KOTWAL, Rupesh, Vasant (A-41 Shivtrith Apartment, N°Suhasini KaryalayaVadagaon Dhayri,Shingad Rd, Pune 1, 41104, IN)
KOTWAL, Rupesh, Vasant (A-41 Shivtrith Apartment, N°Suhasini KaryalayaVadagaon Dhayri,Shingad Rd, Pune 1, 41104, IN)
| We Claim: 1. A method for measuring and analyzing the production data directly from machines comprising : a. measuring the parameters relating to machine and parameters of the process to be carried on by machine from a single input which decides product quality; b. storing values of parameters measured for the analysis purpose; c. providing standard values of said parameters being provided by the user; d. comparing said standard values and the measured values of the parameters for checking performance of machine and consistency in product quality; e. deciding whether the machine performance and product quality and quantity are consistently maintained to required standards; and f. displaying the standard values and measured values of said parameters, and decision taken in respect of machine performance and product quality. 2. The method for measuring and analyzing the production data directly from machines as claimed in claim 1 wherein measurement is done in real time environment. 3. A system for measuring and analyzing the production data directly from machines comprising: a measuring system comprising of a single input being connected to at least one machine for measuring and recording of the parameters relating to machine and parameters of the process to be carried on by machine; processing unit for receiving the measurements of the said parameters taken and recorded by measuring system and to decide whether machine performance and the product quality are consistently maintained to required standards, said processing unit comprises: - second memory for storing the standard values of said parameters set by the user; - data receiving unit to receive the measurement of parameters taken and recorded by measuring system; - comparator to compare the parameters received by data receiving unit and the standard values of parameters stored in second memory and to decide on the basis of said comparison the performance of machine and consistency in product quality; - first memory to store the measurements of parameters taken and received by measuring system and decision taken by the comparator for future reference; Display unit to display: - the standard values of said parameters set by the user, - measurements taken and recorded by measuring system, - Decision taken by the comparator. 4. The system for measuring and analyzing the production data directly from machines as claimed in claim 3 wherein measuring system includes plurality of sensors. 5. The system for measuring and analyzing the production data directly from machines as claimed in claim 3 wherein parameters relating machine includes ON/OFF timing of machine parameter or process. 6. The system for measuring and analyzing the production data directly from machines as claimed in claim 3 wherein data receiving unit receives the measurement of parameters taken and recorded by measuring system in real time. 7. A method for measuring and analyzing the production data directly from machines as herein before described and illustrated with reference to accompanying drawings. 8. A system for measuring and analyzing the production data directly from machines as herein before described and illustrated with reference to accompanying drawings. |
FIELD OF INVENTION:
The present invention relates to a method and system for monitoring the industrial processes and to generate the reports accordingly. More particularly it relates to a method and system for measuring and analyzing the production data directly from machines to evaluate machine performance and product quality and quantity.
BACKGROUND AND PRIOR ART:
In the present era of rapid industrialization and growing competitive environment, it becomes necessary for every industry to provide a quality product to the customer at reasonable price. In order to achieve this, in the industry, the continuous monitoring and analysis of the manufacturing process and manufacturing product is must. Currently this is done by collecting the production data or by higher end data collection system, which communicates only with CNC/PLC Control machines and in conventional machines, by educated personnel physically going to each and every machine in a specific interval and noting it in a manual document. Later this data is fed in the computer for further analysis and corrective action taken accordingly. The drawbacks of the aforementioned data collection system are as follows: i. Higher end data collection system is very expensive and can only communicate with CNC/PLC Controllers. ii. There is a huge scope of manipulation, mistakes and time variation in manual system. iii. Delay done by machine and operators cannot be monitored in manual system. iv. There is always possibility of human error while noting down the data. v. In case of multiple machines extra resources are required. vi. There is a huge time gap between the collection of data and analysis resulting in the delayed corrective action in manual system. vii. Wasted /Delayed time by operators on the machine cannot be ascertained. viii. Manual analysis of data takes huge time and resources. ix. SPC techniques cannot be used automatically for conventional machine. x. material consumption can not be tracked online xi. operator efficiency cannot be ascertained xii. multiple machines status can not be viewed at a glance. xiii. Remote online viewing is not possible in manual system .
Due to aforesaid disadvantages, the current data collection and analysis system fails to ensure that product quality is consistently maintained to required specification. Hence there is a need of a system which will be free from the deficiencies associated with current data collection and analysis system and which can forecast deteriorating quality breakdown of machines.
OBJECT OF THE INVENTION;
The primary object of the present invention is to provide a system for data collection and analysis, which will overcome the drawbacks associated with the system as discussed in the prior art.
Another object of the present invention is to provide a method and system for measuring and analyzing the production data directly from machines.
Another object of the present invention is to provide a system for measuring and analyzing the production data directly from machines to ensure that product quality and quantity is consistently maintained to required standard.
Yet another object of the present invention is to provide a system for measuring and analyzing the production data directly from machines, which provides authentic and unbiased data online. Yet another object of the present invention is to provide a system for measuring ana analyzing the production data directly from machines that is economic and applicable to all kinds of cyclic production machines.
