U.S. patent application number 10/358305 was filed with the patent office on 2003-08-07 for suite of configurable supply chain infrastructure modules for deploying collaborative e-manufacturing solutions.
Invention is credited to Kall, Jonathan J., McCarthy, Robert J., Troy, Thomas A..
Application Number | 20030149608 10/358305 |
Document ID | / |
Family ID | 27765937 |
Filed Date | 2003-08-07 |
United States Patent
Application |
20030149608 |
Kind Code |
A1 |
Kall, Jonathan J. ; et
al. |
August 7, 2003 |
Suite of configurable supply chain infrastructure modules for
deploying collaborative e-manufacturing solutions
Abstract
A suite of configurable supply chain infrastructure modules
provides the "collective manufacturing management infrastructure"
necessary to support a high velocity e-business initiative. At the
core of the collaboration scheme is the Business Process Modeling
Module. The Business Modeling Module consists of two components:
Business Process Event Coordinator, and Business Process Modeler.
To further support the collaborative scheme, a suite of highly
configurable application templates and pre-configured industry
applications provide an interface or wrapper around the business
rules. The application templates are designed to be used as
stand-alone components, or can be assembled/configured into a
cohesive solution to provide a basic foundation layer for a
Collaborative Manufacturing Execution System (CMES). To address the
connectivity of the CMES layer to the business layer and the shop
floor automation layer, an Extensible Markup Language (XML)
Business Connector and Optical Photo Conductor (OPC) Shop Floor
Connector fulfill the interface needs required to support a
collaborative infrastructure.
Inventors: |
Kall, Jonathan J.;
(Glenmoore, PA) ; Troy, Thomas A.; (Lansdale,
PA) ; McCarthy, Robert J.; (Downingtown, PA) |
Correspondence
Address: |
NEIFELD IP LAW, PC
2001 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Family ID: |
27765937 |
Appl. No.: |
10/358305 |
Filed: |
February 5, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60354151 |
Feb 6, 2002 |
|
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Current U.S.
Class: |
705/7.27 ;
700/99 |
Current CPC
Class: |
G06Q 10/063 20130101;
G06Q 10/0631 20130101; G06Q 10/0633 20130101; G06Q 10/06 20130101;
G06Q 10/0637 20130101 |
Class at
Publication: |
705/8 ;
700/99 |
International
Class: |
G06F 017/60 |
Claims
What is claimed is:
1. A manufacturing process, comprising: providing a work flow from
a business decision making layer to a production line and decision
making layer; and implementing a real-time integration of said work
flow.
2. The process of claim 1, further comprising: determining business
objectives at said business decision making layer; performing said
business objectives at said production line and decision making
layer; and carrying out said real-time integration of said business
decision making layer and said production line and decision making
layer by a collaborative infrastructure.
3. The process of claim 2, further comprising: analyzing a result
from said production line and decision making layer; and reporting
said analyzed result to said business decision making layer.
4. The process of claim 3, further comprising: receiving a report
containing analyzed result from said reporting process; and
adjusting said business objectives according to said report.
5. The process of claim 4, wherein said report comprises a
plurality of formats, including Spreadsheet and GANTT Chart.
6. The process of claim 2, wherein said collaborative
infrastructure further comprises a first coordinator connector
providing interface for said collaborative infrastructure and said
business decision making layer.
7. The process of claim 6, wherein said first coordinator connector
is a web-based open technology for electronic data interchange.
8. The process of claim 7, wherein said first coordinator connector
is the Extensible Mark-up language (XML) Business Connector.
9. The process of claim 6, wherein said collaborative
infrastructure further comprises a second coordinator connector
providing interface for said collaborative infrastructure and said
production line and decision making layer.
10. The process of claim 9, wherein said second coordinator
connector is an Application Programming Interface (API).
11. The process of claim 10, wherein said second coordinator is the
Ole Process Control (OPC) Shop Floor Connector.
12. The process of claim 11, further comprises integrating said
business decision making layer, production line and decision making
layer by said collaborative infrastructure through an Intranet or
the Internet.
13. The process of claim 2, wherein said production line and
decision making layer further comprises a plurality of business
rules.
14. The process of claim 13, further comprising: analyzing a result
from said production line and decision making layer; and reporting
said analyzed result to said business decision making layer.
15. The process of claim 14, further comprising: receiving a report
containing analyzed result from said reporting process; and
automatically adjusting said business rules based on said
report.
16. The process of claim 13, wherein said collaborative
infrastructure further comprises a plurality of configurable module
templates.
17. The process of claim 16, wherein said collaborative
infrastructure further comprises a graphical user interface capable
of configuring and modifying said plurality of business rules.
18. The process of claim 16, wherein said configurable application
templates are capable of synchronizing and optimizing execution
activities at said production line and decision layer.
19. The process of claim 18, wherein said infrastructure is a
Manufacturing Executive System (MES).
20. The process of claim 19, wherein said infrastructure is a
Collaborative Manufacturing Executive System (CMES).
21. The process of claim 13, wherein said collaborative
infrastructure further comprises a plurality of scalable
application templates.
22. The process of claim 21, wherein said collaborative
infrastructure comprises at least one custom application
constructed with at least one scalable application template.
23. The process of claim 13, wherein said collaborative
infrastructure further comprises a plurality of maintainable
application templates.
24. The process of claim 23, wherein said maintainable application
templates increase the updating and debugging abilities of said
collaborative infrastructure.
25. A manufacturing method, comprising: providing a work flow from
a business decision making layer to a production line and decision
making layer; and implementing a real-time integration of said work
flow.
26. The method of claim 25, further comprising: determining
business objectives at said business decision making layer;
performing said business objectives at said production line and
decision making layer; and carrying out said real-time integration
of said business decision making layer and said production line and
decision making layer by a collaborative infrastructure.
27. The method of claim 26, further comprising: analyzing a result
from said production line and decision making layer; and reporting
said analyzed result to said business decision making layer.
28. The method of claim 27, further comprising: receiving a report
containing analyzed result from said reporting process; and
adjusting said business objectives according to said report.
29. The method of claim 28, wherein said report comprises a
plurality of formats, including Spreadsheet and GANTT Chart.
30. The method of claim 26, wherein said collaborative
infrastructure further comprises a first coordinator connector
providing interface for said collaborative infrastructure and said
business decision making layer.
31. The method of claim 30, wherein said first coordinator
connector is a web-based open technology for electronic data
interchange.
32. The method of claim 31, wherein said first coordinator
connector is the Extensible Mark-up language (XML) Business
Connector.
33. The method of claim 30, wherein said collaborative
infrastructure further comprises a second coordinator connector
providing interface for said collaborative infrastructure and said
production line and decision making layer.
34. The method of claim 33, wherein said second coordinator
connector is an Application Programming Interface (API).
35. The method of claim 34, wherein said second coordinator is the
Ole Process Control (OPC) Shop Floor Connector.
36. The method of claim 35, further comprises integrating said
business decision making layer, production line and decision making
layer by said collaborative infrastructure through an Intranet or
the Internet.
37. The method of claim 26, wherein said production line and
decision making layer further comprises a plurality of business
rules.
38. The method of claim 37, further comprising: analyzing a result
from said production line and decision making layer; and reporting
said analyzed result to said business decision making layer.
39. The method of claim 38, further comprising: receiving a report
containing analyzed result from said reporting process; and
automatically adjusting said business rules based on said
report.
40. The method of claim 37, wherein said collaborative
infrastructure further comprises a plurality of configurable
application templates.
41. The method of claim 40, wherein said collaborative
infrastructure further comprises a graphical user interface capable
of configuring and modifying said plurality of business rules.
42. The method of claim 40, wherein said configurable application
templates are capable of synchronizing and optimizing execution
activities at said production line and decision layer.
43. The method of claim 42, wherein said collaborative
infrastructure is a Manufacturing Executive System (MES).
44. The method of claim 43, wherein said collaborative
infrastructure is a Collaborative Manufacturing Executive System
(CMES).
45. The method of claim 37, wherein said collaborative
infrastructure further comprises a plurality of scalable
application templates.
46. The method of claim 45, wherein said collaborative
infrastructure comprises at least one custom application
constructed with at least one scalable application template.
47. The method of claim 37, wherein said collaborative
infrastructure further comprises a plurality of maintainable
application templates.
48. The method of claim 47, wherein said maintainable application
templates increase the updating and debugging abilities of said
collaborative infrastructure.
49. A manufacturing system, comprising: a work flow from a business
decision making layer to a production line and decision making
layer; and a real-time integration of said work flow.
50. The system of claim 49, further comprising: a plurality of
business objectives determined at said business decision making
layer and performed at said production line and decision making
layer; and a collaborative infrastructure implementing said
real-time integration of said business decision making layer and
said production line and decision making layer.
51. The system of claim 50, further comprising: a result analysis
from said production line and decision making layer; and a report
of said result analysis sent to said business decision making
layer.
52. The system of claim 51, further comprises an adjustment of said
business objectives according to said report.
53. The system of claim 52, wherein said report comprises a
plurality of formats, including Spreadsheet and GANTT Chart.
54. The system of claim 50, wherein said collaborative
infrastructure further comprises a first coordinator connector
providing interface for said collaborative infrastructure and said
business decision making layer.
55. The system of claim 54, wherein said first coordinator
connector is a web-based open technology for electronic data
interchange.
