U.S. patent number 3,593,008 [Application Number 04/701,979] was granted by the patent office on 1971-07-13 for article/time recording system.
Invention is credited to David A. De Witt, Ralph W. De Witt.
United States Patent |
3,593,008 |
De Witt , et al. |
July 13, 1971 |
ARTICLE/TIME RECORDING SYSTEM
Abstract
This specification describes an article/time/persons working
recording system for manufacturing facilities which provides a
central, continuously up-dated running account of all people hours
worked in the manufacturing facility in a given interval of time,
the number of people working and the number of articles produced.
Additionally, if desired the recording system can identify the
number of people working at a particular assembly line or other
work stations together with the total number of hours being worked
at that station or assembly line and the number of articles being
produced by the assembly line in the given interval of time. With
this information, an accurate and readily obtained up-to-date
figure for the number of articles produced per work hour and/or the
number of articles produced per person for the entire facility
and/or any given assembly line, is instantaneously available for
accounting purposes for anytime during or after a work day.
Inventors: |
De Witt; David A. (Latham,
NY), De Witt; Ralph W. (Latham, NY) |
Family
ID: |
24819424 |
Appl.
No.: |
04/701,979 |
Filed: |
January 31, 1968 |
Current U.S.
Class: |
705/32; 377/20;
705/7.38; 198/958; 377/16; 327/303; 340/870.13 |
Current CPC
Class: |
G06Q
40/10 (20130101); G07C 3/10 (20130101); G06Q
10/0639 (20130101); G06Q 40/125 (20131203); G06Q
10/06398 (20130101); G06Q 10/0633 (20130101); Y10S
198/958 (20130101) |
Current International
Class: |
G07C
3/10 (20060101); G07C 3/00 (20060101); G06g
007/52 (); G06f 015/24 () |
Field of
Search: |
;235/92,151,151.1,179
;198/40 ;340/172.5,182,183 ;328/59,60 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Morrison; Malcolm A.
Assistant Examiner: Gruber; Felix D.
Claims
What we claim is:
1. An article/time recording system for a manufacturing facility
comprising central people-hours-worked counting and readout means
for deriving a count of the number of people-hours including any
fractional parts thereof applied at predetermined work units within
the facility in a given time interval, central articles completed
counting and readout means for deriving a count of the number of
articles completed in the same given time interval in the facility,
at least one unit people-hours-worked-count registering means
coupled to and controlling a corresponding part of the central
people-hours-worked counting and readout means, and at least one
articles completed count registering means coupled to and
controlling a corresponding part of the central articles completed
registering and readout means whereby the number of unit articles
completed and people-hours worked by the facility is readily
determined at any given time during the work day.
2. An article/time recording system according to claim 1 further
including automatic means cooperating with the central
people-hours-worked counting and readout means and with the central
articles completed counting and readout means for dividing the
number of articles completed in a given time interval by the number
of people-hours-worked to provide a continuously updated indication
of the number of unit articles completed per people-hours-worked by
the facility in the given time interval.
3. An article/time recording system according to claim 1 wherein
there are a plurality of unit people-hours-worked-count registering
means located at different work stations throughout the facility
and all units are coupled to and control a corresponding part of
the total people-hours-worked-count accumulated by the central
people-hours-worked counting and readout means.
4. An article/time recording system according to claim 1 wherein
there are a plurality of unit articles completed count registering
means for deriving a count of the number of articles completed in a
given time interval at a plurality of different work stations
throughout the facility and all units are coupled to and control
corresponding part of the total articles completed count
accumulated by the central articles completed counting and readout
means.
5. An article/time recording system according to claim 1 wherein
the central people-hours-worked counting and readout means
comprises counter means providing readout, and
people-time-count-signal digitizing means for producing pulsed
waveform electric signals wherein each electric signal pulse is
representative of a finite time period worked by one person, and
said unit people-hours-worked-count registering means serves
selectively to apply representative numbers of the electric signal
pulses from the people-time-count-digitizing means to the readout
counter means.
6. An article/time recording system according to claim 3 wherein
there are a plurality of unit articles completed count registering
means for deriving a count of the number of articles completed in a
given time interval at a plurality of different work stations
throughout the facility and all units are coupled to and control a
corresponding part of the total articles completed count
accumulated by the central articles completed counting and readout
means.
7. An article/time recording system according to claim 6 wherein
the central people-hours-worked counting and readout means
comprises readout counter means, and people-time-count signal
digitizing means for generating a series of pulsed waveform
electric signals wherein each electric signal pulse is
representative of a finite time period worked by one person, and
said unit people-hours-worked-count registering means serves
selectively to apply desired numbers of the electric signal pulses
from the people-time-count digitizing means to the readout counter
means.
8. An article/time recording system according to claim 7 further
including automatic means responsive to the
people-time-count-signal digitizing means and to the central
articles completed-count for dividing the number of articles
completed in a given time interval by the number of people hours
worked to provide a continuously updated indication of the number
of unit articles completed per people hours worked by the facility
in the given time interval.
9. An article/time recording system according to claim 5 further
including automatic means responsive to the
people-time-count-signal digitizing means and responsive to the
central articles complete count for dividing the number or articles
completed in a given time interval by the number or people-hours
worked to provide a readily accessible indication of the number of
articles completed per people-hours-worked by the facility in the
given time interval.
10. An article/time recording system according to claim 5 wherein
the people-time-count-signal digitizing means comprises a rotated
member driven at a predetermined number of revolutions per minute
and having a plurality of actuating elements secured thereto, a
source of electric potential, a plurality of electric switch means
connected to the source of electric potential and fixedly mounted
with respect to the rotating member and arranged around its
periphery and actuated by the actuating elements for developing a
predetermined total number of electric signal pulses for a given
number of revolutions of the rotating member, and stepping switch
means having fixed and moveable contacts with the fixed contacts
being selectively connected to the plurality of electric switch
means for obtaining a desired number of electric signal pulses from
the outputs of the plurality of electric switch means in accordance
with the setting of the moveable contacts of the stepping switch,
the setting of the moveable contacts being controlled by the
people-hours-worked registering means.
11. An article/time recording system according to claim 10 further
including a bank of isolating diodes operatively interconnecting
the fixed contacts of the stepping switch means to the plurality of
electric switch means mounted around the periphery of the rotating
member for isolating all save selected ones of the outputs of the
several electric switch means from the fixed contacts of the
stepping switch means in order that fixed contacts of the stepping
switch means have applied thereto characteristic numbers of
electric signal pulses within a predetermined range and the setting
of the stepping switch determines the number of electric signal
pulses supplied at its output.
12. An article/time recording system according to claim 11 wherein
the rotated member is driven at a speed of one-third r.p.m. and has
an inner row of five actuating elements that coact with a single
electric switch means and an outer row of 10 actuating elements
that coact with 10 electric switch means whereby the single inner
switch means operates to develop 100 pulses per hour with each
pulse representing one-one hundredth of an hour and each outer
electric switch means operates to develop 200 pulses per hour with
each pulse representing one-one hundredth of an hour and with the
total number of pulses produced representing the time in one-one
hundredths of an hour of a system usable in controlling operation
of up to 21 persons.
13. An article/time recording system according to claim 11 wherein
there are a plurality of unit people-hours-worked-count registering
means located at different work stations throughout the facility
and all units are coupled to and control a corresponding part of
the total people-hours-worked count accumulated by the central
people-hours-worked counting and readout means and wherein there
are a plurality of unit articles completed-count registering means
for deriving a count of the number of articles completed in a given
time interval at a plurality of different work stations throughout
the facility and all units are coupled to and control a
corresponding part of the total articles-completed-count
accumulated by the central articles completed counting and readout
means and further including automatic means responsive to the
people-time-count-signal digitizing means and to the central
articles completed count for dividing the number of articles
completed in a given time interval by the number of
people-hours-worked to provide a continuously updated indication of
the number of unit articles completed per people-hours-worked by
the facility in the given time interval.
14. An article/time recording system according to claim 11 wherein
there are a plurality of unit people-hours-worked-count registering
means located at different work stations throughout the facility
and all units are coupled to and control a corresponding part of
the total people-hours-worked count accumulated by the central
people-hours-worked counting and readout means and wherein there
are a plurality of unit articles-completed-count registering means
for deriving a count of the number of articles completed in a given
time interval at a plurality of different work stations throughout
the facility and all units are coupled to and control a
corresponding part of the total articles-completed-count
accumulated by the central articles completed counting and readout
means whereby a continuously updated and current indication of the
number of unit articles-completed and people-hours-worked by the
facility in the given time interval can be obtained.
15. An article/time recording system according to claim 13 further
including a master time controller and readout means for deriving a
count of the total time being worked by the total number of people
working in the facility, said master time controller and readout
means being controlled by master time clock means which records the
time and number of all time recorded people working in the
facility.
16. An article/time recording system according to claim 15 wherein
the master time clock means includes means for punching-in and
punching-out workers at particular authorized times so as to add to
or subtract from the total number of people working in the facility
at any given time, and ancillary bypass punch-in and punch-out
means for punching-in and punching-out workers at other than the
particular authorized times at the discretion of a supervisor.
17. An article/time recording system according to claim 16 wherein
the articles completed count registering means comprises packing
area counting and readout means for deriving a count of the
completed articles being processed through a packing area located
at the end of a work station, and packing area count registering
means coupled to and controlling the packing area counting and
readout means, and wherein the packing area count registering means
comprises a control tape dispensing means for dispensing an
identifying piece of tape for securing to the completed article to
indicate that the completed article has been processed through the
packing area, and wherein each time a piece of control tape is
dispensed, a completed article processed unit count is registered,
and the control tape dispensing means operates automatically to
dispense one piece of control tape at a time, and is controlled by
a lockout control means that must be activated to enable the tape
dispensing means to dispense another piece of control tape
following a prior dispensing operation.
