card in vicinity of the reader, even if two cards are present in the reader's pouch.
The output of the scheduling engine is fed into the Graphical view which provides graphical visibility of the work in progress my capturing the current statuses of the steps .
Process Flow
Now the procedures for which the tracking and scheduling takes place are mentioned henceforth starting from the tool room till the fitting shop: -

Each item undergoes various operations as per a Detailed Operation Card (DOPC) that moves along with the item. The DOPC has a complete list of activities that are to be performed on the item. The DOPC moves along with the item to the in-process area at the workstation. The DOPC file is attached to the item. The operator performs as per the DOPC and diagram that are available with the item.
With RFID tags not possible to be attached on the items, therefore there is a possibility to attach these tags on the DOPC, which moves along with the item. Every time an item moves to a particular location, it would be scanned at that location to indicate where it has reached that location and thus give information on its current location. The DOPC has a complete sequences of operations that are to be performed on a particular item.The operator based on schedule prepared by the planner performs the necessary job. After completion he places it in the waiting-for-further-processing area (parking area) from where it is taken to the next workstation where it has to be processed. Each item might undergo some operation at various workstations as part of its overall manufacturing plan.
The operator would be generally instructed by the supervisor to take up particular item for processing.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 illustrates the workflow in the tool room.
Figure 2 illustrates the supervisor's routine in the fitting room.
Figure 3 illustrates the manager's routine in the fitting room.
Figure 4 illustrates the process flow in the ETS (engineering tooling solutions).
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 illustrates the tool room workflow.
StepI: At first a Detailed Operation Card (DOPC) is prepared that includes the sequence
of operation and other details related to a tool and those are uploaded to the system.
Step 2: RFID cards are assigned to the employee and the items.
Step 3: Each tool is having DOPC and RFID card
Step 4: Employee card and item card are presented to the reader
Step 5: Step number and status code entered through the RFID
Step 6: Then validation for step and status entry performed.

a) If yes then reader records detail time when the operation has started, the current status
and who is operating on the item and details of the information is sent to the scheduling
engine.
Then 1 st operation is performed.
b) If validation for step and status is no then display error message.
Step7: 1st operation successful then next operation performed then n number of
operations performed.
Step 8: If unsuccessful then rework, touch up and reject
Step 9:Then final assembly and again a final check and then dispatch.
Figure 2 illustrates the fitting shop supervisor's routine
The task of the shop supervisor is to inspect the item for completion of the previous for
taking up operation of the next step by including a timestamp.
Is1 the supervisor put his card and the job card to the reader pouch and press enter for
inspection.
Step 1: Checks the latest step for which the status is finished (stat 70).
a) If it is YES then step or status code changes.
For status code changes - Application needs to validate the authority for changing the
status as per status authorization table and if there is no authority then formatted error
message
For step code changes- Look status code of the Step specified and send a formatted
message to the Reader for display.
After the status code change and validation next is to check whether the "status step
okay"
If yes then Application should add a time-stamped entry corresponding to the changes.
If no then to check is the status "rework"
Rework if yes then time-stamped entry corresponding to the changes.
If no then "is the status reject"?
If its yes then Error Msg: Not Authorized
If no then "is the status touch up".
Yes- Application should add a time-stamped entry corresponding to the changes.
b) If no for the latest step for which the status is finished then check for the latest step for
which the status =10 to 60
i.e, 10 - Cleared to start

20 - Under Setup
SO — Under Process
{4x to 5x} - Halted (Will have a number range from 40 to 59 with different halt messages
assigned to them
60 - Under Dismantle
If yes then allowed to change the status from 20 to 60 and back.
If no then is the status "not cleared to start (stat 00)
Yes-status changes allowed, allowed to change the status to 10.
No-is status cleared to start (stat 10)
Yes- Allowed to change the STATUS to 20 onwards to 60 and 91,And If this is STEP
999 allowed to change.
Figure 3 illustrates the fitting shop manager's routine
Managers put his card and the job card in the reader pouch and press enter for inspection. Application should search the latest transaction according to timestamp entry in database. Stepf :Checfcs Latest step for which the status is finished (stat 70) a) If yes then status or the step change done.
Status code change: Application needs to validate the authority for changing the status as per status authorization table and if there is no authority then formatted error message. Step change: Look at the status code of the Step specified and send a formatted message to the Reader for display.
After the status change check is the step okay? If no then rework or reject or touch up. After the mark of the status change timestamps are added accordingly They are: -
Step okay (stat 80)- The manager is allowed to change the status to "rework", "Reject" or "Touch Up" (Status 90, 91 or 92) from Stat SO.Application should add a time-stamped entry corresponding to the changes. Application should automatically Display the next Step with Status 10 (Cleared to Start). Time stamp entry in database. Rework (stat 90)- Application should add a time-stamped entry corresponding to the changes. In database save as 8XX. And in REWORK all status displayed will have suffix "R" and directly R10 will be displayed and 810 will be stored with timestamp.
[Two entries should be save]