56. The system of claim 55, wherein said first coordinator
connector is the Extensible Mark-up language (XML) Business
Connector.
57. The system of claim 54, wherein said collaborative
infrastructure comprises a second coordinator connector providing
interface for said collaborative infrastructure and said production
line and decision making layer.
58. The system of claim 57, wherein said second coordinator
connector is an Application Programming Interface (API).
59. The system of claim 58, wherein said second coordinator is the
Ole Process Control (OPC) Shop Floor Connector.
60. The system of claim 59, further comprises integrating said
business decision making layer, production line and decision making
layer by said collaborative infrastructure through an Intranet or
the Internet.
61. The system of claim 50, wherein said production line and
decision making layer further comprises a plurality of business
rules.
62. The system of claim 61, further comprising: analyzing a result
from said production line and decision making layer; and reporting
said analyzed result to said business decision making layer.
63. The system of claim 62, further comprising: receiving a report
containing analyzed result from said reporting process; and
automatically adjusting said business rules based on said
report.
64. The system of claim 61, wherein said collaborative
infrastructure further comprises a plurality of configurable
application templates.
65. The system of claim 64, wherein said collaborative
infrastructure further comprises a graphical user interface capable
of configuring and modifying said plurality of business rules.
66. The system of claim 64, wherein said configurable application
templates are capable of synchronizing and optimizing execution
activities at said production line and decision layer.
67. The system of claim 66, wherein said collaborative
infrastructure is a Manufacturing Executive System (MES).
68. The system of claim 67, wherein said collaborative
infrastructure is a Collaborative Manufacturing Executive System
(CMES).
69. The system of claim 61, wherein said collaborative
infrastructure further comprises a plurality of scalable
application templates.
70. The system of claim 69, wherein said collaborative
infrastructure comprises at least one custom application
constructed with at least one scalable application template.
71. The system of claim 61, wherein said collaborative
infrastructure further comprises a plurality of maintainable
application templates.
72. The system of claim 71, wherein said maintainable application
templates increase the updating and debugging abilities of said
collaborative infrastructure.
73. A manufacturing apparatus, comprising: a work flow from a
business decision making unit to a production line and decision
making unit; and a real-time integration of said work flow.
74. The apparatus of claim 73, further comprising: a plurality of
business objective schemes determined at said business decision
making unit and performed at said production line and decision
making unit; and a collaborative infrastructure implementing said
real-time integration of said business decision making unit and
said production line and decision making unit.
75. The apparatus of claim 74, further comprising: a result
analyzing unit for result analyzing at said production line and
decision making unit; and a report generator for generating a
report after said result analyzing.
76. The apparatus of claim 75, further comprises an adjustment unit
at said business decision making unit for adjusting said business
objective schemes according to said report.
77. The apparatus of claim 76, wherein said report comprises a
plurality of formats, including Spreadsheet and GANTT Chart.
78. The apparatus of claim 75, wherein said collaborative
infrastructure further comprises a first coordinator connector
providing interface for said collaborative infrastructure and said
business decision making layer.
79. The apparatus of claim 78, wherein said first coordinator
connector is a web-based open technology for electronic data
interchange.
80. The apparatus of claim 79, wherein said first coordinator
connector is the Extensible Mark-up language (XML) Business
Connector.
81. The apparatus of claim 78, wherein said collaborative
infrastructure comprises a second coordinator connector providing
interface for said collaborative infrastructure and said production
line and decision making layer.
82. The apparatus of claim 81, wherein said second coordinator
connector is an Application Programming Interface (API).
83. The apparatus of claim 82, wherein said second coordinator is
the Ole Process Control (OPC) Shop Floor Connector.
84. The apparatus of claim 83, further comprises integrating said
business decision making unit, production line and decision making
unit by said collaborative infrastructure through an Intranet or
the Internet.
85. The apparatus of claim 75, wherein said production line and
decision making unit further comprises a plurality of business
rules.
86. The apparatus of claim 85, further comprising: analyzing a
result from said production line and decision making layer; and
reporting said analyzed result to said business decision making
layer.
87. The apparatus of claim 86, further comprising: receiving a
report containing analyzed result from said reporting process; and
automatically adjusting said business rules based on said
report.
88. A computer program embodied on computer readable medium with
instructions for controlling manufacturing, comprising: providing a
work flow from a business decision making layer to a production
line and decision making layer; and implementing a real-time
integration of said work flow.
89. The computer program of claim 88, further comprising:
determining business objectives at said business decision making
layer; performing said business objectives at said production line
and decision making layer; and carrying out said real-time
integration of said business decision making layer and said
production line and decision making layer by a collaborative
infrastructure.
90. The computer program of claim 89, further comprising: analyzing
a result from said production line and decision making layer; and
reporting said analyzed result to said business decision making
layer.
91. The computer program of claim 90, further comprising: receiving
a report containing analyzed result from said reporting process;
and adjusting said business objectives according to said
report.
92. The computer program of claim 91, further comprises integrating
said business decision making layer, production line and decision
making layer by said collaborative infrastructure through an
Intranet or the Internet.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 USC 119(e) to U.S.
provisional application serial No. 60/354,151, filed Feb. 6,
2002.
BACKGROUND OF THE INVENTION FIELD OF THE INVENTION
[0002] The present invention relates to Manufacturing Executive
Systems (MES). Particularly, the present invention relates to
Collaborative Manufacturing Executive Systems (CMES), which can be
defined as "collaborative manufacturing management
infrastructure."
DISCUSSION OF THE BACKGROUND
[0003] U.S. Pat. No. 6,470,227 (hereinafter 227 patent) discloses a
method for automating a manufacturing process including configuring
application objects embodied in a computer program. The inventors
recognized that the '227 patent does not provide any solution to
synchronize key supply chain modules (ERP, PLM, and APS etc.) and
production support systems (LIMS and FCS etc.) with events and
activities that occur on the factory floor, and that the '227
patent fails to disclose the ability to synchronize and coordinate
activities across multiple manufacturing sites.
SUMMARY OF THE INVENTION
[0004] A MES system means a software application that provides a
real-time view of manufacturing operations. These systems perform
the task of integrating corporate or plant business systems
information with shop floor data systems. The resulting values
provided by MES are data that can be automatically converted into
"actionable information" that can then be used for improved
decision making at all levels of the manufacturing enterprise. For
example, MES provides values derived from data obtained from
operations, manufacturing management, engineering, IT, planning,
materials management, etc.
[0005] A CMES system is about information, and how to get your data
from the plant floor, from production control, from inventory and
quality control, from purchasing, from engineering, from marketing
and sales, and turn that data into information that can be used by
managers at all levels of the enterprise to make mission-critical
decisions. To summarize. CMES is about communication, and how to
optimize the bi-directional flow of information to and from the
operating units in a manufacturing enterprise.
[0006] Therefore, it is the object of the present invention to
provide a collaborative manufacturing execution system (CMES) and
method. The CMES is designed in the form of a collaborative
software system infrastructure that interfaces with business
systems, the supply chain modules, such as Enterprise Resource
Planning (ERP) and Advanced Planning & Scheduling (APS),
production support systems, such as Laboratory Information
Management Systems (LIMS), Finite Capacity Scheduling (FCS)
Systems, and plant floor systems, such as Supervisory Control and
Data Acquisition Systems (SCADA), Distributed Control Systems
(DCS), and Programmable Logic Controllers (PLC).
[0007] This collaborative infrastructure, which is a collaborative
manufacturing execution system (CMES), supports and enables high
velocity e-business initiatives for manufactures in many different
market segments, e.g., automotive, consumer products, food and
beverage, pharmaceutical, electronic. Furthermore, this
collaborative infrastructure is able to coordinate and synchronize
business systems, production support systems and plant floor
systems across multiple manufacturing sites through an enterprise
intranet or the Internet.
[0008] FIG. 1 illustrates a commercial embodiment of a CMES
application of this invention, named Interwave Coordinator.
Interwave Coordinator is used to reduce time and expense spent in
understanding process and product flow in manufacturing
environments and provide real-time integration among them.
Interwave Coordinator is also utilized by enterprises to make
business objectives decision and determine the requirements for
manufacturing and designing products using quantitative information
regarding defects, downtime, rework requirements, and resulting
quality.
[0009] Furthermore, FIG. 1 illustrates how Interwave Coordinator
provides all of the coordination and synchronization with the
external entities (ERP, PLM, PDM, etc.) at a business level that
are impacted by the events and activities that occur on the plant
floor. This coordination and synchronization is provided via
business process modeling modules, such as the Business Process
Event Coordinator, along with a supporting communication connector
module, such as the XML Business Connector. In addition, Interwave
Coordinator provides the internal coordination and synchronization
to support typical plant floor production management functions,
such as Work Order Management, WIP Management, Inventory
Management, etc. This coordination and synchronization is provided
via another supporting communication connector module, such as the
OPC Shop Floor Connector. These two types of coordination and
synchronization provide a completely synchronized information
system to support the tremendous information demands of a CMES
model. As a result, there will be no overlapping and disconnected
segments in various levels of manufacturing work flow and among
remote manufacturing sites. The CMES of this invention includes a
suite of universal application templates, utilities and
pre-configured solutions that leverage Microsoft technology such as
Visual Basic, COM+ and SQL Server.