18. An article/time recording system according to claim 17 further
including loading area counting and readout means for deriving a
count of the completed articles being processed through a loading
area, loading area count registering means coupled to and
controlling the loading area counting and readout means, a conveyor
mechanism for moving completed articles out of the loading area,
and loading area count registering trigger means mounted on the
conveyor mechanism and actuated by a completed article passing over
the conveyor mechanism for registering one unit count in the
loading area counting and readout means for each completed article
transported by the conveyor mechanism out of the loading area.
19. An article/time recording system according to claim 18 further
including a plurality of different characteristic article counters
comprising a part of the loading area counting and readout means
for deriving a count of each different type of article completed in
the manufacturing facility, and type of article selector means
comprising a part of the loading area count registering means for
selectively activating a desired one of the plurality of different
characteristic article counters in accordance with the type of
article being processed through the loading area.
20. An article/time recording system according to claim 19 wherein
the conveyor mechanism includes a power-driven portion that
normally in its inactive condition engages a completed article
subsequent to the completed article being loaded upon the conveyor
mechanism and wherein the count-registering trigger means in
addition to registering a unit count for each completed article
loaded upon the conveyor mechanism also actuates the power-driven
portion of the conveyor to cause the conveyor to convey the
completed article thus counted to another location, and wherein
there are a plurality of differently located count-assuring stop
means for assuring an accurate count of articles loaded on the
conveyor and for accommodating different types of articles being
loaded on the conveyor mechanism, and said type of article selector
means further controls which particular type count-assuring stop
means is rendered active for use in controlling the supply of
articles to the power-driven portion of the conveyor mechanism.
21. An article/time recording system according to claim 19 wherein
the conveyor mechanism also includes a gravity-operated portion
that feeds the power-driven portion and upon which the completed
articles are initially placed, the count-registering trigger means
being supported on the gravity-operated portion at a distance from
the power-driven portion designed to assure simultaneous engagement
of the gravity-operated portion and actuation of the
count-registering trigger means whereby the power-driven portion
will be enabled upon each occurrence of a completed article being
placed on the conveyor mechanism to withdraw the completed article
off the count-registering trigger means and onto the power-driven
portion a sufficient distance to assure return of the trigger means
to its normally inactive position while simultaneously loading the
power-driven portion of the conveyor with one completed
article.
22. An article/time recording system according to claim 21 wherein
the conveyor mechanism further includes at its discharge-unloading
end a discharge-unloading portion to which the power-driven portion
delivers articles stored thereon for unloading, and said
discharge-unloading portion includes at least one overdelivery
sensing and inactivating control means for sensing a buildup of
unloaded articles being delivered to the discharge-unloading
portion above a predetermined number and for inactivating the
power-driven portion of the conveyor mechanism is response thereto,
and further including manually operable control means for
inactivating the power-driven portion of the conveyor mechanism at
the option of an operator-unloader working at the
discharge-unloading end of the conveyor mechanism.
23. An article/time recording system according to claim 22 further
including unloading area counting and readout means for deriving a
count of the completed articles being stored in the unloading area
in which the discharge-unloading end of the conveyor mechanism is
located and to which the articles are transported from the
manufacturing facility by the conveyor mechanism and unloading area
count registering means located in the unloading area and coupled
to and controlling the unloading area counting and readout
means.
24. An article/time recording system according to claim 23 wherein
the unloading area count registering means comprises unloading
article sensing trigger means mounted on a discharge-unloading
portion of the conveyor mechanism for registering one unit count
for each article transported over such discharge-unloading portion
into the loading area.
25. An article/time recording system according to claim 24 wherein
said unloading area counting and readout means includes a plurality
of different characteristic article counters for deriving a count
of each different type of article coming into the unloading area,
and type of article selector means comprising a part of the
unloading area count registering means for selectively activating a
desired one of the plurality of different characteristic article
counters in accordance with the type of article coming into the
unloading area.
26. An article/time recording system according to claim 1 further
including a master time controller and readout means for deriving a
count of the total time being worked by the total number of people
working in the facility, said master time controller and readout
means being controlled by master time clock means which records the
time and number of all time recorded people working in the facility
and serving to synchronize operation of the central people-hours
worked counting and readout means.
27. An article/time recording system according to claim 26 wherein
the master time clock means includes means for punching-in and
punching-out workers at particular authorized times so as to add to
or subtract from the total number of people working in the facility
at any given time, and ancillary bypass punch-in and punch-out
means for punching-in and punching-out workers at other than the
particular authorized times at the discretion of a supervisor.
28. An article/time recording system according to claim 27 further
including people recording and readout means for recording the
total number of people working in the facility in a given time
interval, the people recording and readout means being connected to
and controlled by the master time clock means.
29. An article/time recording system according to claim 28 wherein
the articles completed count registering means comprises packing
area counting and readout means for deriving a count of the
completed articles being processed through a packing area located
at the end of a work station, and packing area count registering
means coupled to and controlling the packing area counting and
readout means and wherein the packing area count registering means
comprises a control tape dispensing means for dispensing an
identifying piece of tape for securing to the completed article to
indicate that the completed article has been processed through the
packing area, and wherein each time a piece of control tape is
dispensed, a completed article processed unit count is registered,
and the control tape dispensing means operates automatically to
dispense one piece of control tape at a time, and is controlled by
a lockout control means that must be activated to enable the tape
dispensing means to dispense another piece of control tape
following a prior dispensing operation.
30. An article/time recording system according to claim 26 further
including people recording and readout means for recording the
total number of people working in the facility in a given time
interval, the people recording and readout means being connected to
and controlled by the master time clock means.
31. An article/time recording system according to claim 26 wherein
the articles completed count registering means comprises packing
area counting and readout means for deriving a count of the
completed articles being processed through a packing area located
at the end of a work station, and packing area count registering
means coupled to and controlling the packing area counting and
readout means.
32. An article/time recording system according to claim 1 wherein
the articles completed count registering means comprises packing
area counting and readout means for deriving a count of the
completed articles being processed through a packing area located
at the end of a unit work station, and packing area count
registering means coupled to and controlling the packing area
counting and readout means.
33. An article/time recording system according to claim 32 wherein
the packing area count registering means comprises a control tape
dispensing means for dispensing an identifying piece of tape for
securing to the completed article to indicate that the completed
article has been processed through the packing area, and wherein
each time a piece of control tape is dispensed, a completed article
processed unit count is registered.
34. An article/time recording system according to claim 33 wherein
the control tape dispensing means operates automatically to
dispense one piece of control tape at a time, and is controlled by
a lockout control means that must be activated to enable the tape
dispensing means to dispense another piece of control tape
following a prior dispensing operation.
35. An article/time recording system according to claim 1 further
including loading area counting and readout means for deriving a
count of the completed articles being processed through a loading
area, loading area count registering means coupled to and
controlling the loading area counting and readout means, a conveyor
mechanism for moving completed articles out of the loading area,
and loading area count registering trigger means mounted on the
conveyor mechanism and actuated by a completed article passing over
the conveyor mechanism for registering one unit count in the
loading area counting and readout means for each completed article
transported by the conveyor mechanism out of the loading area.
36. An article/time recording system according to claim 35 wherein
the conveyor mechanism includes a power-driven portion that
normally in its inactive condition engages a completed article
subsequent to the completed article being loaded upon the conveyor
mechanism and wherein the count registering trigger means in
addition to registering a unit count for each completed article
loaded upon the conveyor mechanism also actuates the power driven
portion of the conveyor to cause the conveyor to convey the
completed article thus counted to another location.
37. An article/time recording system according to claim 36 wherein
the conveyor mechanism also includes a gravity operated portion
that feeds the power-driven portion and upon which the completed
articles are initially placed, the count-registering trigger means
being supported on the gravity-operated portion at a distance from
the power-driven portion designed to assure simultaneous engagement
of the gravity-operated portion and actuation of the count
registering trigger means whereby the power-driven portion will be
enabled upon each occurrence of a completed article being placed on
the conveyor mechanism to withdraw the completed article off the
count-registering trigger means and onto the power-driven portion a
sufficient distance to assure return of the trigger means to its
normally inactive position while simultaneously loading the
power-driven portion of the conveyor with one completed
article.
38. An article/time recording system according to claim 37 further
including a plurality of differently located count assuring stop
means for assuring an accurate count of articles loaded on the
conveyor and for accommodating completed articles of different
size, and means for controlling which particular size count
assuring stop means is rendered active for use in controlling the
supply of articles to the power-driven portion of the conveyor
mechanism.
39. An article/time recording system according to claim 37 wherein
the conveyor mechanism further includes at its discharge unloading
end a discharge-unloading portion to which the power-driven portion
delivers articles stored thereon for unloading, and said
discharge-unloading portion includes at least one overdelivery
sensing and inactivating control means for sensing a buildup of
unloaded articles being delivered to the discharge-unloading
portion above a predetermined number and for inactivating the power
driven-portion of the conveyor mechanism in response thereto.
40. An article/time recording system according to claim 39 further
including manually operable control means for inactivating the
power-driven portion of the conveyor mechanism at the option of an
operator-unloader working at the discharge-unloading end of the
conveyor mechanism.
41. An article/time recording system according to claim 40 further
including unloading area counting and readout means for deriving a
count of the completed articles being transported to the unloading
area from the manufacturing facility, and unloading area count
registering means located in the unloading area and coupled to and
controlling the unloading area counting and readout means.
42. An article/time recording system according to claim 35 further
including a plurality of different characteristic article counters
comprising a part of the loading area counting and readout means
for deriving a count of each different type of article completed in
the manufacturing facility, and type of article selector means
comprising a part of the loading area count registering means for
selectively activating a desired one of the plurality of different
characteristic article counters in accordance with the type of
article being processed through the loading area.
43. An article/time recording system according to claim 42 wherein
the conveyor mechanism includes a power-driven portion that
normally in its inactive condition engages a completed article
subsequent to the completed article being loaded upon the conveyor
mechanism and wherein the count registering trigger means in
addition to registering a unit count for each completed article
loaded upon the conveyor mechanism also actuates the power-driven
portion of the conveyor to cause the conveyor to convey the
completed article thus counted to another location, and wherein
there are a plurality of differently located count assuring stop
means for assuring an accurate count of articles loaded on the
conveyor and for accommodating different types of articles being
loaded on the conveyor mechanism, and said type of article selector
means further controls which particular count assuring stop means
is rendered active for use in controlling the supply of articles to
the driven portion of the conveyor mechanism.