Reject (stat 91) - if yes then The ITEM CARD is REJECTED, inactive and is available for further Association. Application should add a time-stamped entry corresponding to the changes. In data base save as 710
If no then check is the status touch up (stat 92) then Application should add a time-stamped entry corresponding to the changes. In database save as 9XX. And in TOUCH UP all status displayed will have suffix "T"
b) If No then check is status cleared to start (stat 00)
If yes then status changes allowed (allowed to change the status to 10). For any other Step the Status is automatically changed to lO.If no check is the status cleared to start (stat 10) onwards. Allowed to change the STATUS to 20 onwards to 60 and 91, And If this is STEP 999 allowed to change.
Figure 4 illustrates the process flow in the ETS (engineering tooling solutions).
There arc three stages are (a) design (b) Pre-hcat treatment (c) Post heat treatment.
(a) At first the tool request is raised by the initiator who initiates the operation, then purchase/sales order and enquiry of the tool is performed. The tool request is received by the TMG department followed with discussion with TED (HOD) relating to estimated cost and delivery schedule. Tool request is received from the TMG with estimates, then the estimates sent to initiator. If further enquiry for the estimate is required then it is sent back to the initiator. TMG creates job no for the tool for further booking and identification. Simultaneously tool entry is made in ERP/SAP systems. After this TMG sends the tool request copy to ED with details such as estimates, job no, tool no and others if specified that is one copy each with designer, with TR file on approval, for group order send to initiator. The TR is received by TED (HOD). The TR received then passes to the group leader then the allocation of recourses available are checked and allocated as per availability. Tooling sequence and blank development is performed in the next step followed with the approval the design of press tool (layout generation). Afterwards initiators are met for design discussions and manufacturing review with M/C shop. If it is not approved or has to be modified by the initiator and the M/C shop then its goes back to design of press tool and the whole process it performed again. If approved 2D, 3D models, hole charts and detailed drawings started then checking is done by the checker, if not correct then correction done. Then approved by HOD (TED), if not approved then modification, correction performed. After the final approval by the HOD

the job ticket is generated. Finally the design released to the TMG (four copies of design sent). The TMG performs the final revision of the estimates, also the revision of the BOM, 3D model and frame.
(b) BOM (bill of materials) received from the TMD are entered in the system and items
categorized. Preparation of material request (M.R). M.R sent to TMD, sent to concerned
vendor. Materials received at the incoming material rack. The pre-machining sizes are
calculated and materials sent to the vendor and the partial data entry into e-star and cards
are issued. Then a check is performed whether the SG (surface grinding) is in-house or
outsourced followed by the gate pass preparation.
For in-house: material sent for pre-machining and is received by the stores. Material moved to Precision Machine Shop (PMS) for surface grindings performed and materials moved to the SG parking.
For outsourced: at first Job Outsourced, then Gate pass preparation and material sent for finish VMC, material received by stores, Material moved to Jig grinding parking, Resume process as per normal flowchart.
Now from the SG parking the DPMS is conducted and preparation of the DOPC (Detailed operation process card) is performed. Then the materials are moved to the M/C parking and rough VMC is performed. The job is moved to the fitting shop for Burr removal and cleaning performed. Visual Inspection, Stamping, Drilling and Tapping. Finally job sent for heat treatment.
(c) Job received after Heat Treatment, then Material sent for cryogenic treatment, Gate
pass preparation for outsourcing job. The stores receive the materials. Job moved to PMS
input rack .SG performed. Now a check is performed whether to finish VMC in-house or
outsourced.
For in-house: material moved to finish VMC input,finish VMC performed. Material
moved to Jig grinding parking.
For outsourcing: at first Job Outsourced, then Gate pass preparation and material sent for
finish VMC, material received by stores, Material moved to Jig grinding parking, Resume
process as per normal flowchart.
From materials moved to the Jig grinding parking the job moved to the fitting shop and
burr removal and cleaning performed.