[0010] The universal application templates are configurable,
scalable, and maintainable application templates that can be
deployed in a stand-alone mode, or can be assembled into a fully
functional solution, that is a custom application, based on
specific business needs. Specifically, the universal application
templates are configurable because they are configurable through a
user friendly Graphical User Interface panel or panels to designate
a particular business specification by way of selecting parameters
in various entries. Further, the universal application templates
are scalable because each and every one of them can function
independently or in combination with other application template or
templates. Enterprises can design a custom application to fit
special business needs in manufacturing simply by selecting at
least one appropriate application template. This is the reason why
the present invention is capable of operating in a stand-alone mode
or being packaged into a fully functional business solution.
Finally, the universal application templates are maintainable
because it is easy to maintain these templates. Due to the
independence nature of each application template, it is less
costly, less time-consuming and easy-access to fulfill maintenance
needs, such as debugging and updating.
[0011] These application templates provide capabilities, such as
Work Order Management, WIP Management, Inventory Management,
Material Management, Tool Management, Quality Management, Quality
Data Collection, Defect Tracking, Downtime Tracking, Specification
Management, Receiving and Inspection, Shipping, Return Merchandise
Authorization, Engineering Change Order, Work Instructions and
Electronic Notebook.
[0012] Pre-configured solutions are also provided to address
specific vertical industries. These market available pre-configured
solutions utilize and extend the basic functionality in the
universal application templates to address the unique information
requirements of a particular manufacturing industry. These
solutions include Roll Tracker, which provides basic roll tracking
functions for manufacturers in the roll goods industry; Discrete
Assembler, which provides discrete assembling and tracking
functions for customers in the discrete manufacturing sector;
Pharma Manager, which provides specification management, batch
execution, on-line data collection, and genealogy for preweigh and
dispensing operations under FDA control; MedDevice Tracker, which
provides basic tracking, genealogy, quality management, and data
collection functions for manufacturers in the medical device
industry under FDA control; and Food Processor, which provides
basic tracking, genealogy and quality control of inventory and
product in the regulated food industry.
[0013] This new CMES application, Intewave Coordinator, also
includes a plurality of support applications, such as Shop
Scheduler and Lab Manager, providing basic functionality for
scheduling and laboratory management. Utility modules are also
included in the invention to address common functions such as label
printing, event messaging, data archiving, auto tracking, auto data
collection and work traveler printing. Furthermore, the invention
provides modules to interface to the business systems and shop
floor systems, such as the Extensible Markup Language (XML) and Ole
for Process Control (OPC) technologies to provide open and
standardized interfaces.
[0014] The Interwave Coordinator embodiment also provides a
visualization module that provides standard or ad-hoc reporting
capability through Microsoft Excel. This module provides visibility
into the performance of the manufacturing enterprise by analyzing
and reporting Key Performance Indicators (KPIs) and Overall
Equipment Efficiency (OEE), such as performance to schedule,
downtime, scrap, utilization and efficiency. Because of the
visibility of manufacturing performance, enterprises are able to
adjust and make better business objectives and, therefore, increase
overall enterprise achievements based on the received analysis and
report. Moreover, some of the business rules are automatically
adjusted based on the visibility feedback.
[0015] There are many advantages of this inventive CMES
application. First, the invention decreases time-to-deployment,
which accelerates payback and Return On Investment (ROI). Secondly,
this invention enables easy, rapid, and cost effective pilots or
proof-of-concept. This CMES application is cost-effective and
provides affordable industry-based solutions that reduce total cost
of ownership (TCO) and increase return on investment. Furthermore,
this CMES application reduces project risk and utilizes modular
approach that accommodates phased implementations and scalable
point solutions. Based on extensive domain expertise, this CMES
application contains proven knowledge of market best practices,
operational and business processes and enhances lean manufacturing
initiatives.
[0016] In one aspect, the invention provides a system and method
for providing a work flow from a business decision making layer to
a production line and decision making layer; and implementing a
real-time integration of said work flow. In additional aspects, the
invention provides systems and methods for determining business
objectives at said business decision making layer; performing said
business objectives at said production line and decision making
layer; and carrying out said real-time integration of said business
decision making layer, said production line and decision making
layer by a collaborative infrastructure, analyzing a result from
said production line and decision making layer; and reporting said
analyzed result to said business decision making layer; receiving a
report containing analyzed result from said reporting process; and
adjusting said business objectives according to said report;
wherein said report comprises a plurality of formats, including
Spreadsheet and GANTT Chart; wherein said collaborative
infrastructure further comprises a first coordinator connector
providing interface for said collaborative infrastructure and said
business decision making layer; wherein said first coordinator
connector is a web-based open technology for electronic data
interchange; wherein said first coordinator connector is the
Extensible Markup language (XML) Business Connector; wherein said
collaborative infrastructure further comprises a second coordinator
connector providing interface for said collaborative infrastructure
and said production line and decision making layer; wherein said
second coordinator connector is an Application Programming
Interface (API); wherein said second coordinator is the Ole Process
Control (OPC) Shop Floor Connector; integrating said business
decision making layer, production line and decision making layer by
said collaborative infrastructure through an Intranet or the
Internet; wherein said production line and decision making layer
further comprises a plurality of business rules; analyzing a result
from said production line and decision making layer; reporting said
analyzed result to said business decision making layer; receiving a
report containing analyzed result from said reporting process; and
automatically adjusting said business rules based on said report;
wherein said collaborative infrastructure further comprises a
plurality of configurable module templates; wherein said
collaborative infrastructure further comprises a graphical user
interface capable of configuring and modifying said plurality of
business rules; wherein said configurable application templates are
capable of synchronizing and optimizing execution activities at
said production line and decision layer; wherein said
infrastructure is a Manufacturing Executive System (MES); wherein
said infrastructure is a Collaborative Manufacturing Executive
System (CMES); wherein said collaborative infrastructure further
comprises a plurality of scalable application templates; wherein
said collaborative infrastructure comprises at least one custom
application constructed with at least one scalable application
template; wherein said collaborative infrastructure further
comprises a plurality of maintainable application templates;
wherein said maintainable application templates increase the
updating and debugging abilities of said collaborative
infrastructure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing and other objects of the invention are
described with reference to the following figures in which like
elements are referred to by the same or similar reference
numerals.
[0018] FIG. 1 is a diagram demonstrating how Interwave Coordinator
supports a CMES model.
[0019] FIG. 2 is a diagram showing the Internal Supply Chain
Integration of one of the preferred embodiment of the present
invention.
[0020] FIG. 3 is an illustration of a preferred embodiment of the
system architecture of the present invention.
[0021] FIG. 4 is an illustration of an embodiment of the
manufacturing information system architecture of the present
invention shown in FIG. 1.
[0022] FIG. 5 is an illustration of a collaborative e-manufacturing
solution model of the present invention.
[0023] FIG. 6 is an illustration of a method of use of the
invention to achieve better planning, better processing and better
sequencing.
[0024] FIG. 7 is a flow chart of a process of module installation
of the invention.
[0025] FIG. 8 is continuation of the process shown in FIG. 7.
[0026] FIG. 9 is an illustration of a product overview of the
present invention, depicting the relationship among business
decisions, manufacturing decisions, and production line and process
decisions.
[0027] FIG. 10 is an illustration of a typical plant operations
model which is supported by embodiments of the invention.
[0028] FIGS. 11 and 12 are illustrations of the GUI for the Work
Order Management application template.
[0029] FIG. 13 is an illustration of the GUI for the WIP,
Management application template.
[0030] FIG. 14 is an illustration of the GUI for the Business
Process Modeler module.
[0031] FIGS. 15-21 are displays of reports generated by the Digital
Dashboard/Visualization module.
[0032] FIG. 22 is an illustration of the GUIs for the Material
Management application template.
[0033] FIG. 23 is an illustration of the GUIs for the ECO
application template.
[0034] FIG. 24 is an illustration of the GUI for the Quality Data
Collection application template.
[0035] FIG. 25 is an illustration of the GUI for the Work
Instructions application template.
[0036] FIG. 26 is an illustration of the GUI for the Defect
application template.
[0037] FIG. 27 is an illustration of the GUI for the Downtime
Tracker application template.
[0038] FIG. 28 is an illustration of the GUI for the RMA
application template.
[0039] FIG. 29 is an illustration of the GUI to support sample
management within the Lab Manager support application.
[0040] FIG. 30 is an illustration of the GUI to support test data
collection within the Lab Manager support application.
[0041] FIG. 31 is an illustration of the GUI to support test
template maintenance within the Lab Manager support
application.
[0042] FIG. 32 is an illustration of the GUI to support
instrumentation management within the Lab Manager support
application.
[0043] FIG. 33 is an illustration of the Dynamic Environments
framework under which the Shop Scheduler support application is
utilized.
[0044] FIG. 34 is an illustration of MS Project that enables
adjustment of result schedule under the Shop Scheduler application
template.
[0045] FIG. 35 is an illustration of a GUI for the Shop Scheduler
support application.
[0046] FIG. 36 is a diagram showing the assembly lines parameters
and machine groups parameters for scheduling.
[0047] FIG. 37 is an illustration of a Scheduling Engine of Shop
Scheduler support application.
[0048] FIG. 38 is an illustration of a Schedule GANTT Chart
report.
[0049] FIG. 39 is an illustration of a GANTT report for a selected
machine.
[0050] FIG. 40 is an illustration of a GANTT report for a selected
work order.
[0051] FIG. 41 is an illustration of an ad-hoc Query Generator.