44. An article/time recording system according to claim 42 wherein
the conveyor mechanism further includes at its discharge-unloading
end a discharge-unloading portion to which the power-driven portion
delivers articles stored thereon for unloading, and said
discharge-unloading portion includes at least one over delivery
sensing and inactivating control means for sensing a buildup of
unloaded articles being delivered to the discharge-unloading
portion above a predetermined number and for inactivating the
power-driven portion of the conveyor mechanism in response thereto
and further including manually operable control means for
inactivating the power-driven portion of the conveyor mechanism at
the option of an operator-unloader working at the
discharge-unloading end of the conveyor mechanism.
45. An article/time recording system according to claim 22 further
including unloading area counting and readout means for deriving a
count of the completed articles being transported to the unloading
area from the manufacturing facility, and unloading area count
registering means located in the unloading area and coupled to and
controlling the unloading area counting and readout means.
46. An article/time recording system according to claim 45 wherein
the unloading area count registering means comprises unloading
article sensing trigger means mounted on a discharge-unloading
portion of the conveyor mechanism for registering one unit count
for each article transported over such discharge-unloading portion
into the unloading area.
47. An article/time recording system according to claim 46 wherein
said unloading area counting and readout means includes a plurality
of different characteristic article counters for deriving a count
of each different type of article coming into the unloading area,
and type of article selector means comprising a part of the
unloading area count registering means for selectively activating a
desired one of the plurality of different characteristic article
counters in accordance with the type of article coming into the
unloading area.
48. An article/time recording system according to claim 1 further
including unloading area counting and readout means for deriving a
count of the completed articles being transported to the unloading
area from the manufacturing facility, and unloading area count
registering means located in the unloading area and coupled to and
controlling the unloading area counting and readout means.
49. An article/time recording system according to claim 48 wherein
the unloading area count registering means comprises unloading
article sensing trigger means mounted on a discharge-unloading
portion of the conveyor mechanism for registering one unit count
for each article transported over such discharge-unloading portion
into the unloading area.
50. A people-time-count-signal digitizing device for an
article/time recording system generating electric signal pulses
comprising a rotated member driven at a predetermined number of
revolutions per minute and having a plurality of actuating elements
secured thereto, a source of electric potential, a plurality of
electric switch means connected to the source of electric potential
and fixedly mounted with respect to the rotating member and
arranged around its periphery and actuated by the actuating
elements for developing a predetermined total number of electric
signal pulses for a given number of revolutions of the rotating
member, and stepping switch means having fixed and movable contacts
with the fixed contacts being selectively connected to the
plurality of electric switch means for obtaining a representative
number of electric signal pulses from the outputs of the plurality
of electric switch means in accordance with the setting of the
movable contacts of the stepping switch, the setting of the movable
contacts being controlled in accordance with the number of people
working in a given time interval for which a people-time count is
desired.
51. A people-time count-signal digitizing device according to claim
50 further including a bank of isolating diodes operatively
interconnecting the fixed contacts of the stepping switch means to
the plurality of electric switch means mounted around the periphery
of the rotating member for isolating all save selected ones of the
outputs of the several electric switch means from the fixed
contacts of the stepping switch means in order that the fixed
contacts of the stepping switch means have applied thereto
characteristic numbers of electric signal pulses within a
predetermined range and the setting of the movable contacts of the
stepping switch determines the number of electric signal pulses
supplied at the output of the stepping switch.
Description
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to an article per unit of time worked
recording system.
More particularly, the invention relates to a system for obtaining
a central, continuously updated, running account of all
people-hours worked in a manufacturing facility in a given interval
of time, the number of people working and the number of articles
produced whereby an accurate and readily obtained up-to-date figure
for the number of articles produced per worked hour and/or the
number of articles produced per person, is instantaneously
available for accounting purposes at any time during the workday as
well as at the end of the workday.
2. Description of Prior Art
Heretofore, manufacturing facilities have had no convenient and
reliable means for rapidly assimilating important data relating to
the operation of the facility and its efficiency at any given
instant during the workday. This is particularly true of larger
manufacturing facilities having manufacturing operations carried
out at a number of unit assembly line areas or work stations in
different location. It has generally been the practice to wait to
the end of each day's production to accumulate such data manually
by a clerk, etc. However, in many operations which are highly
competitive and border on being marginal in return, to wait for a
full days' results in order to determine whether or not a given
operation is running efficiently, may very well turn out to be
catastrophic. What is needed in this kind of operation, is some
system which makes available at a central location, continuously
updated, accurate data bearing on the efficiency of the
manufacturing facility on a substantially instantaneous demand
basis at any time during or after a workday. To satisfy this need
the present invention was developed.
SUMMARY OF INVENTION
It is therefore a primary object of the present invention to
provide a new and improved article/time/persons working recording
system for manufacturing facilities which provides a central,
continuously updated running account of all people-hours worked in
the facility in a given interval of time, the number of people
working and the number of articles produced whereby an accurate and
readily obtained up-to-date figure for the number of articles
produced per worked hour and/or the number of articles produced per
person, is instantaneously available for accounting purposes at any
time during or after a workday.
The system automatically accumulates hours worked by individuals or
groups from the time they are started on a job until they are
removed. Start and stop may be at random but accumulated time and
totals always reads on a counter up to the actual time that the
reading is taken to the nearest one-hundredth of an hour. The
control which collects time for the entire facility may emanate
from a time clock which would begin to record at the end of the
initial starting time (which may extend over a 10-minute interval)
and continue to record until the stopping time at noon, or at the
end of a workday. People punching in late or leaving early are
detected and compensated for. The counter shows accumulated hours
for all persons working in the facility during any given time
interval regardless of when they punched in or out, and another
master counter indicates the total number of persons punched in and
working in the facility at any given time. The total number punched
in are broken down into groups and accounted for by an arrangement
which monitors each group and the sum of people working as
individuals or groups must equal the total punched in. When this is
true, then the total of accumulated hours recorded for each group
will also equal the total hours indicated as being worked.
In addition to the above features, where the individual or group is
generating a manufactured article as a work product, the number of
pieces of the article can also be registered as part of the same
system. Consequently, where production standards of either
individual or group type are set up, an immediate and exact
comparison with the "standard" may be made at any time during the
workday up to the exact moment that it is made, by simply dividing
the number of pieces or units completed up to the point in time
where the comparison is made by the total accumulated hours worked
by a particular person or group. Comparing the sum of the time for
all groups with the total time being paid makes possible constant
and exact cost checking which otherwise is difficult, if not
impossible, to obtain without much complicated paperwork, and then
only at the end of a work period or day because everything changes
during the workday at the time computations and collection of such
information is being made. The system can be made to read out
directly in pieces per hour or dollars per thousand as a further
addition to the equipment thereby eliminating the need for any
mental computation and thereby provide an instantaneous comparison
of actual cost with the "standard" cost.
From the above set forth brief summary of the characteristics of
the new and improved article/time/person recording system, it will
be appreciated that:
1. The system keeps an accurate count of every employee punching
into or out of work in the facility on a time clock which may be of
conventional construction if desired.
2. The system keeps an accurate count of everyone employed on any
work station, assembly line, packing area or any other type of
operation utilized by the firm.
3. The system makes available at any time the total amount of
accumulated worker time for those employees on any desired
operation. This information is in direct readout form, accurate to
any desired decimal amount of the total accumulation of worked
time, on any operation, by any number of employees, and is
available at any desired time of readout. The important feature to
note is that the readout is accumulated constantly and is
instantaneously available at any time during the workday.
4. The system also records all of the items or parts produced, in
any unit amount desired, that are or are not a direct result of the
previously mentioned operations. In cases where the items produced
are a direct result of those operations, it can be readily
appreciated that a figure of units per worked hours is available by
simply dividing the total number of units produced by the total
number of worked hours used in producing those units. Here again,
the figure is available either manually through mental division
computation, or electrically through a direct acting computation
device of an electromechanical or electronic nature. This figure
also is available on an instantaneous basis at any desired readout
time during the workday.
5. The system can completely record all of the items passing over a
conveyor system for transporting the completed articles from an
assembly area to an unloading or storage area. This can be done
item by item again reading out in any units desired. Another
important feature is that the items to be transported by the
conveyor can be placed on the conveyor at random without any coded
markings necessary on the item, other than to indicate that an item
has been counted, and the system can be set so as to not only count
the randomly placed items unit by unit, but also sort them by item
into a separate count of each type of item being transported.
6. The system supplies information on how many people are working
at any instant since they have been recorded by the time clock. It
will also provide information as to the total time accumulated up
to a given point of readout to any decimal amount desired, and the
total number of people and amount of time worked by the same people
on any given operation. This supplies an instantaneous check of
time and people to be paid against time worked or people working
respectively on the several operations being conducted in the
facility.
7. The system will also supply information as to the unit pieces
per worked hour or per person on an instantaneous demand basis.
These figures are extremely important in any firm employing
standard cost control measures. It will aid in obtaining accurate
and adequate standards for a given manufacturing facility using
standard units per worked unit of time. This helps in controlling
production and evaluating the advantages or disadvantages of
different production techniques on and "on the spot" instantaneous
basis after introducing new procedures or changing old
techniques.
8. The system also aids in recording all of the units of an item
produced and supplies a triple check on this figure which is
important in obtaining accurate inventory control.
In practicing the invention an article/time recording system for a
manufacturing facility is provided which comprises central
people-hours-worked counting and readout means for deriving a count
of the total number of people-hours worked and fractional parts
thereof in a given time interval. Central articles completed
counting and readout means are also provided for deriving a count
of the number of articles completed in the same given time interval
in the facility. At least one people-hours-worked-count registering
means is coupled to and controls at least partially the central
people-hours-worked counting and readout means, and, at least one
articles completed count registering means is coupled to and
controls at least partially the central articles completed per
people-hours worked by the facility can be readily determined at
any given time during the workday.