Yet another object of the present invention is to provide a system for measuring and analyzing the production data directly from machines, which performs the measurements and analysis in the real time and online basis.
SUMMARY OF THE INVENTION;
Accordingly to achieve the aforementioned objects present invention provides a method for measuring and analyzing the production data directly from machines comprising:
a. measuring the parameter deciding the product quality carried on by machine using a single input; b. storing values of parameters measured for the analysis purpose; c. providing standard values of said parameters being provided by the user; d. comparing said standard values and the measured actual values of the parameters for checking performance of machine and consistency in product quality; e. deciding whether the machine performance and product quality are consistently maintained to required standards; and f. displaying the standard values and measured values of said parameters, and decision taken in respect of machine performance, product quality, operator performance, raw material consumption and such like.
Present invention also provides a system for measuring and analyzing the production data directly from machines for implementing the method of present invention. The system for measuring and analyzing the production data comprises: a measuring system comprising of a single input being connected to at least one machine for measuring and recording of the parameters relating to machine and parameters of the process to be carried on by machine; processing unit for receiving the measurements of the said parameters taken and recorded by measuring system and to decide whether machine performance and the product quality are consistently maintained to required standards, said processing unit comprises:
- first memory for storing the standard values of said parameters set by the user;
- data receiving unit to receive the input to measure the parameters and records;
- comparator to compare the parameters received by data receiving unit and the standard values of parameters stored in first memory and to decide on the basis of said comparison the performances of machine and consistency in product quality and quantity;
- second memory to store the measurements of parameters received by data receiving unit and decision taken by the comparator for future reference, report generation and analysis;
display unit to display:
- the standard values of said parameters set by the user,
- measurements taken and recorded by measuring system,
- decision taken by the comparator.
- Charts and graphs
- Reports Analysis
- Warnings (in the form of color code)
- Process capability (CpCPK)
- Schedule quantity, Balance Production quantity.
- Ideal Cycle Time
- Online station of machine
- Online station on machine - Operator Name
- Product Name
- Delay Time (Operator delay, down time)
- Shift wise total quantity produced(Ok Quantity, Rejected Quantity)
BRIEF DESCRIPTION OF DRAWINGS:
Figure 1 : Shows the block diagram of the system for measuring and analyzing the production data directly from machines in accordance to the present invention. Figure 2 : Shows the flow diagram illustrating method of measuring and analyzing the production data directly from machines in accordance to the present invention. Figure 3 : Shows the flow diagram illustrating method of analyzing the machine performance, product quality and productivity on the basis of various parameters of the machine measured during the operational state of the machine. Figure 4 : Shows the flow diagram illustrating method of analyzing the machine performance, product quality and productivity on the basis of ON/OFF period of the machine. Figure 5 : Shows the flow diagram illustrating method of analyzing the machine performance, product quality and productivity on the basis of various parameters of the process to be carried on by machine.
DETAILED DESCRIPTION OF THE INVENTION:
The above, and the other objects, features and advantages of invention will become apparent from following description read in conjunction with the accompanying drawings.
Referring to figure 1, system for measuring and analyzing the production data directly from machines in accordance to present invention is shown. This system can be connected to all kinds of cyclic production machines, from conventional, manual up to latest CNC control without modification in existing system. This system is online, which collects the actual data directly from the functional output of the machine which decides the quality status. Using internal statistical process control technique to display, process capability can be viewed online which helps in getting process capability figures. Online rejection status can be reviewed and online production data can be seen using such system.
This system is used for multiple machine monitoring in parallel even with single input from each machine. In one embodiment of the invention, the method and system comprises measuring the parameter deciding the product quality carried on by machine using more than a single input.
The system of the present invention is basically utilized for following purposes: i. To establish process capability of machines . ii. To compare the performance of the machine and quality of product against the standard performance and quality being decided by the user, iii. To evaluate machine efficiency, iv. To evaluate the performance of a machine before and after its repair v. To manage and improve the machine performance and processes carried on by such machine to ensure consistency in product quality. vi. To evaluate worker performance on a machine, vii. To generate data regarding power consumption of a machine, viii. To evaluate material consumption in Ok production quantity, rejected quantity, scrap generated ix. To evaluate operator delay, machine down time x. To evaluate balance quantity Vs scheduled quantity xi. To take corrective action as process is in progress to ensure product compliance to pre-established parameters xii. To utilize the data generated by the system to ensure product quality
As shown in figure 1, the system for measuring and analyzing the production data in accordance to present invention comprises measuring system, processor, output unit and display unit.
This measuring system is connected to the machines to be analyzed and the processor unit. It mainly consists of plurality of sensors to measure the parameter of machine and parameters of the processes carried on by the machine. Such data relating to parameters measured by the measuring system is taken by processor unit for the analysis purpose. The data collected using a measuring system is used to monitor machines and processes carried on by such machines, in estimating the existence of relationship between variables that can affect the outcome of a machine performance and processes and to conduct analytical studies to increase the knowledge about the system of causes and its effect on performance and processes. Further, the system works on the principle of taking preventive action. Data collected aids operator to prevent further rejects and give quality and consistent output as desired.