[0052] FIG. 42 is an illustration of a Web View of a Dispatch
Report.
[0053] FIG. 43 is an illustration of the GUIs that support
formulation functions within the Food Processor industry
application.
[0054] FIG. 44 is an illustration of the GUIs that support
production and packaging functions within the Food Processor
industry application.
[0055] FIG. 45 is an illustration of the GUIs that support
receiving and inventory control functions within the Inventory
Management application template.
[0056] FIG. 46 is an illustration of the GUI for the Shipping
application template.
[0057] FIG. 47 is an illustration of the GUIs that support QA lab
product evaluation functions within the Food Processor industry
application.
[0058] FIG. 48 is an illustration of the GUIs that support QA lab
product test functions within the Food Processor industry
application.
[0059] FIG. 49 is an illustration of the GUIs that support QA lab
environmental test functions within the Food Processor industry
application.
[0060] FIG. 50 is an illustration of the GUIs for the Quality
Management application template.
[0061] FIG. 51 is an illustration of the GUIs that support QA
product retention functions within the Food Processor industry
application.
[0062] FIG. 52 is an illustration of the GUIs that support QA
production checklist functions within the Food Processor industry
application.
[0063] FIG. 53 is an illustration of the GUIs that support HACCP
enforcement functions within the Food Processor industry
application.
[0064] FIG. 54 is an illustration of the GUI that supports
Electronic Notebook application template.
[0065] FIG. 55 is an illustration of the GUIs that support Tool
Management application template.
[0066] FIG. 56 is an illustration of the GUIs that support
Specification Management application template.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
[0067] FIG. 1 illustrates all of the coordination and
synchronization provided by this invention with respect to the
decision support systems (ERP, APS, CRM, etc.) and production
control systems (i.e. automation/plant floor production systems)
employed by a typical manufacturing enterprise. The coordination
and synchronization provided by this invention is key in supporting
a collaborative execution model.
[0068] Collaborative Manufacturing Executive Systems (CMES) are the
key to extending the principles of e-business throughout the
enterprise. The extended enterprise is the core business, and the
web of suppliers, partners, alliances, and customers in which the
business participates. At the heart of this extended enterprise is
the value chain from raw material to user. The business will have
to optimize this value chain in order to be competitive in the
future. An example of optimization is using the least raw material
and going through most efficient process to produce the best
possible products. Hence, open, maintainable, and scalable
manufacturing solutions are required to be able to optimize the
value chain in the extended enterprise. Collaborative MES pertains
to information and how to get data from the plant floor, production
control, inventory and quality control, purchasing, engineering,
marketing, and sales, and turning that data into information that
can be used by management at all levels in the extended enterprise
to make mission-critical decision.
[0069] Further, CMES deals with communication, and how to optimize
the bi-directional flow of that information to and from the
operating units of an enterprise. Collaborative MES opens that
bi-directional flow of information to the entire strategic value
chain of the extended enterprise. Because CMES enables most of the
value-add in of an enterprise derived from the factory floor, CMES
becomes the vital link that makes enterprise-wide integration
possible. As shown in FIG. 9, in an extended enterprise, real-time
integration with the business decision making sector and the
production line and process decision sector is made possible
utilizing a CMES application. Thus, CMES greatly improves the
return on applied assets for any given enterprise by increasing
on-time delivery, shortening inventory turn time, increasing gross
margin and, most of all, improves the cash flow performance. A CMES
application synchronizes key supply chain modules (ERP, PLM, PDM,
APS, CRM, SCM) in a manufacturing enterprise with events and
activities that occur on the factory floor.
[0070] FIG. 2 shows an overview of an example of internal supply
chain integration using a CMES system of the invention including
steps 1-8.
[0071] In step 1, an order is entered via the Web and then
downloaded into the MES.
[0072] In step 2, once the download is finished, BOM (Bill of
Materials) and order specifications are transmitted to the
e-Manufacturing System. Step 2 also includes transmitting order
information to devices performing step 3 and step 4.
[0073] In step 3, the order is sent to FCS for real time scheduling
and optimal sequencing, and the result is then feed back to step
2.
[0074] In step 4, an automatic process is set up which performs the
manufacturing and quality testing and transmits information to the
structure performing step 5.
[0075] In step 5, the system generates total product genealogy and
automatic device history record, and then sends the generated
information to step 6.
[0076] In step 6, shipping labels are generated when the order is
completed.
[0077] Step 7 is responsible for ERP updates and invoicing.
[0078] In step 8, advanced customer notification of shipment is
generated along with shipping instructions. As a result, product is
shipped via overnight from the plant.
[0079] FIG. 3 shows a preferred embodiment of a system architecture
of the CMES disclosed by the present invention. The business server
10 provides the decision support functions for the manufacturing
enterprise, the Interwave Coordinator Database Server 20 provides
the RDBMS for the Interwave Coordinator suite of modules, the
Interwave Coordinator Application Server 30 serves up the Interwave
Coordinator application templates and support applications, the
Interwave Coordinator Production Server 40 provides the business
process modeling and event coordination. The Interwave Coordinator
Web Sever 50 provides web services for report printing, the Report
Printer 60 is used for printing system reports and labels, the
Interwave Coordinator Client Work Station 70 provides the GUI
interface for the system user. All system components are connected
via an local area and/or wide area network.
[0080] FIG. 4 illustrates a manufacturing information system
architecture in which there are deployed a plurality of information
packages, and is based upon the system architecture illustrated by
FIG. 3. More specifically, FIG. 4 illustrates the flow of
information between the three tiers of systems that support a
manufacturing enterprise, along with the material flow that is
typical for a manufacturing entity.
[0081] At the business level, the business system 110 is equipped
with a business system database 220. Various pieces of information
are passed between the business system 110 and the production
management system (CMES). The business system 110 requires key
information from the production management system (CMES) 120 in
order to fulfill the informational needs (i.e. raw material
consumption, production order status, finished good quantities) of
the decision support systems that execute within the business
system 110. Furthermore, the production management system requires
information from the business system 110 to execute manufacturing
orders on the plant floor. This invention provides a XML business
system connector module 140 to fulfill the interface needs between
the business system 110 and the production management system (CMES)
120.
[0082] At the production management system (CMES) level, a
production management (CMES) database 230 is employed to provide a
common data repository for all plant execution functions. Various
pieces of information are passed between the production management
system (CMES) 120 and the SCADA & Process Control System 130.
The SCADA & Process Control System 130 requires information,
such as machine setup parameters, from the production management
system (CMES) 120 to manufacturer the product to the proper
specification. Furthermore, the production management system (CMES)
120 requires information, such as process alarms and production
events, from the SCADA & Process Control System 130 in an
effort to manage the production process. This invention provides an
OPC shop floor connector module 150 to fulfill the interface needs
between the production management system (CMES) 120 and the SCADA
& Process Control System 130.
[0083] The basic manufacturing work flow demonstrated in FIG. 4 is
that raw materials 170 are received from a plurality of raw
material vendors 160. These raw materials 170 are processed through
a sequence of production work centers 180/190 until a semi-finished
or finished product 100 is produced. Upon completing the
manufacturing process, the finished product 100 is shipped to the
customer 210. At each production work center 180/190, vertical
databases and dedicated process control systems are employed to
control and manage the manufacturing process.
[0084] FIG. 5 shows an embodiment of a system of deployed modules
of the invention. At the core of the Collaborative e-Manufacturing
Solution Model is the Business Process Event Coordinator. This
module synchronizes and coordinates activities at the supply
chain/business system level, at the automation/plant floor level,
and with the production support systems such as Laboratory
Information Management Systems (LIMS), Computerized Maintenance
Management Systems (CMMS), Finite Capacity Scheduling Systems
(FCS), Time and Attendance Systems, etc. An XML Business System
Connector and Ole Process Control (OPC) Shop Floor Connector are
leveraged to provide standardized interfaces to the respective
systems, wherein the industry standard API called OPC (OLE for
Process Control) is used to communicate with hardware PLC devices,
OPC can be directly accessed using the simple Data Socket component
accesses, and the Extensible Markup Language (XML) is a new format
designed to bring structured information to the Web. It is a
Web-based language for electronic data interchange. XML is an open
technology standard of the World Wide Web Consortium (W3C), which
is the standards group responsible for maintaining and advancing
HTML and other Web-related standards.
[0085] Application templates are leveraged to build industry
specific solutions, or custom solutions that provide typical
production management functions such as work order management, WIP
management, inventory management, material management, tool
management, quality management, etc. These templates operate
together in a seamless fashion to provide a cohesive and integrated
solution. Some of the benefits realized as a result of the
execution of this model are waste reduction, higher process
excellence, greater throughput, accurate capability, accurate
inventory levels. This feature can be better illustrated by FIG.
6.
[0086] FIG. 6 illustrates the basic sequence of operations that
occur with respect to manufacturing a product. These sequences are
Plan 300, Schedule 301, Execute 302 and Analyze/Report 303. A
business master plan of forecast orders is produced at the Plan 300
stage and then communicated to the Schedule 301 stage. At the
Schedule 301 stage, a plant schedule is produced either manually or
by a FCS system. Many variables need to be considered within this
stage to produce a schedule that utilizes machines, materials, and
manpower in an efficient manner.