In the preferred arrangement, automatic means responsive to the
central people-hours-worked counting and readout means and to the
central articles completed counting and readout means, are provided
for dividing the number of articles completed in a given time
interval by the number of people-hours worked to provide a
continuously up-dated indication of the number of unit articles
completed per people-hours worked by the facility in the given time
interval.
Preferably, there are a plurality of unit people-hours-worked-count
registering means and a plurality of unit articles completed count
registering means for deriving people-hours worked at different
work stations located throughout the manufacturing facility, and
for deriving a count of the number of articles completed in the
same given time interval at the plurality of different work
stations, respectively. The plurality of unit
people-hours-worked-count registering means and the plurality of
unit articles completed count registering means are all coupled to
the central people-hours-worked counting and readout means for
controlling proportionate parts of the total people-hours-worked
count accumulated by that means, and the plurality of different
unit articles completed count registering means are coupled to and
control the central articles completed counting and readout means
to provide a proportionate part of the total articles completed
count accumulated by that counter.
The central people-hours-worked counting and readout means
comprises readout counter means, and people-time count signal
digitizing means for generating a series of pulsed waveform
electric signals wherein each electric signal pulse is
representative of a finite time period worked by one person and the
unit people-hours-worked-count registering means serves selectively
to apply desired numbers of the electric signal pulses from the
people-time count-digitizing means to the readout counter
means.
The system also further includes a master time controller and
readout means for deriving a count of the total time being worked
by the total number of people working in the facility, and is
controlled by a master time clock means which records the time and
number of all time recorded people working in the facility. The
master time clock means preferably includes means for punching-in
and punching-out workers at particular authorized times so as to
add to or subtract from the total number of people working in the
facility at any given time, and ancillary bypass punch-in and
punch-out means for punching in and punching out workers at other
than the particular authorized times at the discretion of a
supervisor.
The system further includes people recording and readout means for
recording the total number of people working in the facility in any
given time with the people recording and readout means being
connected to and controlled by the master time clock means.
A packing area counting and readout means is also provided for
deriving a count of the completed articles being processed through
a packing area located at the end of any particular work station,
and packing area count registering means are coupled to and control
the packing area counting and readout means.
The article/time recoding system also further includes loading area
counting and readout means for deriving a count of the completed
articles being processed through a loading area supplied from a
predetermined number of packing areas in the facility for deriving
a count of the completed articles being processed through the
loading area. Loading area count registering means are coupled to
and control the loading area counting and readout means and
preferably include a loading area count registering trigger mounted
on a conveyor mechanism for moving completed articles out of the
loading area. The count registering trigger is actuated by a
completed article passing over the conveyor mechanism for
registering one unit count in the loading area counting readout
means for each completed article transported by the conveyor
mechanism out of the loading area. The conveyor mechanism
preferably includes a power driven portion which normally in its
inactive condition engages a completed article subsequent to the
completed article being loaded upon the conveyor mechanism. The
mechanism is arranged such that the count registering trigger in
addition to registering a unit count for each completed article
loaded upon the conveyor mechanism, also actuates the power driven
portion of the conveyor to cause the conveyor to withdraw the
completed article off the count registering trigger and onto the
power driven portion a sufficient distance to assure return of the
trigger to its normally inactive position while simultaneously
recording one unit count and loading the power driven portion of
the conveyor with one completed article. It is preferred that the
loading area counting and readout means also include a plurality of
different characteristic article counters for deriving a count of
each of the different type of articles completed in the
manufacturing facility and processed through the loading area. Type
of article selector means are also provided which comprise a part
of the loading area count registering means for selectively
activating a desired one of the plurality of different
characteristic article counters in accordance with the type of
article being processed through the loading area.
The article/time recording system also preferably includes a
conveyor mechanism which has at its discharge unloading end at
least one overdelivery sensing and inactivating control means for
sensing a buildup of unloaded articles being delivered to the
unloading end of the conveyor above a predetermined number and for
inactivating the power driven portion of the conveyor in response
to this buildup. A manually operable control means is also provided
for inactivating the power driven portion of the conveyor at the
option of an operator-unloader working at the discharge-unloading
end of the conveyor.
Unloading area counting and readout means are also provided for
deriving a count of the completed articles being transported to the
unloading area from the manufacturing facility, and unloading area
count registering means located in the unloading area are coupled
to and control the unloading area counting and readout means. The
unloading area count registering means preferably comprises an
unloading article sensing trigger mounted on the
discharge-unloading end of the conveyor mechanism for registering
one unit count for each article transported over the conveyor from
the loading area into the unloading area. If desired, the unloading
area may comprise a warehouse, a vehicle for transporting the
finished articles away from the manufacturing facility, etc.
BRIEF DESCRIPTION OF DRAWINGS
Other objects, features and many of the attendant advantages of
this invention will be appreciated more readily as the same becomes
better understood by reference to the following detailed
description when considered in connection with the accompanying
drawings, wherein like parts in each of the several figures are
identified by the same reference character, and wherein:
FIG. 1 is an overall functional block diagram of an
article/time/persons working recording system for a manufacturing
facility constructed in accordance with the invention;
FIG. 2 is a more detailed, functional block diagram illustrating
the construction of a people-hour count signal-digitizing portion
of a people-hours worked registering, counting and readout
subsystem for use in the article/time recording system shown in
FIG. 1 of the drawings;
FIG. 3, 3A and 3B are respective plan, side and sectional views of
a synchronously driven, timing wheel subassembly comprising a part
of the people-time count signal-digitizing subsystem shown in FIG.
2;
FIG. 4 of the drawings is an electrical wiring diagram illustrating
the manner in which the microswitches mounted on the timing wheel
shown in FIG. 3 are electrically connected in the signal digitizing
circuit shown in FIG. 2;
FIGS. 5, 5A and 5B are wiring diagrams illustrating how an
isolating bank of diodes is connected into the signal-digitizing
circuit shown in FIG. 2;
FIGS. 6, 6A and 6B are wiring diagrams showing how a conventional
commercially available stepping switch which comprises a part of
the signal-digitizing circuit of FIG. 2, is connected into the
system;
FIG. 7 is a sectional view of an unpowered, gravity operated roller
loading section of a conveyor mechanism for use in the loading area
of a manufacturing facility, and shows the construction of a count
recording and power conveyor actuating trigger device used on the
loading section; and
FIG. 8 is a sectional view of a discharge-unloading end of a
conveyor mechanism illustrating a count trigger arrangement and
load limiting power inactivating switch arrangement for controlling
operation of the conveyor in the unloading area and simultaneously
obtaining a count of all articles processed through the unloading
area.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
Overall Article/Time Recording System-- People-Time Counting and
Readout
FIG. 1 of the drawings illustrates the overall article/time/people
recording system comprising the invention as applied to a
manufacturing facility having some five assembly lines where each
assembly line produces an individual type of product that is then
packed into suitable containers at the end of the line and
transferred out to a warehouse storage area to await distribution.
It is to be expressly understood that the system is in no way
restricted to the particular manufacturing facility herein
described, but may be applied to any manufacturing facility wherein
it is desired to utilize the system. For example, should it be
desired the system could be used in connection with only a single
assembly line supplying a single warehouse storage area. However,
it is believed that the multiple assembly line manufacturing
facility poses the more general problem, and hence, it has been
chosen as the background with which to describe the present
invention.
The article/time recording system installation illustrated in FIG.
1 utilizes a readout information station room shown at 11 where the
several counters and meters used in monitoring the people-hours
worked, and the number of articles produced by all of the time
recorded people working on a plurality of assembly lines shown at
12.sub.1, 12.sub.2, 12.sub.3, etc. are located. The articles
produced on each of the assembly lines 12 are packed in a suitable
packing area and simultaneously counted by packing area counters
shown at 13.sub.1, 13.sub.2, 13.sub.3, etc. The packed articles are
then supplied to a conveyor loading area shown at 14 where they are
loaded onto a conveyor shown at 15 for transportation to an
unloading or warehouse area shown at 16. The conveyor loading area
14 also includes a loading area count registering device 17 which
supplies a count of the articles passing through the conveyor
loading area to a loading area counter 18 located in the readout
information station. Similarly, an unloading area count registering
device 19 supplies a count of the articles coming into the
unloading area or warehouse storage area 16 to an unloading area
counter 21 likewise located in the readout information station
11.
In producing the completed articles packed at the end of each
assembly line 12, the scheduled production (as determined by a line
supervisor) requires that the assembly line to have a certain
number of workers or people applied to the work for a certain
amount of time. In order to obtain an accurate record of the
required amount of worker-time or people-time needed to produce the
articles, a line people-hours count registering device shown at
22.sub.1, 22.sub.2, 22.sub.3, etc. is provided for each assembly
line and is under the control of the line supervisor. The output
for each of the line people-hours count registering devices 22,
which is electrical in nature, is supplied to a plurality of line
time controllers and people-time count signal-digitizing means
23.sub.1, 23.sub.2, 23.sub.3, etc. located in a control room 24.
The outputs from the line time controllers and digitizers 23 are
supplied to a plurality of counters 25.sub.1, 25.sub.2, etc.
located in the readout information station 11 which together with
the people-time count digitizers 23 comprise the central
people-hours-worked counting and readout means. The counters 25 are
conventional, commercially available direct current counters of the
type manufactured and sold by a number of United States
manufacturers. For example, the 24-volt direct current counter-type
No. 19835--006 manufactured and sold by the Veeder Root
manufacturing company is satisfactory for this component. Counters
of this type generally comprise decade counters which provide a
visual indication of the count accumulated in the counters.
The electrical output signals derived from all the line
people-hours count signal-digitizing devices 23.sub.1, 23.sub.2,
23.sub.3, etc. also are supplied to an hours-worked per article
computing and readout machine shown at 26 and located in the
readout information station 11, in parallel with the counters 25.
Alternatively, for less elaborate installations, it is possible to
omit the articles per worked hour computing and readout machine 26
and perform the necessary division mentally from the reading of the
counters 25 and the reading of a plurality of articles completed
counters 26.sub.1, 26.sub.2, 26.sub.3, etc. to which are supplied
the output count signals derived from all of the packing area count
registering devices 13. The articles completed counters 26 may be
similar in construction to the counters 25.