The processor unit consists of first memory, data receiving unit, comparator and second memory. The data receiving unit receives the parameters measured by the measuring system in real time environment. The second memory stores the standard values of the parameters, which are provided by the user. The comparator of the processing unit receives data relating to parameters from both second memory as well as first memory. Then comparator compares both data and decides whether parameters measured from the machines and standard parameters provided by the user are same or different and accordingly decides the machine performance and product quality. Such decision taken by the comparator and the data received by data receiving unit are stored in the second memory for the purpose of future reference for taking any correctional measures and generations of reports. The display unit displays the standard values of said parameters set by the user, measurements taken and recorded by measuring system and decision taken by the comparator. The online display unit helps the user to view analyzed status of all the machines at a glance. Output given to machines helps operator to get online status of product and machine. Now referring to figure 2, method of measuring and analyzing the production data directly from machines is shown in flow diagram form. As per the method firstly the parameters relating to machine and parameter deciding product quantity of the process to be carried on by machine are measured. The measured values are then stored for analysis purpose in the memory device. There after the standard values of the parameters and the measured values of the parameters are compared for analyzing the performance of the machines and product quality. From such comparison decision is taken whether the machine performance and product quality are consistently maintained to required standards or not. Then the standard values and measured values of parameters and decision taken in respect of machine performance and product quality are displayed on the display unit.
Now referring to figure 4, which shows flow diagram illustrating method of analyzing the machine performance, product quality and productivity on the basis of ON/OFF period of the machine. One can check the ON/OFF status of the machines for the purpose of analyzing the machine's performance as well as operator's workability. Delays done by operator are recorded with date and time to derive operator efficiency and improve productivity. Also variation in machine cycle time is recorded for machine efficiency, consistency and variation analysis report. Lowest cycle time report of system can be used to set new target.
The implementation of the method and system of present invention ensures that machine is properly tested and calibrated, product conformity is continually assessed and any non- conforming product can be managed accordingly. It is also used to assess the statistical properties of the machine and product quality. It helps in detecting whether failure caused is by machine or personnel.
The system of the present invention can be made applicable in the wireless communication network. One can receive the measurement and analysis report through Short Message Services (SMS) on the mobile phone. Also web option can be provided in such system for remote viewing of such reports, so that remedial measures if necessary can be taken by person from remote place. The measurement and analysis report can be also be a light indicator with colour coding, a sounding buzzer, print out, a product sticker to be put on component for traceability up to raw material, graph or e-mail. In the system of the invention, input is directly from machine to the computer.
The system of the invention amongst other uses has the following salient applications:
System for product monitoring Maintaining and ensuring product quality Statistical Process Control
On line status of following parameters/attributes are determined:
injection time, cycle time, ok product, rejected product, injection progress bar, cycle time progress bar, operator name, component name, machine name, schedule production quantity, delay time, total delay time, cpcpk, online status of delay, ok and bad component
Data is obtained for machine name, product name, standard cycle time, standard injection time, no. of cavity, preventive maintenance schedule, standard production per hour, component weight, runner weight, machine operating cost and component cost
Reports with the combination of shift wise date wise, machine wise, product wise daily production report, rejection report, downtime report, efficiency report, operator efficiency, machine efficiency, product efficiency, run chart, standard variation, product performance, pmass log (rejection), pmass log (downtime), raw material consumption report, scrap report summary, operator delay, power consumption efficiency and such like. More variants of reports possible are: daily production report, productivity, rejection analysis, down time analysis, ppm rejection wise, delay analysis, material used in production, best cycle time analysis, (day wise/product wise), value wise m/c down time analysis, value wise rejection analysis, operator efficiency, product efficiency, analysis of machine efficiency, OEE and such like.
Advantages of the system of the present invention: i. As manpower cost is going high, the prior art data collection and analysis system are very costly. But system of present invention provides the results in very economic way, especially when there is a need for only one input directly from machine ii. It provides authentic data which can be used for corrective & preventive action, iii. It removes man dependency. iv. It increases the productivity, consistency and overall efficiency, v. It allows to overview the status of all machines at a glance, vi. It gives the raw material consumption
vii. It gives Loss due to machine downtime viii. It gives loss due to operator delay ix. It gives output to operator for bad production, delay x. Out put may be as a SMS on mobile phone or to light stick
INDUSTRIAL APPLICATION;
The system of the present invention is applicable to almost all kinds of the industrial machinery and processes. This system can be connected to all kinds of cyclic production machines, from conventional, manual up to latest CNC control without modification in existing system. It establishes process capability for suitability and acceptability of machines or manufacturing process in the industry. It manages and helps to improve the performance of machine and productivity. Ultimately it leads to growth and development of the industry.
The present invention is not limited to the above described embodiments, and various changes may be made, if desired, without departing from the essence or spirit of the invention which can be read from the claims and the entire specification.
All these changes are also intended to be within technical scope of the present invention.