[0087] Subsequently, the plant schedule is executed at the Execute
302 stage. The Execute 302 stage facilitates machine setup,
processing and tear down by product code. Upon completion of the
Execute 302 stage, the execution process is analyzed to surface
issues that cause waste to be generated, excessive cycle times,
etc. This feedback ultimately triggers an effect that produces
better sequencing at the Schedule 301 stage, and better planning at
the Plan 300 stage. The net effect that is achieved by this
invention is that through coordination and synchronization,
continuous improvement is realized at all stages of the
process.
[0088] FIGS. 7 and 8 illustrate the Coordinator Module installation
of Interwave Coordinator business process modeling components,
application templates, industry applications, support applications,
connectors and utilities. In the beginning, as shown in FIG. 7, at
step 410, Rational Database Management System (RDBMS) on the
Coordinator Database Server is installed. Then, the Web Services on
the Coordinator Web Server module is installed at step 420. At step
430, the Coordinator Business Process Modeler on the Coordinator
Production Server is installed. Thereafter, the Coordinator
Business Process Event Coordinator is installed on the Coordinator
Production Server (authoring and runtime components) at step 440.
Subsequently, desired Coordinator Application Templates are
installed on the Coordinator Application Server at step 450. There
are many available application templates that can be installed at
this step to suit each individual business special needs. Those
available application templates include Work Order Management, WIP
Management, Inventory Management, Material Management, Tool
Management, Quality Management, Quality Data Collection, Defect
Tracker, Downtime Tracker, Specification Management, Receiving
& Inspection module, Shipping, Return Merchandise Authorization
(RMA), Engineering Change Order (ECO), Material Review Board (MRB),
Work Instructions, and Electronic Notebook.
[0089] After installation of desired application templates at step
450, desired Coordinator Industry Applications are installed on the
Coordinator Application Server at step 460, and desired Coordinator
Support Applications are installed on the Coordinator Application
Server at step 470. The available Industry Applications include
Roll Tracker, Discrete assembler, Food Processor, Pharma Manager
module, and Med Device Tracker module. The available Coordinator
Support Applications for installation are Lab Manager, and Shop
Scheduler.
[0090] Referring to FIG. 8, after installation of all the desired
Application Templates, Industry Applications, Support Applications,
desired Coordinator Connectors are installed on the Coordinator
Application Server at step 480. Those available Coordinator
Connectors are XML Business Connector and OPC Shop Floor Connector.
The installation process continues to step 490. At step 490,
desired Coordinator Utilities are installed on the Coordinator
Application Server. The available Coordinator Uitilites include
Auto Tracker, Auto Collector, Event Messenger, Work Traveler, Label
Manager, and Data Archiver. Finally, desired Coordinator
Visualization Tools are installed on the Coordinator Application
Server at step 500, such as Digital Dashboard. The present
invention is better described with further detailed information
regarding the configurable modules. The modules have classified as
Business Process Modeling, Application Template, Industry
Application, Support Application, Connector, Visualization or
Utility modules.
[0091] Business Process Modeling
[0092] The Business Process Modeling modules address event
transaction modeling and execution, along with static process
modeling. It includes two modules, the business process event
coordinator and business process modeler.
[0093] Business Process Event Coordinator
[0094] The Business Process Event Coordinator (BPEC) provides the
end users with the ability to graphically model and configure the
manufacturing business rules required by a particular manufacturing
entity. The business rules essentially describe the interaction and
synchronization required between supply chain modules (ERP, APS,
etc.), production support systems (LIMS, FCS, etc.), other
manufacturing plants, and the factory floor. For example, how to
record the machine downtime and dispose defect product. Once
business rule models have been established, a runtime component of
(BPEC) enforces or executes the models and rules through the
runtime component/module.
[0095] Examples of business rules that would be enforced or
executed by BPEC are: when a machine downtime event is detected,
send a message to the Computerized Maintenance Management System to
create an emergency work order to repair the machine and send a
message to the Finite Capacity Scheduling System to re-schedule the
others currently assigned to the machine. When a production test
sample is created, send a message to the Laboratory Information
management System to create a new lab sample. When a new product is
being introduced to manufacturing (even if received from external
system), retrieve all necessary product specifications (i.e.,
routes, bills of materials, etc.) from the Product Data Management
System. When a work order has been put on hold by Quality, send a
message to the ERP to update the status of the order to "Hold."
[0096] Business Process Modeler
[0097] The Business Process Modeler (BPM) provides the ability to
model static manufacturing entities such as: departments, work
centers, routes, materials, tooling, machines, locations, users,
security profiles, user certifications, data collection templates,
recipes, and work instructions.
[0098] Application Templates
[0099] In order to further support the collaborative scheme, a
suite of highly configurable application templates have been
engineered to provide basic production management functions such as
work order management, WIP management, inventory management,
material management, etc. The application templates are designed to
be used as stand-alone components, or can be either assembled or
configured or both into a cohesive solution to provide a basic
foundation layer for a Collaborative Manufacturing Execution System
(CMES). Once configured, these application templates provide a
highly integrated factory floor information system that is
essential to operating a highly efficient manufacturing operation.
The application templates leverage ActiveX OCX technology to
promote rapid solution configuration and deployment.
[0100] The Intewave Coordinator application templates provide the
essential production management functions of the Execution layer
illustrated in FIG. 9. In particular, the templates provide
production dispatching, schedule execution, WIP and resource
tracking, document control, data collection, resource management,
quality management and process management. These functions are
essential with respect to supporting a truly collaborative
manufacturing model.
[0101] FIG. 10 illustrates a typical plant operations model. The
model breaks down into Schedule and Execution phases. Within each
phase, multiple steps are required to be executed in a sequential
manner. The application templates have been engineered to
specifically address the functionality illustrated in each of these
steps. The integrated manner in which the templates have been
designed promote the coordination illustrated in the FIG. 10.
[0102] Work Order Management Application Template
[0103] FIGS. 11 and 12 demonstrate the Work Order Management
application template Graphical User Interface (GUI), The Work Order
Management application template supports Work Order Creation,
Machine Assignment, Picklist Assignment, Work Order Update, Work
Order Release, and Work Order Deletion. In addition, the Work Order
Management application template provides visibility with respect to
the status of orders, quantity produced, required bill of material,
required process routing.
[0104] Work Order Creation supports automatic creation of work
orders based on the latest schedule received from the ERP/APS. It
includes Bill of Materials (BOM) and routing, and also provides the
ability to manually create work orders to support WAN/LAN failure,
or R&D production scenarios.
[0105] Machine Assignment provides the ability to manually
assign/schedule machines to work orders at specific work
centers.
[0106] Picklist Assignment provides the ability to create material
picklists for production work orders. It provides the ability to
reserve inventory items against specific BOM items within a
production work order.
[0107] Work Order Update provides the ability to modify the
quantity, priority, BOM, or routing assignment associated with
existing work orders, as shown in FIG. 12. It also provides the
ability to assign special instructions to work orders to support
custom orders. Work Order Release provides the ability to dispatch
work orders for production execution. It also provides the ability
to suspend/hold in-process work orders. Work Order Deletion
supports the automatic deletion of work orders based on the revised
work order schedule received from ERP/APS. It also provides the
ability to manually delete existing work orders.
[0108] WIP Management Application Template
[0109] FIG. 13 demonstrates the WIP Management application template
Graphical User Interface (GUI). The WIP Management application
template supports Lot Create, Lot Start/Complete, and
Containerization. In addition, the WIP Management application
template provides visibility with respect to WIP items currently
queued or in-process at a particular work center.
[0110] FIG. 14 shows the Resource Modeler functions of the
ProcessStudio under Work In Progress (WIP) manager application
template. The Resource Modeler models and maintains static
manufacturing resources, including departments, work centers,
routes, and materials. It also models and maintains resources at
the plant floor and the end user parts, such as tooling, machines,
locations, user security profiles, user certifications, and data
collection templates and recipes, and work instruction.
[0111] FIGS. 15 through 21 show the various reports generated by
the Report Manager under Work In Progress (WIP) manager application
template. This Report Manager can be utilized for various reports,
including WIP Status Report, as shown in FIG. 15, Material
Genealogy Report, as shown in FIG. 16, Route Genealogy Report, as
shown in FIG. 17, Inventory Summary Report, as shown in FIG. 18,
Work Order Status Report, as shown in FIG. 19, Defect Data Report,
as shown in FIG. 20, and Downtime Report, as shown in FIG. 21. As
discussed in previous FIGS. 9 and 10, a better work instruction
will be generated based on previous performance analysis and
reports when the Schedule module operates to generate instructions
next time. The business decision making process is especially
depending on the analysis and reports feedback to amend its master
plan in the future.
[0112] If required, the Lot Create automatically creates WIP lots
when production is reported at a particular work center. Lot
Start/Complete provides the ability to Start and/or Complete a WIP
entity at a given work center or a specific work operation. It also
supports the ability to disposition WIP to scrap, rework,
inventory, or next work center on route. The Lot Start/Complete
further enforces data collection, material issue, and disposition
requirements established for each work order. Containerization is
used to provide the ability to assign WIP or Inventory items to a
container in order to support bulk transaction processing.
[0113] Inventory Management Application Template
[0114] FIG. 45 demonstrates the Inventory Management application
template Graphical User Interface (GUI). The Inventory Management
application template supports Receiving and Inspection, Picklist
Delivery, Lot Disposition/Move, Lot Split, Lot Merge, Material
Re-grade, Quantity Adjustment, Tiered Storage, Containerization. In
addition, the Inventory Management application template provides
visibility to all items in inventory.