The construction and operation of the line time controllers and
digitizers 23 will be described more fully hereinafter in
connection with FIGS. 2 through 6 of the drawings as will be the
line people-hours count registering devices 22. Similarly, the
construction and operation of the packing area count registering
devices 13, the loading area count registering device 17, the
construction of the conveyor 15, the unloading area count
registering device 19, the loading area counter 18 and the
unloading area counter 21 likewise will be described more fully
hereinafter in a more detailed manner. The articles per worked hour
readout machine 26 may comprise an on line, general purpose digital
computer for use in inventory control or the like which generally
can be found in more expensive and elaborate manufacturing
installations.
In addition to the above several subsystems, the article/time
recording system further includes a master time controller 27
located in control room 24 and a master time readout counter 28
located in the readout information station 11. The master time
controller 27 is similar in construction and operation to the line
time controllers and digitizers 23 and will be described more fully
hereinafter in connection with FIGS. 2 through 6. Similarly, the
master time readout counter 28 is similar to the counters 25 and 26
with the exception that it is capable of accumulating a much
greater count then are the counters 25 and 26. Also included in the
readout information station 11 is a total people working counter 29
which preferably is a reversible counter of conventional
construction. The total people working counter 29 and the master
time controller 27 are connected to and controlled by the output
from a time clock 31 that is located in an area where people going
to and coming from the assembly lines 12 are required to punch in
and punch out when going to and from their work stations at the
beginning and the end of each workday, and during the noon lunch
period.
The time clock 31 may comprise a conventional, commercially
available time clock such as the Simplex time recorder model No. 63
JD 8 manufactured and sold by the Simplex Time Recording Company.
However, it is preferred that the time clock 31 comprise a
specially designed time clock which is described more fully in our
copending U.S. application Ser. No. 705,262 entitled "Control
Circuit For Time Clock and Master Counter" filed Jan. 31,
1968--(concurrently with this application)-- David A. and Ralph W.
DeWitt, Inventors. The specially designed time clock and control
circuit described in our above-identified copending U.S.
application includes not only a means for punching-in and
punching-out workers at particular authorized times such as the
morning starting time, the noon lunch break, and the normal evening
quitting time, so as to add to or subtract from the total number of
people shown as being punched in and working in the facility at any
given time; but it also includes ancillary bypass punch-in and
punch-out means which are key operated for punching-in and
punching-out workers at other than the particular authorized times
at the discretion of a supervisor. The time clock circuit disclosed
serves to develop a number of electric output signal pulses which
correspond to the punching-in or punching-out of workers coming to
and leaving the manufacturing facility. These electric signal
pulses are supplied to the total people working counter 29 which is
a reversible counter and provides an instantly available count of
all time recorded people working in the facility at any given time.
These electric signal pulses also are supplied to the master time
controller 27 for controlling the master time readout count
accumulated by counter 28.
In operation, the article/time recording system shown in FIG. 1
functions in the following manner. At a predetermined time before
actual work is begun a warning signal is triggered by the time
clock 31. At this time, a device wired into the time clock actuates
and places the clock in a "punch-in" mode of operation in a known
manner. During this period, the workers to be assigned to the
assembly lines may punch their time cards, and proceed to their
various work assignments. At the exact time that work is to begin,
a second signal is sounded which is again controlled by the time
clock 31. At this time, the master time controller enables all of
the line time controllers 23.sub.1, 23.sub.2, etc. through a
connection 27' that includes suitable relay actuated contacts in
series with the power supply to the line time controllers, with the
relay actuated contacts being actuated by the master time clock
control circuit. Also, the special device in the time clock
actuated the clock mechanism so as to put the clock in a "no-punch"
mode. That is, after this time no further punching by the simple
process of inserting a time card into the clock, is possible, and
from this point on workers arriving to punch in will be considered
late for work. Since most manufacturing firms place their workers
on the assembly lines before the work signal, it is quite
difficult, along with all the other tasks that a supervisor has to
do during normal work operations, to place a late person on an
assembly line immediately. Since the worker must then stand and
wait, with this system the worker now waits without being punched
in and therefore he must wait on his "own" time and not the
company's. Thereafter, when the supervisor has a place on an
assembly line for the late worker, he can then bypass the
"no-punch" circuit with a key supplied to the supervisor for this
purpose, allow the worker to punch his time card, and then place
the worker at a particular place on an assembly line where he is to
be assigned.
Each time a worker punches in on the time clock 31 he is entered
into the article/time recording system, whether it be during a
regular "punch-in" period or with the "punch-in" bypass key, the
counter 29 in the readout room 11 advances by one count. Thus, the
counter 29 can supply at any time the total number of people
working in the facility at any given time, and hence the people to
be paid at this time. Concurrently with the actuation of the total
working counter 29, a stepping switch on the master time controller
27 (to be described more fully hereinafter) is advanced by one
count. At the time of the start work signal, all of the time of
those people punched into the clock starts to record on the master
time readout 28. This provides the readout of the total time of all
of the time recorded people working in the facility on the various
assembly lines 12. As workers are allowed to punch in by a
supervisor through the use of his key operated "bypass" of the
no-punch of the time clock, these workers times likewise will start
to be added to the total time being accumulated by the master time
readout counter 28.
At the noon lunch break normally occurring around 12 p.m., the time
clock 31 automatically changes to a punch-out mode during which
period workers can punch out automatically by inserting a time card
into the clock in a normal manner and thereby allow the workers to
punch out for their noon luncheon break. After a short interval of
time, it is preferable that the time clock again revert to a
no-punch mode of operation until the end of the noon luncheon
break, normally occurring around 12:30 p.m. At this time, the time
clock 31 again automatically goes into a punch-in mode during which
time workers can again punch-in their time card by merely inserting
the time cards into the time clock. Thereafter, the time clock
again reverts to its no-punch mode until the end of the work period
when the punching out process is again repeated. Each time that a
worker punches out, whether it is during the prescribed "punch-out"
period at noon or at the end of the workday, or whether it is a key
operated bypass form of punch-out with the assistance of the
supervisor, the reversible total people working counter 29 will
count down by one count for each worker punching-out, and
similarly, one worker will be subtracted from the total number of
workers times being registered in the master time controller 27 so
as to show on the master time readout 28. For a more detailed
description of the construction and operation of the time clock 31,
and particularly the means for punching-in and punching-out workers
at particular authorized times so as to add to or subtract from the
total number of people working in the facility at any given time
recorded on the total people working counter 29, as well as the
ancillary, key operated, bypass punch-in and punch-out means for
punching-in and punching-out workers at other than the particular
authorized times at the discretion of a supervisor, reference is
made to our above-identified copending U.S. application, Ser. No.
705,262.
After punching-in at the time clock 31, a worker is placed on one
of the five assembly lines 12, and at this time, a supervisor adds
one count to his line people-hours-count-registering device
22.sub.1, 22.sub.2, etc. which preferably also includes a readout
light located in the assembly line area to indicate to the
supervisor the total number of people working on that particular
assembly line. The line people-hours-count-registering device
actually is a pair of electric switches with one switch
representing a plus (+) and the other is representing a minus (-)
for adding to or subtracting from the number of workers indicated
by the readout light. Upon a worker being added, the plus (+)
switch is presses by the supervisor and will add one count to the
number indicated by the readout light in the assembly area, and
simultaneously will add one count to the number being readout by
the line time controllers and digitizers 23 located in the control
room 24 as will be described more fully hereinafter in connection
with FIG. 2 through 6. Similarly, if a worker is removed from the
assembly line, the supervisor merely actuates the minus (-) switch
so as to subtract one count from the number indicated on the
assembly line readout light, and simultaneously subtract one count
from the people-time count of the line time controllers and
digitizers 23. If it is desired to change a worker from one
assembly line to another assembly line, the minus (-) control on
the assembly line that he is leaving is depressed, and the plus (+)
control switch on the line that he is entering is actuated.
From the foregoing description, it will be appreciated that
whenever a plus (+) or minus (-) switch in the line people-hours
count registering devices 22, is actuated, two simultaneous events
take place. The number recorded in the readout light located in the
assembly line area is changed by adding or subtracting one digit
due to a stepping switch on the line time controllers and
digitizers 23 located in the control room 24 being stepped up or
stepped down, respectively. The stepping up or down of the stepping
switch also changes the people-hours count being recorded on the
counters 25 located in the readout information station 11. In
addition, preferred installations will include readout counters
shown at 32.sub.1, 32.sub.2, 32.sub.3, etc. located in the readout
information station 11 for a purpose to be disclosed more fully
hereinafter. Thus, if these counters are provided, a third event
will occur upon the line people-hours count-registering device 22
being actuated which results in changing the number indicated by
the readout counters 32 located in the information station.
Whenever the stepping switch on one of the line time controllers
and digitizers 23 is stepped up or down, that persons time on the
line begins to be either added or stops being recorded,
respectively to the total hours-worked time being recorded on the
counters 25 located in the readout information station 11. Hence,
it will be appreciated that at any time when a person is added or
subtracted from an assembly line, his time instantaneously begins
to be added to the total on the line he is assigned to, and ceases
to be recorded on the line at which he was previously working.
Completed Article Counting And Readout
The next important feature provided by the article/time recording
system of the invention is the exact tallying of all articles being
produced on each assembly line 12. This tallying of the articles
produced throughout the manufacturing facility, is accomplished in
three places; namely, in the packing area for each assembly line
with the packing area count registering devices 13, in the loading
area 14 with the loading area count registering device 17, and in
the unloading area or warehouse 16 with the unloading area count
registering device 19. The construction and operation of each of
the devices 13, 17, and 19 will be described more fully
hereinafter; however, it is important to note that the article
counts derived by these devices are supplied to counters in the
readout information room for producing a readily available
centrally located tally of all of the items produced and
subsequently handled in the manufacturing facility.