Now a check whether Spark Erosion is in-house or outsourced is performed.
For 'in house: material are moved to the spark erosion input, wire erosion performed,
materia! is again moved to the jig grinding parking.
For Outsourced: at first Job Outsourced, then Gate pass preparation and material sent for
finish VMC, material received by stores, Material moved to Jig grinding parking, Resume
process as per normal flowchart.
From materials moved to the Jig grinding parking the job moved to the fitting shop and burr removal and cleaning performed.
Now from the jig grinding parking a check is performed whether wire erosion in-house or
out sourced.
For in house: material moved to wire erosion input, further wire erosion is performed,
then the material is polished as per fitting shop instructions. The material is then moved
again to the jig grinding parking.
For out source: at first Job Outsourced, then Gate pass preparation and material sent for
finish VMC, material received by stores, Material moved to Jig grinding parking, Resume
process as per normal flowchart.
From material in the jig grinding parking ,it is sent for nitriding and gate pass is prepared for outsourcing job. Material received by stores and then moved to PMS. Then again SG is performed and jib moved to the SG parking. The job is inspected.Finally the job is moved to the fitting shop for final assembly.

WE CLAIM
1. An automated system for scheduling and/or monitoring/tracking a work in
progress (WIP) of real time manufacturing of parts, sub assemblies and final
assembly, the said system comprising:
RF1D module for collecting, validating and transferring data based on the user
inputs;
a middleware forming an interface between RFID module and the database;
wherein said database comprises access controlled software adapted to integrate
and generate performance monitoring reports in analytical and graphical formats;
and
scheduling engine adapted for scheduling the process steps while a real time
manufacturing process is on.
2. System as claimed in claim 1 wherein the said RFID module comprising plurality of RFID tags, namely the employer tag and the item tag.
3. System as claimed in claim 1 wherein the said RFID tags comprise unique ids providing information/data to the RFID reader.
4. System as claimed in claim 1 wherein the said RFID reader comprises an unique id.
5. System as claimed in claim 1 wherein the said RFID reader further comprises alphanumeric display.
6. System as claimed in claim 1 wherein the said RFID reader further comprises keypad having numeric keys, and function keys adapted to enter two short digit status code and step number into the reader for transferring information/data to the database.
7. System as claimed in claim 1 wherein the said scheduling engine is a commercial scheduling system.
8. System as claimed in claim 1 wherein the said scheduling engine outputs are fed into the graphical view.

9. System as claimed in claim8 wherein the said graphical view is adapted for graphical monitoring, by capturing the current statuses of the tools/tool parts in the tool room.
10. System as claimed in any of the preceding claims wherein the said parts, sub assemblies are made up of several items to form a complete final assembly.
11. System as claimed in claims 1 to 10 wherein the said items are attached with the Detailed operation card (DOPC) which moves along with item wherein the said DOPC has a complete sequences of operations that are to be performed on a particular item.
12. System as claimed in claim 1 wherein the said status codes have twelve predefined status codes to mark the current status of operation within steps.
13. A method for scheduling and/or monitoring/tracking a work in progress (WIP) of real time manufacturing of tools and/or tool parts, said method steps comprising: detecting RFID tag by means of RFID reader;
entering status code and the step number into the RFID reader;
validating , filtering and transferring the inforniation/data from the user given
inputs into the RDIF module to the Database with the help of middleware;
providing initial and master inputs , validation for any status change from the
RFID module with the help of a software application present in the database;
providing information/data to the scheduling engine from the database;
providing the output of the scheduling engine to the graphical view and report
generation application to easily locate the tools/tool parts in the tool room;
providing scheduling and tracking/recording/monitoring of work in progress by
capturing the current statuses (not cleared to start/ cleared to start, under setup/
under process/halt/touch up/ rework/reject/ under dismantle/ finished/ step Ok) of
operations
viewing the steps with the current statuses of operation of each step with the help
of graphical view; and
changing the status to indicate the status of operation within the changed step.

14. A software application program installed inside the said database adapted to transfer initial inputs like the bill of material, detailed operations and their routes, expected processing time for each operation, target date of completion, current statuses of parts and part assemblies through the RFID reader to the said scheduling engine.