[0115] Receiving and Inspection provides the ability to receive and
inspect incoming raw materials. Receiving and Inspection supports
manual receipt or receipt against purchase orders. Picklist
Delivery provides the ability to view picklists for a particular
work order/work center and confirm delivery. Lot Disposition/Move
provides the ability disposition/move inventory entities to
different locations within the system. Lot Split provides the
ability to split an inventory entity into multiple entities. The
Lot Split further supports the ability to re-grade the split
entity.
[0116] Lot Merge provides the ability to merge multiple inventory
entities into a single entity. Material Re-grade provides the
ability to re-grade an existing inventory entity to support
material re-classification. Quantity Adjustment provides the
ability to modify the quantity of an inventory entity to support
cycle counting. Tiered Storage provides the ability to create a
hierarchical inventory storage location scheme to support
parent/child storage relationships. Containerization provides the
ability to assign inventory items to a container to support bulk
transaction processing.
[0117] Material Management Application Template
[0118] FIG. 22 demonstrates the Material Management application
template Graphical User Interface (GUI). The Material Management
application template supports Genealogy, BOM Enforcement, BOM
Substitution, Material Staging, Automatic Consumption and Manual
Consumption.
[0119] Genealogy provides full component genealogy and tracking by
work center for each work order.
[0120] BOM Enforcement displays BOM requirements for a designated
work center and work order. BOM Enforcement also provides
validation to ensure that proper components are consumed to produce
the finished good.
[0121] BOM Substitution provides the ability to define substitutes
for standard items in the BOM. BOM Substitution also enforces
substitute definition within the BOM Enforcement function.
[0122] Material Staging provides the ability to stage material at a
given work center for automatic consumption.
[0123] Automatic Consumption provides the ability to automatically
consume staged materials based upon the BOM established for a
particular work order.
[0124] Manual Consumption provides the ability to manual consume
material against BOM items established for a particular work
order.
[0125] Tool Management Application Template
[0126] FIG. 55 demonstrates the Tool Management application
template Graphical User Interface (GUI). The Tool Management
application template supports Genealogy, Tool Enforcement, Tool
Substitution, and Tool Maintenance.
[0127] Genealogy provides full tool genealogy and tracking by work
center for each work order.
[0128] Tool Enforcement displays tooling requirements for a
designated work center and work order. Tool Enforcement also
provides validation to ensure that proper tools are utilized to
produce the finished good.
[0129] Tool Substitution provides the ability to define substitutes
for standard tooling. Tool Substitution enforces substitute
definition within the Tool Enforcement function.
[0130] Tool Maintenance provides the ability to add new tools to
the system, or modify the attributes of existing tools. Tool
Maintenance also provides full inventory management and tracking
capabilities.
[0131] Quality Management Application Template
[0132] FIG. 50 demonstrates the Quality Management application
template Graphical User Interface (GUI). The Quality Management
application template supports Quality Hold, Hold Resolution,
Quality Quarantine, and Quarantine Resolution.
[0133] Quality Hold provides the ability to issue one or more
quality holds against a single WIP or Inventory entity and further
implements quality holds by restricting transactional access to
held entities. Hold Resolution provides the ability to resolve and
release quality holds against a single WIP or Inventory entity.
However, it requires selection of a resolution code from a
configurable list.
[0134] Quality Quarantine provides the ability to issue one or more
quarantines against a single WIP or Inventory entity, and further
implements quarantines by restricting the ability to release a
finished good to inventory. Quarantine Resolution provides the
ability to resolve and release quarantine holds against a single
WIP or Inventory entity. It also requires selection of resolution
code from a configurable list.
[0135] FIG. 23 demonstrates the GUIs that support Process Deviation
function under Quality Manager application template. The Process
Deviation module requests quality management and submits change
requests for new or changed materials, products, procedures,
processes, or methods to management. The Process Deviation module,
once it has received instruction from the quality management, also
initiates and manages the authorization process.
[0136] Quality Data Collection Application Template
[0137] FIG. 24 demonstrates the Quality Data Collection application
template Graphical User Interface (GUI). The Quality Data
Collection application template under Quality Manager implements
data collection requirements defined for a particular work center,
operation, and material. FIG. 24 shows the GUI access window of the
Quality Data Collection Module user access window. This application
template provides the ability to pre-populate data collection
templates from OPC or XML source. Quality Data Collection
application template also performs limits checks and applies
quality holds when out-of-limits conditions are experienced.
Furthermore, this application template allows data to be applied
against a single entity (e.g., WIP or Inventory) or multiple
entities (e.g., container with multiple WIP or Inventory
entities).
[0138] Work Instructions and Electronic Notebook Application
Template
[0139] FIG. 25 demonstrates the Work Instruction application
template Graphical User Interface (GUI). The Work Instruction
application template provides the ability to manually assign work
instructions to work orders and/or work centers and operations. The
Work Instruction Viewer provides a drop-down selection of work
instruction for user to pick a particular instruction to review.
Furthermore, it supports receipt of work instructions from ERP, and
a means to access and display documents contained within 3.sup.rd
party Enterprise Document Management System (EDMS) systems.
[0140] Electronic Notebook Application Template
[0141] FIG. 54 demonstrates the Electronic Notebook application
template Graphical User Interface (GUI). The Electronic Notebook
application template provides the ability to capture and display
log notes electronically. Particularly, data can be captured
against pre-configured categories such as machines issues, material
issues, productions issues, and shift changes, etc.
[0142] Material Review Board Application Template
[0143] The Material Review Board (MRB) application template under
Quality Manager supports the features of MRB Submission and MRB
Management. MRB Submission provides the ability to submit and
subject semi-finished or finished goods to an evaluation prior to
being processed or shipped to customers. The MRB Management
provides the ability to manage the evaluation, disposition, and
documentation processes associated with non-conforming or
discrepant materials.
[0144] Defect or Waste Tracker Application Template
[0145] FIG. 26 demonstrates the Defect Tracker application template
Graphical User Interface (GUI). The Defect Tracker application
template or the Waste Tracker application template supports the
defect tracker features of Defect Recording and Defect Resolution.
Defect Recording provides the ability to manually capture defects
against a WIP or Inventory entity. It supports automatic recording
of defects from automated test equipment while Defect Resolution
provides the ability to resolve defects against a single WIP or
Inventory entity. The resolution transaction requires selection of
resolution code from a configurable list, as shown in FIG. 26, a
two-tier window used as an access of Defect or Waste Tracker
application template.
[0146] Downtime Tracker Application Template
[0147] FIG. 27 demonstrates the Downtime Tracker application
template supports Downtime Recording and Downtime Resolution.
Downtime Recording provides the ability to manually capture
downtime events against an asset. It supports automatic recording
of downtime events from automated machinery or assets. Downtime
Resolution, on the other hand, provides the ability to resolve
downtime events against an asset, and requires selection of
resolution code from a configurable list.
[0148] Specification Management Application Template
[0149] FIG. 56 demonstrates the Specification Management
application template Graphical User Interface (GUI). The
Specification Management application template supports
Specification Definition, Specification Display and Parameter
Download. Specification Definition provides the ability to define
one or more specifications for a given material/item at a given
work center. Specification Display provides visibility to
specification parameters for a given work order at execution time.
Parameter Download provides the ability to download specification
data to an OPC server.
[0150] Shipping Application Template
[0151] FIG. 46 demonstrates the Shipping application template
Graphical User Interface (GUI). The Shipping application template
under Depot Manager supports the shipping features of Reservation,
Data Collection, and Order Shipment. Reservation provides the
ability to reserve product against a particular work order and/or
customer order for shipment. Data Collection is designed to capture
data against the shipped entities. Order Shipment is then utilized
to support the ability to ship one or more Inventory entities
against a customer order.
[0152] Return Merchandise Authorization Application Template
[0153] The Return Merchandise Authorization application template
supports Product Return, Product Repair, and Product Shipment.
Product Return receives a returned product into the system for
repair. It also provides the ability to document the symptoms and
problems of the returned product, then determining the disposition
of the product as either repair or scrap. Product Repair supports
the ability to initiate the repair process and document the repair
procedures via pre-configured repair codes. Product Repair can
recommend repair procedures based upon repair history. Finally,
Product shipment provides the ability to ship the repaired product
after all the symptom and repair procedures are well
documented.
[0154] FIG. 28 demonstrates the GUIs that support the Repair
function under the Return Merchandise Authorization application
template. The Repair handles product return, repair, and shipment.
It receives returned product to the system for repair and documents
symptoms, problems, and repair procedures via pre-configured repair
codes. The Repair is able to initiate the repair process and the
disposition of the product to repair or scrap. It also recommends
repair procedures based upon repair history and, afterwards, ships
out the repaired product.
[0155] Engineering Change Order Application Template
[0156] The Engineering Change Order (ECO) application template
supports the features of Engineering Change Requests (ECR) and ECO
Management. At first, ECR submits Engineering Change Requests that
may suggest or recommend the possible use of new or changed
materials, products, procedures, processes, or methods.
Subsequently, ECO provides the ability to initiate and manage the
authorization process centered around the use of new or changed
materials, products, procedures, processes, or methods within a
manufacturing organization.
[0157] Support Applications
[0158] The Interwave Coordinator CMES application includes support
applications to further support its collaborative infrastructure.