The count recorded by the packing area count registering devices 13
is supplied to respective central articles completed counting and
readout counters 26.sub.1, 26.sub.2, 26.sub.3, etc. located in the
readout information room 11. The loading area count derived by the
loading area count registering device 17 is supplied to the loading
area counter 18, and the unloading area count derived by the
unloading area count registering device 19 is supplied to an
unloading area counter 21 with both counters 18 and 21 being
substantially identical and located side by side in the readout
information station 11. It should be noted at this point that the
loading area counter 18 and the unloading area counter 21 located
in the readout information room may readily keep track of all the
packed articles moving from the loading area into the unloading
area by the conveyor 15. This also supplies a cross-check against
the counts obtained on the packing area counters 26 from all of the
unit assembly line readouts. This is achieved by designing counters
18 and 21 to include separate assembly line unit counters 1--5 for
providing a count of each separate type of article produced by the
respective assembly lines, as well as a total count of all articles
passing through the loading and unloading areas.
In operation, the article tallying portion of the article/time
recording system functions in the following manner. At the
beginning of the workday, or at the beginning of some other similar
period of work time, all of the unit meters are set at zero, and at
the end of the period, all to the articles produced during the
period are placed in the warehouse storage area. With these
operating conditions satisfied, the sum total on each assembly line
counter 26 should equal the total, for each item respectively, of
the unit meters 1--5 on the panels of the loading area counter 18
and the unloading area counter 21. Also, the total of all of the
assembly line readouts 26 together should equal the totals shown on
both the loading area counter 18 and the unloading area counter 21.
Should it prove desirable, it is also possible to have a pieces
produced per hour meter for each assembly line which can be made
visual to the workers on that line so that they can see how well or
how poorly they are producing as compared to a predetermined
standard. This can serve to keep up incentive and work interest. It
is also possible by means of suitably designed operational
amplifiers to convert the pieces per hour into a dollars and cents
cost, and read this particular value off on a suitable electrical
meter with an altered unit measuring scale.
From the foregoing description of the overall article/time
recording system, it will be appreciated therefore that the system
is capable of keeping an accurate count of every employee punching
into or out of work on a standard commercial time clock. The system
when properly operated by the line supervisors and packing station
operators keeps an accurate count of the total number of employees
on any assembly line, packing station, or any other type of
operation utilized by the manufacturing firm. It makes available at
any time, the total amount of accumulated worker time by those
employees on any of the above operations. It provides a direct
readout accurate to any desired decimal amount, of the total
accumulation of work time, on any operation by any number of
employees at any desired time of readout. In other words, the
readout is accumulated constantly and is instantaneously available.
The system also records all of the items or parts produced, in any
unit amount desired, that are or are not a direct result of the
manufacturing operations. In any case where the items produced are
a direct result of those operations, a cost control figure of units
per worked hour is readily available by simply dividing the total
number of units produced by the total number of worked hours
required to produce those units. This figure is available either
manually through division on the part of an operator assigned to
the readout information station, or it may be obtained electrically
through direct acting computation devices. Here again, this figure
is available on an instantaneous basis at any desired readout time.
The system can completely record all of the items passing out of
the manufacturing areas over a conveyor system into a storage area.
This can be done item by item again reading out in any unit
desired. Another important feature (to be discussed more fully
hereinafter in connection with FIGS. 2 to 6) is that the articles
placed on the conveyor, can be placed at random without any special
markings necessary on the items, and the system can be so set as to
not only count these items at random by units, but also sort them
by type of item into any combination desired. The system will
provide information as to how many people are being recorded for
pay purposes at any instant since they are being recorded by the
time clock. It will also tell one the total time being paid for at
any instant to any decimal figure desired. It will record the total
number of people and the amount of time being worked by these same
people on any particular operation. This provides an instantaneous
check of the time and people being paid for, for comparison to
particular job standards for the jobs at which these people are
working, and the time spent on the job. The system will aid in
obtaining good standard costs using standard units per worked-unit
of time and will also help in controlling production and evaluating
the advantages or disadvantages of different production techniques
on an "on the spot" instantaneous basis. It provides a record of
all of the units of a particular article produced, and supplies the
manufacturer with a triple check on this figure which is quite
important in obtaining accurate inventory records.
Line Time Controllers and People Time Count Signal Digitizing
Means
FIG. 2 of the drawings illustrates in greater detail the
construction of the line time controller and people time count
signal digitizing circuit for generating a series of pulsed
waveform electric signals wherein each electric signal pulse is
representative of a finite time period worked by one person on an
assembly line. It will be understood from a consideration of FIG. 1
of the drawings, that there is one such line time controller and
digitizer unit for each assembly line area, and further, that the
master time controller 27 will be built in a substantially similar
fashion, but must be designed to accommodate a greater number of
workers times since it is totalizing the time for the entire
manufacturing facility. The particular line time controller and
digitizer shown in FIG. 2 and described in greater detail in
connection with FIGS. 3 through 6, is designed to accommodate an
assembly line having from 1 to 21 persons working on it. However,
the principles here disclosed are in no way restricted to these
particular numbers, and may be applied to the design of any desired
type of control and digitizer to accommodate either greater or
smaller numbers of persons. It is anticipated that in the design of
the master time controller, such modifications are required in
order to accommodate the total number of people working on all of
the lines. The principles applied to the design of the individual
assembly line time controllers and digitizers, however, may be
applied in constructing the master time controller.
Each of the line time controllers and digitizers is comprised by an
electromechanical timing wheel shown in FIGS. 3, 3A and 3B, and to
be described more fully hereinafter, which operates to actuate a
plurality of microswitches mounted around its periphery at unique
time intervals. These microswitches are shown as microswitch
section at 41 in the electrical wiring diagram of FIG. 2. The
output from the timing wheel microswitch section 41 is supplied
through a multiprong connector 42 to a bank of isolating diodes 43
which serve to interconnect the fixed contacts of a stepping switch
44 through a connector plug 45 to selected ones of the plurality of
timing microswitches in the microswitch section 41. The diode bank
43 serves to isolate all save particular ones of the outputs of the
several microswitches in the microswitch section 41 from the fixed
contacts of the stepping switch in order that the fixed contacts of
the stepping switch 44 have applied thereto characteristic numbers
of electric signal pulses. The interconnection of the diode bank 43
through the intermediary of the connecting plugs 42 and 45 to the
respective timing microswitches 41 and stepping switches 44 is best
illustrated in FIG. 4 through 6 of the drawings.
Referring to FIG. 4 of the drawings, it will be seen that in the
particular embodiment of the invention described, the timing wheel
microswitch section 41 is comprised by eleven microswitches
41.sub.1, 41.sub.2, 41.sub.3, etc. mounted around the periphery of
a timing wheel in the manner shown in FIGS. 3, 3A and 3B. These
microswitches may be conventional, commercially available
alternating current microswitches such as are manufactured and sold
by the Micro Switch Corporation, model No. V3L-5-V8, or some
similar microswitch structure. One side of all of these switches is
connected to the respective output terminals 1 through 11 of an
output connector plug 42. As shown in FIG. 5, connector plug 42 has
its terminals connected in the manner shown to certain ones of the
terminals 1 through 21 located on one side of a wiring board 43 to
which the respective isolating diodes 43A, 43B, etc. that make up
the bank of isolating diodes 43, are connected. FIG. 5A of the
drawings illustrates the back side of the diode board, and FIG. 5B
illustrates the terminal connections of the plug 45 that connects
the output of the diode bank 43 to the stepping switch 44.
FIG. 6 of the drawings illustrates the manner of interconnecting
the connector plug 45 to the fixed contacts of the stepping switch
44 which may be of the type manufactured and sold by
Telecommunications Ltd. under the trademark "Bothway Selector" type
U-3314-E. Each prong of the plug 45 is connected to a respective
terminal of bank 3 of the stepping switch shown in FIG. 6. In banks
2, contacts 1--9 are open-circuited, contacts 10--19 are connected
to prong A of plug 47, and contacts 20 and 21 are connected to
prong B. The prongs A and B when energized by wiper contact 2 of
the stepping switch light a "period" on the left or right side 2
respectively of the numbers on the number lights 57 and 58. The
lighted period on the left of the numbers 0--9 indicates that the
number is preceded by a "1", hence equal to 10--19, and the lighted
period on the right indicates a "2" in the first digit, and hence
equal to 20 and 21. This is a cost saving feature, and if desired,
A and B could be employed to light up digit numbers 1 and 2
provided for this purpose. Bank 1 of the stepping switch is wired
in the following manner. Contacts 1, 11 and 21 are in series with
prong 1 of plug 47. Contacts 2 and 12, 3 and 13, 4 and 14, 5 and
15, 6 and 16, 7 and 17, 8 and 18, 9 and 19 and 10 and 20 are all
connected to prongs 2--10 of plug 47, respectively. These
connections are depicted by the boxes to the left of the contacts
of bank 1. Each box is numbered and employs arrows to indicate
connections to and from correspondingly numbered contacts with like
numbers being connected to each other in a series circuit
arrangement.
FIG. 6A of the drawings illustrates the wiring connection to the
stepping coil for the stepping switch 44. It will be seen from FIG.
6A and FIG. 2 that opposite terminals of the stepping coil are
connected through a suitable two prong connector 48 back to a pair
of add (plus) and subtract (minus) microswitches 49 and 51,
respectively, which comprise the line people-hours
count-registering devices 22 located in each assembly line area 12.
The middle or third input terminal to the stepping coil is
connected back to a 24-volt of direct current power 52 which is
excited from a conventional 110-volt, 60 cycles AC power
source.
As is shown in FIG. 2, the output from the 24-volt DC power source
is supplied through a 12-volt DC to DC converter 53 of conventional
construction, and hence through a single prong connector plug 54 to
one of the brush terminal connections of the stepping switch 44 in
the manner shown in FIG. 6B of the drawings. The remaining input
terminal of the brush connections for stepping switch 44 are
connected back through a single prong plug connector 60 (p-5), and
through a people-hours counter 25 to the opposite side of the
24-volt DC source 52. By connection in this manner, the brushes of
the stepping switch 44 will be excited with only a 12-volt DC
potential instead of the 24-volt DC potential that is used to
excite the stepping coils by means of the interconnection shown in
FIG. 6A and the add or subtract switches 49 or 51, so as to prolong
their operating life.
Referring back to FIG. 2 of the drawings, it will be seen that the
add and subtract microswitches 49 and 51 that comprise the line
people-hours-count-registering device 22 are excited from the
24-volt direct current power source 52 through an add switch
counter 55 and a subtract switch counter 56, respectively. The add
and subtract switch counters 55 and 56 comprise the line unit
counting and readout devices 32 located in the readout information
station for providing to this central monitoring point a permanent
record count of the number of people working on any given assembly
line at a given time. This number is obtained by subtracting the
subtract count shown on counter 56 from the add count shown on
counter 55. The counters 55 and 56 as well as the people-hours
counter 25 all comprise conventional, commercially available direct
current counters of the type manufactured and sold by the Veeder
Root manufacturing company, and identified as the type 19835-006
counter. It is also desirable to include a separate "downtime"
people-hours counter 25 in some installations where it is necessary
to keep separate records of "standard" work time and "downtime" of
the assembly lines or other working station whose time is being
accumulated. For this purpose, either the "standard" people hours
counter 25, or the "downtime" people-hours counter 25a is
selectively activated by a relay 25b controlled from a selector
switch 25c located at the assembly line area. The switch 25c is
controlled by a line supervisor to indicate that the people-time
being counted is applied either to standard work or is being wasted
in downtime. At this point, it should be noted that the people-time
should not be construed as limiting the disclosure to the count of
man-hours worked, but should be considered generically as applying
to machine-hours, plane-hours, etc. where the system might be
employed to measure the unit-hours of operation of any device or
mechanism, or combinations thereof. It should be noted at this
point, that although the brushes of the stepping switch 44 are
excited with only a 12-volt direct current potential, the readout
of the stepping switch utilizes the 24-volt DC potential due to the
manner which the people-hour counter 25 is connected to the readout
terminals. If desired, the add and subtract counters 55 and 56
could be replaced with a more expensive, reversible counter,
however for purposes of economy the arrangement described is
preferred.
In addition to the count tabulated by the counters 55 and 56, the
output count indicating signals derived from the stepping switch 44
through the connector plug 47 is supplied back to a number
indicating lighting board 57 located in the assembly line area 22
and is also supplied back to a second number indicating lighting
board 58 located in the readout information station. The inclusion
of these number indicating lighting boards 57 and 58 provides to
the supervisor in the assembly line area 22 a readily perceived
indication of the number of people which the article/time recording
system had indicated are working in his area. In addition, it
provides a cross-check on the count being accumulated by the
counters 55 and 56 to the person in the readout information station
for monitoring purposes.
FIGS. 3, 3A and 3B of the drawings illustrate the construction of
the timing wheels and the manner in which the several microswitches
41.sub.1, 41.sub.2, 41.sub.3, etc. are mounted around the periphery
of this assembly. The main body of the device is a frame comprised
by a backing member 61 which is connected to a front web 62 by a
plurality of brackets 63. A conventional, commercially available
synchronous electric motor 64 (such as the Hurst--Model No. GA
1RP=synchronous motor) is mounted on the backing member 61 along
with a suitable reduction gear assembly 65. The front web 62 is
used to support the microswitching elements 41.sub.1, 41.sub.2,
41.sub.3, etc. In the center of the front web there is a bearing
for a main shaft which rotatably supports a circular plate or
rotating member 66 containing two circumferentially spaced series
or rows of actuating pins 67 and 68. The inner set of five
actuating pins are circumferentially arranged to engage and actuate
the single microswitch 41.sub.1 located on the inner portion of the
web 62. The outer row of 10 circumferentially arranged actuating
pins 68 are arranged to contact and actuate the remaining
microswitches 41.sub.2 through 41.sub.11. The rotating member 66 is
driven by the synchronous motor 64 which is a one revolution per
minute synchronous motor geared down through the gearing assembly
65 to rotate the rotating member 66 at a speed of one-third
revolutions per minute.
In the following discussion, the concentric series of pins and
switches will be referred to as rows of pins and switches. Each
switch consists of an actuator arm and three contacts (normally
open, normally closed and common). When any pin in a row comes in
contact with the actuator arm, the switch makes and breaks a
circuit. The switches are so spaced on the supporting web in a
manner such that no two switches are actuated at the same time. In
the particular embodiment of the invention disclosed, there are 11
such switches, with one switch being located in the first row and
10 switches in the second row. The output of all the switches are
arranged so that when the rotating member 66 completes one
revolution, the microswitch in the first row produces five electric
signal pulses, and each microswitch in the second row produces 10
electric signal pulses. THis is due to the fact that in the first
row there are five actuating pins and one switch and in the second
row there are 10 pins and 10 switches. Thus, with the rotating
member 66 turning at a speed of one-third revolutions per minute,
this results in five switches for each 3 minutes or 100 switches in
1 hour for the switch in the first row. This is analogous to one
persons registered time in hundreds of an hour per switch. In the
second row there are 10 switches and 10 pins. Thus, there are 10
switches produced by each microswitch in the second row in every 3
minutes or 200 switches for each switch in 1 hour. This is
analogous to two persons recorded time in hundreds of an hour.
From the foregoing description, it will be seen that each switch in
the first row represents one persons recorded time and each switch
in the second row represents two persons recorded time. Since the
impulses from these switches do not overlap, then the combination
of the outputs of all the switches would equal the recorded time of
21 people. Thus, by using appropriate various combinations of the
output from these switches, any number of recorded peoples time
from 1 to 21 can be obtained. By wiring the output of these
switches through the diode bank 43, any desired number of switch
outputs can be isolated. The wiring of the diode bank is shown in
greater detail in FIG. 5 of the drawings. As will be appreciated,
the output from this diode bank can be taken at any one of 21
different junctions which is representative of 21 different switch
combinations required for recording the time of from 1 to 21
people.
This timing wheel switching arrangement may also be expanded to
record any number of peoples times. About the only limit is the
size of the rotating member and the frame and also the placement of
the switches. Since each switch must be actuated at a unique
instant of time, the angle at which each switch is placed becomes
critical as the number of switches increases. Another limiting
factor is the time and distance of travel needed for mechanical
actuation of the switch arm itself. A solution to these problems
would be to provide some form of nonconducting disc using a
conducting disc below it and a concentric series of holes (instead
of pins) and a circumferentially arranged series of brushes for
establishing the desired electrical pulse producing circuits.
Another arrangement would be to employ a series of concentric
photoelectric cells using a perforated disc between the cells and a
light source. Thus, the photocells would be activated each time
that the light beam from the light source was uninterrupted. By
these or other similar arrangements, the capacity of the timing
wheel can be greatly increased to accommodate large numbers of
people.
In operation, the line time controllers and digitizing circuits
shown in FIGS. 2 through 6 of the drawings operates in the
following manner. At the time that a worker is assigned to a
particular assembly line and goes into the assembly line area, a
supervisor for the assembly line actuates the add switch 49.
Actuation of add switch 49 causes the stepping coil of stepping
switch 44 to step the brushes of the stepping switch up one count.
This results in connecting the output of the output of the
microswitch 41.sub.1 that produces 100 electric signal pulses per
hour to be supplied to the people-hours counter 25. Concurrently,
the number indicating lights 57 and 58 to are energized show that
one person has been added to the assembly line. When the next
worker arrives, the supervisor again actuates the add switch 49 to
cause the stepping switch 44 to be stepped to its number 2 contact.
The number 2 contact would be connected to the output of one of the
microswitches such as 41.sub.2 in the outer row that produces 200
electric signal pulses per hour and is representative of the worked
time of two workers. Similarly, when the third worker arrives the
stepping switch will connect both the microswitch 41.sub.1 and the
microswitch 41.sub.2 to the people-hours counter 45 to provide it
with 300 electric signal pulses per hour. This process is continued
until the assembly line is entirely staffed. Should it prove
necessary to remove one of the workers, all the supervisor needs to
do is to actuate the subtract switch 51. This will then cause the
stepping switch to be stepped down one unit count and this fact
will be recorded on the subtract switch counter 56 as well as on
the number indicating lights 57 and 58. It will be appreciated
therefore that the line time controllers and digitizers in effect
convert the unit count to be added or subtracted signal derived
from the switches 49 and 51 in the assembly line area into a series
of digitized electric signal pulses representative of people-hours
measured in one/one hundredths of an hour.
Packing Area Counting and Readout Device
At the end of each assembly line, as the completed article leaves
the assembly line, it is generally packed into a container usually
in some predetermined quantity such as one per box, one half dozen
per box, one dozen per box, etc. When each container is closed, a
special piece of "control tape" is placed on it in a predetermined
location on the container. In order for the packer to obtain this
"control tape" a conventional, commercially available
electromechanical dispensing and counting apparatus is employed.
This apparatus may be any one of a number of commercially available
dispensing and preset count, counting mechanisms wherein the preset
count is one. Actuation of the tape dispenser to issue one piece of
`control tape` causes the counter registering device to register
one count in the unit counters 26.sub.1, 26.sub.2, 26.sub.3, etc.
located in the readout information room. If desired, the count may
also be recorded on a suitable indicating dial located in the
packing area.
In addition to registering a count for each piece of `control tape`
issued, the dispenser activates a visual or audible signal which is
locked "on," and is not turned "off" until the packer places the
container in a specified area (such as a loading platform or on the
loading section of a conveyor), and then presses a second control
switch which will deenergize the visual or audible alarm. This
second control switch preferably also is used to control the
dispenser which is designed so that it is locked out and cannot
dispense another piece of control tape until such time that the
second control switch is actuated thereby indicating that the
packer has placed the container in the specified area. This is a
safety feature which diminishes the possibility of a packer placing
two pieces of control tape on one package, and thereby botching up
the count of the number of articles coming off the assembly line.
It also makes it mandatory for the packer to place each container
in the specified area. The count provided by the packing area
counting and readout means then gives a running and instantaneous
count of the number of articles produced by each assembly line.