They are Lab Manager and Shop Scheduler.
[0159] Lab Manager Support Application
[0160] Lab Manager provides basic Laboratory Information Management
System (LIMS) functions to assist engineers and technicians with
managing lab data in a manufacturing environment. Lab Manager is a
highly configurable LIMS application that supports Sample
Management, Lab Test Data Collection, Lab Test Template Maintenance
and Lab Instrumentation Management.
[0161] The Sample Management function provides automatic (CSV file)
and manual sample logging. The manual logging manually logs in
samples via a configurable template, as shown in FIG. 29. The
configurable template offers multiple or single sample login
process and prints out sample ID labels. It also provides
visibility to samples and associated test and result data.
Furthermore, it provides comprehensive audit trail and enforces a
configurable electronic signature scheme, such as Performed By and
Verified By.
[0162] FIG. 30 shows the GUI that supports Lab Test Data Collection
activities. The Lab Test Data Collection function can be easily
performed manually or automatically, and displays result entry
schemes through a GUI window. A browser can also be activated to
allow easy review of the collected lab test data.
[0163] The Lab Test Data Collection function supports result entry
against a group of samples to reduce data entry and partial result
entry. It can also enforce automatic holds when specification
limits have been exceeded. Repetitive entry schemes are also
supported to enhance data entry capabilities. Lab Test Data
Collection allows displays of specification limits and supports
many types of results, such as textual, list select, or file.
[0164] The Lab Test Template Maintenance function supports the
ability to configure lab test templates on an item or item class
basis, as shown in FIG. 31. It supports template versioning and
enables modification of existing templates or browsing of previous
revisions. Lab Test Template Maintenance further tracks changes to
templates and enforces electronic signatures. Specification limits
can defined on a per parameter basis with auto hold capability.
[0165] FIG. 32 shows the access windows of the Lab Instrumentation
Management function within the Lab Manager support application. The
Lab Instrumentation Management function provides the ability to
easily define lab instruments and associated calibration schedules.
Lab Instrumentation Management supports two types of calibrations,
i.e., the "time" based calibration intervals and "use" based
calibration intervals, and defines one or more calibration tasks
for a particular instrument. Lab Instrumentation Management issues
warnings whenever an instrument requires calibration or service.
Finally, the Lab Instrumentation Management function records
calibration results that are configurable for each instrument type
and provides a comprehensive audit trail and electronic
signature.
[0166] Shop Scheduler Application Template
[0167] The Shop Scheduler support application is ideal for finite
capacity scheduling, which optimizes the efficiency of
manufacturing resources, in dynamic environments. The dynamic
environments, as shown in FIG. 33, are environments that focuses on
fulfilling established work priorities, such as due date, etc. The
application pro-actively schedules items in a changing environment,
rather than optimizing a stable environment. Shop Scheduler
supports the ability to rebuild a production schedule around
changing orders, priorities, inventory, or resource
availability.
[0168] The Shop Scheduler leverages the planning and scheduling
capability native to MS Project, which is shown in FIG. 34. MS
Project can be used to display, analyze, and manually adjust the
resulting schedule. For example, the calculated schedule is
displayed in MS Project, including dependencies and summarization
of tasks. The MS Project displays can be manually adjusted by using
the drag-n-drop features. Furthermore, the Shop Scheduler is
featured with an auto update function that automatically updates
Shop Scheduler with the changes made within MS Project.
[0169] The Shop Scheduler is aimed to provide Finite Capacity
Scheduling functions to assist manufacturers in coordinating
manufacturing activities on the shop floor and generating realistic
production sequences. Moreover, it enables the users to visualize
the effects of schedule changes and significantly improves accuracy
and timeliness of production schedule in dynamic production
environment.
[0170] Furthermore, the Shop Scheduler enables enterprises to
improve their ability to react to business changes rapidly. Shop
Scheduler provides the feature of real-time scheduling that quickly
updates schedules as changes occur on the factory floor. The
visualization feature enables accurate available-to-promise
delivery for customer service, and end users get to the visualize
impact of, for example, inserting a "hot" order on the schedule
before dispatching.
[0171] In FIG. 35, a flexible and easy way to use the Shop
Scheduler is demonstrated by two GUI panels. One panel shows an
intuitive user interface that does not require complex
synchronization, scripts or functions to create a Schedule
Calendar. The second panel shows user-defined prioritization rules
in scheduling a particular machine for a job. Besides machines and
assembly lines, tools and inventory can be addressed by Shop
Schedule. With respect to tool configuration, whether to utilize
the tools, and whether to assign a machine, or what assignment to
which machine need to be scheduled. With respect to inventory
configuration, whether to use inventory, and whether to delay start
based on inventory or even the availability dependency all need to
be scheduled. The scheduling granularity can be work orders,
batches, individual items, or mixed granularity.
[0172] FIG. 36 illustrates the scheduling parameters that are
addressed by the Shop Scheduler. There can be up to n assembly
lines and n machine groups available to the Shop Scheduler for
scheduling work orders. Furthermore, the Shop Scheduler can address
n number of dependencies between machine groups and assembly
lines.
[0173] The Shop Scheduler functions as a pure scheduling engine and
retrieves required input constraint information from external
systems to eliminate the need of maintaining redundant data within
the application. The data import and export routines are
customizable to support a variety of external system
interfaces.
[0174] The scheduling engine of Shop Scheduler is illustrated in
FIG. 37. As shown in FIG. 36, the scheduling engine has many user
friendly GUI features for easy access, such as drop-down menu and
radio buttons. The radio buttons selection facilitates forward or
backward job-step scheduling and drop-down menu specifies the
schedule period. It can also coordinate dependant orders by using
existing or planned inventory, and incorporate changeover times and
yield constraints as well.
[0175] Shop Scheduler also includes many standard or custom
displays and report capabilities, as shown in FIGS. 38-42. FIG. 38
shows a total schedule GANTT chart display with detailed order
input window and a spreadsheet display of resultant schedule. FIG.
39 shows a machine GANTT display with a overview of machine
schedule and a particularly selected machine. FIG. 40 shows a order
GANTT display with a overview of order and a particularly selected
order. FIG. 41 shows an Ad-hoc Query Generator with a query input
window and a result display window. FIG. 42 shows a Web-enabled
view of the schedule dispatch report, which can be easily
transformed into a Schedule GANTT display via IE 5+ browser.
[0176] Industry Applications
[0177] The Interwave Coordinator CMES application includes industry
applications to accelerate time-to-deployment and leverage industry
best practices and standards. The industry applications utilize and
extend the basic functionality in the universal application
templates to address the unique information requirements of a
particular manufacturing industry. The specific industry
applications claimed by this invention are Roll Tracker, Discrete
Assembler, Pharma Manager, MedDevice Tracker and Food
Processor.
[0178] Roll Tracker Industry Application
[0179] The Roll Track industry application provides basic roll
tracking functions for manufacturers in the roll goods industry.
Roll Tracker is also a highly configurable MES application that
supports the capability to coordinate the track the many to one,
and one to many production scenarios typical in the roll goods
industry.
[0180] Specifically, Slit Optimization is included to accommodate
unique industry requirements with respect to slitting production
items. Slit Optimization applies order cut requirements and
calculates allocation for order set up. It also enables fast
execution, which significantly reduces time when the number of
orders and widths increase. Slit Optimization further supports use
of "overage" to improve optimization results and integrates work
order output with external scheduling systems.
[0181] Discrete Assembler Industry Application
[0182] The Discrete assembler industry application provides
discrete assembling and tracking functions to customers in the
discrete manufacturing sector. Discrete Assembler is a highly
configurable MES application that supports component tracking and
validation features necessary in the assembly of a discrete
product.
[0183] Electronics Box Builder Industry Application
[0184] Electronics Box Builder industry application provides basic
assembly and test functions for manufacturers in the electronics
industry that relies heavily on contract equipment manufacturers
for board assemblies and components.
[0185] Surface Mount Technology (SMT) Assembler Industry
Application
[0186] SMT Assembler industry application provides surface mount
component placement and printed circuit board tracking/testing
functions for manufacturers in the electronics industry printed
circuit board manufacturing.
[0187] High-speed Data Acquisition is particularly included to
accommodate unique industry requirements. Specifically, there are
two features involved in High-speed Data Acquisition, they are
AutoTracker and AutoCollector. AutoTracker is designed for
highly-automated production lines to track electronic components
through highly-automated work centers. AutoTracker is configurable
for work center tracking stations. Further, AutoTracker recognizes
bar code ID and is able to register each process step in MES.
AutoTracker also recognize out-of-sequence production and is able
to do bi-directional feedback to control layer.
[0188] AutoCollector supports product genealogy and is designed for
automatic collection of quality data from installed test stations.
Furthermore, AutoCollector provides the ability to configure
collection frequency and times, such as data source.
[0189] Semiconductor Assembler Industry Application
[0190] Semiconductor Assembler Industry Application provides basic
wafer tracking and data collection for manufacturers in the
semiconductor industry. The present invention, a CMES application,
can improve the production work flow a great deal.
[0191] Pharma Manager Industry Application
[0192] The Pharma Manager industry application provides
recipe/specification management, batch execution, on-line data
collection and genealogy for pre-weigh and dispensing operations
under Food and Drug Administration (FDA) control. Further, Pharma
Manager implements all its functionalities in compliance with 21
CFR Part 11 security, and electronic record management
guidelines.