This figure coupled with the total worked time on each line as
indicated by the meter 25 for that particular line, will then
supply the instantaneous pieces per unit per person-hour rate which
can be compared against a standard. The desirability of having this
figure on an instantaneous demand basis has been pointed out
above.
Loading Area Count and Readout
As is illustrated in FIG. 1 of the drawings, the next article count
to be obtained following the packing area count, is that derived in
the conveyor loading area 14 by the loading area count registering
device 17. This count is obtained automatically by an operator
loading the conveyor 15. A standard roller or belt-type
electromechanical powered conveyor is used in conjunction with a
gravity operated loading area portion employing a special circuit
such as that shown in FIG. 7 of the drawings. Referring to FIG. 7,
each container of completed articles is loaded by placing the
container on an inclined, unpowered, roller (loading) section of
the conveyor shown generally at 71. Thereafter, the container will
roll down until it encounters the activation arm or trigger arm 72
of a microswitch 73 for deriving a count of the articles loaded on
the conveyor. The trigger arm 72 is placed in the center of the
conveyor and is pivotally mounted with a spring return so that it
always returns to a normal inactive position where it will be
contacted by the next container passing over the loading section of
the conveyor. The unpowered, gravity operated loading portion of
the conveyor is placed immediately adjacent to a powered section 74
in a manner such that a container traveling down the gravity
operated portion will slide onto and engage at least a part of the
powered portion of the conveyor while simultaneously depressing the
trigger arm 72.
The powered conveyor portion shown generally at 74 is designed so
that it runs only when the switch arm 72 is depressed. Therefore,
as a container moves past and depresses the switch arm 72, the
powered section of the conveyor is activated so as to withdraw the
container off of the count registering trigger 72, and onto the
power driven portion of the conveyor a sufficient distance to
assure return of the trigger 72 to its normally inactive position
thereby recording one count while simultaneously loading the power
driven portion of the conveyor with one completed article. Upon
this occurrence, the powered portion of the conveyor will again
stop due to the trigger 72 no longer being depressed. It will be
seen therefore that as each container is placed on the loading
position 71 of the conveyor, the powered section 74 inches forward
only enough to accept each container that passes the trigger arm
72. Concurrently with this action, activation of the switch 73 by
the trigger arm 72 operates to record one count in the loading area
counter 18 located in the readout station 11. If desired, a similar
counter may be activated in the loading area to indicate to the
loading operator that the container has been properly counted and
recorded.
Another safety factor which is built into the article/time
recording system is to protect against two or more containers being
counted as one by the trigger arm 72. This is possible because if,
for example, two containers are placed on the loading portion 71 of
the conveyor back to back, trigger arm 72 will be depressed and
power section 74 activated. As the first container moves into the
powered section, the second container (being back to back against
the first) does not allow the trigger arm 72 to return to its
normally inactive position, which is required in order to record a
count for the second container. Consequently, the loading area
counter would record only one unit count instead of two. To prevent
this occurrence, a count assuring, cylinder actuated, stop shown at
75 and having a stopping arm 76 is provided. The cylinder actuated
stop 75, 76 is activated by the switch 73 so that the stopping arm
76 is raised to prevent containers moving down the loading section
71 in back-to-back fashion. Therefore, during the time that a
container is on the trigger arm 72, no other container may enter
the area (at a predetermined distance) in front of the arm 72
without being stopped by the extended stop arm 76 of cylinder 75.
Since in most manufacturing firms, the length of the containers
will vary widely, a number of such stops are required at various
positions in the unpowered section 71, the activation of which is
determined by a selector switch to be described more fully
hereinafter.
Referring again to FIG. 1 of the drawings, it will be seen that the
loading area counter 18 located in the readout information station
11 has on its face a plurality of dials indicated as numbers 1
through 5 together with a total dial. Each of these dials 1 through
5 comprises a separate meter which may be selectively activated by
a selector switch arm, the setting of which is determined by the
setting of an identical counter located in the loading area 14.
This setting adjustment is made by the loading operator in
accordance with the type of article being loaded. Hence, it will be
appreciated that each meter 1 through 5 will represent the total
number of a given type of article or container being loaded. The
fact the 5 meters are used is purely for explanatory purposes since
there may be any number of meters to correspond to the number of
different items being produced by the assembly lines being
serviced. With this arrangement, if the loading operator decides to
load containers of item number 3 for example, he sets the selector
switch to the unit meter representing item number 3. Thereafter,
each time that the trigger arm 72 and switch 73 are actuated in the
loading area, one unit count will be added to the count accumulated
on the unit meter 3. Also, one count is added to the total units
out of the loading area meter shown in the lower portion of the
counter 18. It will be seen therefore that as each different item
is loaded onto the conveyor, the selector switch is changed to
record the total number of each different type of article or
container being loaded, and that the lower totaling meter will
provide a total count of all of the articles or containers being
processed through the loading area.
It should also be noted at this point that the selector switch arm
for the loading area counters also activates the previously
mentioned differently positioned stopping arms 76 for accommodating
different length containers of completed articles. It will be seen
therefore that as each different item is loaded onto the loading
portion 71 of the conveyor, the selector switch is actuated by the
loader-operator so as to count and record separately the total
number of this particular type of container being loaded, and that
the selector switch also selects which particular stopping arm 76
will be actuated so as to accommodate the particular size container
for the type of article being loaded.
Unloading Area Counting and Readout
Another control feature made available by the article/time
recording system of the invention is the provision of an unloading
area counting and readout means for deriving a count of the
completed articles being transported to an unloading area from the
manufacturing facility. As is best seen in FIG. 1 of the drawings,
this unloading area is located at the discharge-unloading end of
conveyor 15 and comprises an unloading area count registering
device 19. The count registering device 19 may comprise any form of
electric switch for producing one electric signal pulse for each
container or article coming into the unloading area. However,
preferably the device 19 comprises a counter similar to the loading
area counter 18 described previously for accommodating different
types of articles being processed through the unloading area. It is
also preferable that the device 19 comprise an automatically
triggered counter mechanism such as the trigger actuated switching
arrangement 72, 73 shown in FIG. 7. This arrangement may be mounted
on an unpowered, gravity operated discharge-unloading portion of
the conveyor mechanism for automatically recording one count for
each container supplied to the unloading portion of the conveyor.
If a multitype counter 21 is used as the unloading area counter in
the readout information station 11, a similar multitype counter
will be employed as the unloading area count registering device 19.
With such an arrangement, all that the unloader-operator has to do
is to change the position of the selector switch to identify the
particular type of article being unloaded, and the count for such
article will be registered on his own and on the unloading area
counter 21 in the readout information station 11. Concurrently, a
totalized count of all containers passing through the unloading
area will be registered on the total count appearing in the lower
portion of the counter 21.
FIG. 8 of the drawings illustrates in sectional view the discharge
unloading portion of the conveyor 15 wherein the count registering
trigger arm is shown at 81 for actuating a microswitch 82 that
records the count of a container passing through the unpowered,
gravity operated roller section 83 supplied from the powered
section 74 of the conveyor. Thereafter, a container passing through
the unloading-discharge portion of the conveyor rolls onto a
section 84 which may be either gravity operated or a powered
section. This section includes at least one overdelivery sensing
and inactivating control means for sensing a buildup of unloaded
containers being delivered to the discharge-unloading portion above
a predetermined number, and for inactivating the power driven
portion 74 of the conveyor mechanism in response to this buildup.
This overdelivery sensing and inactivating control is comprised by
a series of limit switches 85 and 86 which control the power
operated section 74 of the conveyor. This protective feature is
provided in order to enable an operator-unloader to remove the
containers from the section 84 without fear of the containers being
put on by the loading area operator so fast that they pile up in
the unloading area. The limit switches 85 and 86 are spaced farther
apart in distance than the longest container to be processed.
Therefore, if the containers start to pile up at the
unloading-discharge end of the conveyor, then either one, or both
of the limit switches 85 and 86 will be depressed so as to
deenergize the powered section 74. Whether one or two of the limit
switches 85 or 86 is employed is determined by the degree of
buildup that will be tolerated before the limiting action is
introduced. Upon the powered section 74 being thus deenergized by
either or both of the limit switches 85 and 86, the stop 76 at the
loading end will automatically be raised by cylinder 75 so that no
further containers may be loaded onto the conveyor until the limit
switches 85 and 86 are again cleared.
As stated previously, in the readout information station 11 there
is located all of the counters and meters employed in the
article/time recording system. This enables one man in the readout
information station to keep track of all of the information
necessary to obtain the desired cost accounting information in
controlling the operations of the manufacturing facility. By
reading the loading area counters 18 and the unloading area counter
21 it is possible for him to keep track of all of the containers
moving from one area of the plant to another. It also provides a
check against the counts that are obtained from the unit line
readouts 26 on a continuously updated substantially instantaneous
basis. Under normal operations, at the beginning of any one work
day or other work period of time, all the unit meters are set to
zero and all the containers made during that period are placed in
the storage area at the end of the period. Under these conditions,
the sum total on each unit line readout 26 should equal the total
for each item respectively of the unit meters on the loading area
and unloading area counters 18 and 21, respectively. Also the total
of all the unit line readout 26 should equal the total counts shown
on both the loading area counter 18 and unloading area counter
21.
From the foregoing description, it will be appreciated that the
present invention provides a new and improved article/time/persons
working recording system for manufacturing facilities which provide
a central, continuously updated running account of all people-hours
worked in the facility in a given interval of time, the number of
people working and the number of articles produced whereby an
accurate and readily obtained up-to-date figure for the numbers of
articles produced per worked hour and/or the number of articles
produced per person, is instantaneously available for accounting
purposes at any time during the work day or at the end of the
day.
Having described one embodiment of a new and improved
article/time/persons working recording system constructed in
accordance with the invention, it is believed obvious that other
modifications and variations of the invention are possible in the
light of the above teachings. It is therefore to be understood that
changes may be made in the particular embodiment of the invention
described which are within the full intended scope of the invention
as defined by the appended claims.
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