[0193] MedDevice Tracker Industry Application
[0194] The MedDevice Tracker industry application provides basic
tracking, genealogy, quality management and data collection
functions for manufacturers in the medical device industry under
FDA control. Further, MedDevice Tracker implements all its
functionalities in compliance with 21 CFR Part 11 security, and
electronic record management guidelines.
[0195] Food Processor Industry Application
[0196] The Food Processor industry application provides basic
tracking, genealogy and quality control of inventory and product in
the regulated food industry. Moreover, Food Processor industry
application implements its functions in accordance with the United
States Department of Agriculture (USDA) and Hazards Analysis and
Critical Control Points (HACCP) standards.
[0197] Food Processor is utilized to track waste against production
orders for both individual components and finished goods. It also
increases WIP visibility and control with on-line KPI's and
embedded reporting. Food Processor is able to configure and enforce
electronic signature schemes and improve the flexibility of the
production process. The Food Processor industry application further
includes a plurality of food processing features, such as
Formulation, Production and Packaging, QA Product Evaluation, QA
Product Test, QA Environmental Test, QA Product Retention, QA
Checklist, and HACCP Enforcement.
[0198] FIG. 43 shows the Formulation overview and Batch History of
the Food Processor. The overview panel of Formulation displays
formulation ingredients and required amount, and records execution
of formula, such as the quantity, ingredient lot number, operator,
date, time, etc. The overview panel also supports and tracks
deviations, i.e., additions and modifications, to production
formula. Furthermore, the panels enforce a configurable electronic
signature scheme. All the entries and deviations are recorded as
part of the Batch History.
[0199] Particularly, Formulation supports containerization, which
is production of multiple batches or containers against a single
production order. It also tracks scrap produced against production
order, such as ingredients and/or finished product. Further,
Formulation displays formulation step and order specific
instructions and current batch history for each production
order.
[0200] FIG. 44 shows the Production and Packaging function within
Food Processor industry application. The Production and Packaging
monitors one or more work centers (or "machine groups") from the
same GUI panel. It supports palletized and non-palletized
production reporting. The Production and Packaging tracks scrap
produced against the production order, components of either
finished or unfinished product, and tracks complete production and
consumption genealogy.
[0201] The Production and Packaging GUI displays label printing
requirements, label format, product specifications, product
recipes, and performance information, i.e., target vs. produced
quantity and yield. Moreover, the Production and Packaging GUI
displays and enforces bill of material requirements and HACCP data
collection requirements.
[0202] The QA Lab Product Evaluation function within Food Processor
industry application is shown in FIG. 47. The GUI panel provides
the ability to configuring product evaluation specifications on a
production item basis, and further, define one or more evaluation
specifications for a production item. The panel is also capable of
enforcing a configurable electronic signature scheme. Moreover, the
GUI panel is able to link evaluation data to a plurality of
production lots and enter evaluation data against multiple samples
for a particular production lot.
[0203] The QA Lab Product Test function within the Food Processor
industry application is shown in FIG. 48. The GUI panel supports
the ability to enter test data against multiple samples for a
particular production lot and define minimum and maximum values for
each parameter within a test specification. The end users can
easily configure product test specifications on a production item
basis and define one or more test specifications for a production
item through the GUI panel. The panel further links test data to
production lots and enforces a configurable electronic signature
scheme.
[0204] The QA Lab Environmental Test function within the Food
Processor industry application is shown in FIG. 49. The GUI panel
provides the ability to configure environmental test specifications
on a location basis and define one or more test specifications for
a location. It is also capable of defining minimum and maximum
values for each test specification parameter and enforces a
configurable electronic signature scheme.
[0205] The QA Hold Management function within the Food Processor is
shown in FIG. 50. The QA Hold Management is used to issue multiple
holds against a production entity and for issuing individual
releases. The QA Hold Management is able to prevents raw materials
from being consumed with a status of HOLD and prevents production
entities from being shipped with the status of HOLD. Further from
being able to capture hold and release reason codes, the QA Hold
Management is able to enforce configurable electronic signature
under Performed By and Verified By scheme.
[0206] The QA Product Retention function within Food Processor is
shown in FIG. 51. The GUI panel provides the ability to enter
product retention samples and associated data, disposition samples
to other locations within the system, and discard retained samples
that have exceeded the required retention window. Furthermore, the
QA Production Retention function links retention samples to
production lots for genealogy and product recall purposes. As other
GUI panels discussed above, the QA Product Retention function
enforces a configurable electronic signature scheme.
[0207] The QA Checklist function within Food Processor is used to
define an execution schedule for each checklist, and to log a
deficiency and corrective action, and preventive measure for each
item in a checklist. The QA Checklist displays required and actual
execution date and time for each checklist, as shown in FIG. 52,
and enforces a configurable electronic signature scheme.
[0208] In FIG. 53, a HACCP Data Entry window and a HACCP Data
Collection Log window of the HACCP Enforcement functions within
Food Processor are shown. Both quantity and time based HACCP data
collection schemes are enforceable by the HACCP Enforcement
function. Data is collected through the configurable data
collection templates. Further, it supports full audit trail of data
collection activities, and displays the history of HACCP data
collection activities for a particular work order.
[0209] Connectors
[0210] The Interwave Coordinator CMES application includes two
connector modules to provide a standardized mechanism to interface
with the business system and plant floor automation systems. These
connectors are the XML Business System Connector and the OPC Shop
Floor Connector.
[0211] XML Business Connector Module
[0212] The XML Business Connector module provides connectivity to
upply chain modules/business systems such as ERP, APS, PDM, etc. It
provides a standard mechanism (XML schema) for receiving work
orders, bill of materials (BOM), bill of routes (BOR), and tooling.
Additionally, the XML Business Connector provides a standard
mechanism (XML schema) for reporting material consumptions/issues,
scrap and production associated with a work center.
[0213] Ole for Process Control (OPC) Shop Floor Connector
Module
[0214] The OPC Shop Floor Connector module provides connectivity to
the shop floor control automation systems via an OPC connection. It
also provides a standard mechanism for downloading machine
setup/recipe information, or work order specification information
from the production management layer to the shop floor automation
system. Furthermore, the shop floor automation system sends alerts
and events to the production management layer via the OPC Shop
Floor Connector module.
[0215] Visualization
[0216] The Digital Dashboard module is a visualization module
included in the Interwave Coordinator CMES application. It provides
visibility into the performance of the manufacturing enterprise.
The Digital Dashboard module enables the configuration of a
personalized performance dashboard view on an individual user
basis.
[0217] FIGS. 15 through 21 show the various reports generated by
the Digital Dashboard module. These include the WIP Status Report,
as shown in FIG. 15, the Material Genealogy Report, as shown in
FIG. 16, the Route Genealogy Report, as shown in FIG. 17, the
Inventory Summary Report, as shown in FIG. 18, the Work Order
Status Report, as shown in FIG. 19, the Defect Data Report, as
shown in FIG. 20, and the Downtime Report, as shown in FIG. 21.
[0218] Utilities
[0219] The Interwave Coordinator CMES application includes six
utility modules to perform standard utility type functions. These
are Event Messenger, Work Traveler, Label Manager, Data Archiver,
Auto Tracker and Auto Collector. Each of these modules has
strengthened the performance of the CMES disclosed in the present
invention.
[0220] Event Messenger Module
[0221] Event Messenger module provides the ability of sending
e-mail or text based pager messages to users based upon production
events or upset conditions that affects the manufacturing
production. It is also able to configure user groups and associate
event messages with user groups.
[0222] Work Traveler Module
[0223] Work Traveler module supports the ability to define the
content of the traveler from pre-configured option lists (.i.e.,
BOM, routing, work instructions, etc). Work Traveler specifies the
text displayed in the header and footer of the traveler, and
further assigns work traveler definitions to products or classes of
products. Furthermore, Work Traveler prints travelers on demand or
automatically at the start or completion of a process
step/operation. Work Traveler is also able to store travelers in a
central location to reduce maintenance and deployment costs.
[0224] Label Manager Module
[0225] Label Manager module supports the ability to define the
content of a label from pre-configured option lists (i.e., BOM,
routing, work instructions, etc.). Label Manager assigns label
definitions to products or classes of products, and further prints
labels on demand or automatically based upon an event (i.e., the
start or completion of a work order). Finally, Label Manager store
labels in a central location to reduce maintenance and deployment
costs.
[0226] Data Archiver Module
[0227] Data Archiver module provides the ability to configure an
archiving scheme for the production database to increase system
performance. Further, Data Archiver supports the ability of
archiving data to a data warehouse and deleting information from
the production database.
[0228] Auto Tracker Module
[0229] Auto Tracker module provides the ability to track WIP items
through highly automated work centers via barcode technology.
Furthermore, it supports the ability to create and configure
tracking stations, and attach specific tracking attributes.
Finally, Auto Tracker sends alerts and events to the shop floor
automation system to annunciate upset conditions and events that
occur in the production management layer.
[0230] Auto Collector Module
[0231] Auto Collector module provides the ability to automatically
collect quality data from test machines against a particular
production entity. Furthermore, it supports the ability to define
collection scenarios such as collection frequency and data
source.
[0232] While the invention has been particularly shown and
described with reference to a preferred embodiment or a
specifically designed template, it will be understood by those
skilled in the art that various changes in form and detail may be
made therein without departing from the spirit and scope of the
invention.
* * * * *