PROCEDURE AND AUTOMATIC SYSTEM FOR THE MEASUREMENT OF TIMES AND METHODS ON WORK AND ASSEMBLY LINES

This invention concerns a procedure and an automatic system for measuring the times and, therefore, the efficiency and safety parameters for a production process of the type specified in the preamble of the first claim.

In particular, this invention concerns a procedure and a system capable of detecting - automatically and with little complexity and invasiveness - the information necessary for a technical analysis of the execution times and methods for one or more operations called“Times and Methods”.

More specifically, one possible application of the invention is to support the measurement of different operations carried out by operators and machinery along a production or assembly line with automatic systems. The line can be totally manual or mixed (i.e. the operator carries out only some operations, such as assembling and dismantling parts from pallets for automatic machines).

The Time and Motion Analysis is an engineering technique that evolved over decades with the aim of identifying and implementing actions to improve the processes to which it is applied.

One of the key measures of the analysis is the actual time in which the activities are performed, which is the reference against which actions for improvement are undertaken and evaluated. To obtain an estimate of the duration of each activity under analysis, basically two techniques are conventionally used:“Chronotechnics” and the Standard Time Method.

The first consists in the detection, on a sample basis, of the duration of the activities using an operator equipped with a stopwatch or it is based on the analysis of films taken using audio-visual tools. Sometimes laser gun scanners are used or integrated in special gloves that are pointed at barcodes corresponding to each operation and printed close to the working area.

The second is based on the breaking down of the processes into a sequence of micro-activities, of which special standard tables (M.T.M tables) show the execution times.

The prior art described comprises some significant drawbacks and, in particular, fails to meet the needs of those present in the field of application envisaged for the invention.

The main drawbacks include the fact that both technical solutions involve a great expenditure of time for analysts: one spent in direct detection, the other in the breakdown of processes up to the level of micro-activity.

Another drawback is the use of cameras that has greatly impacted the privacy of operators (or at least is perceived as potentially impacting such).

A not-insignificant drawback is the fact that the scanners alter the normal flow of the operator’s operations by introducing unnecessary time and tiring the operator, who sometimes forgets to scan bar-codes generating errors in the data acquired.

In this context, the technical task underlying this invention is to devise a procedure and an automatic system for measuring job parameters that is capable of substantially overcoming at least some of the above-mentioned drawbacks.

In the context of said technical task, it is an important purpose of the invention to provide an information acquisition method/system for said analysis that is automated, simple, non-invasive in terms of the operator's work and completely respectful of privacy.

The technical task and specified aims are achieved with a procedure and an automatic system for measuring job parameters as claimed in the one or more appended independent Claims. Examples of preferred embodiments are described in the dependent claims.

In particular, according to this invention, a procedure and/or a system for measuring times and methods is shown that can be implemented by a computer and that may comprise one or more of the following steps:

- analysing, by means of Natural Language Processing, Image processing, and Artificial Intelligence software the technical documentation relating to the process, in order to obtain a list of elementary operations constituting the process itself and a correlation table of the status variables in passing from one said elementary operation to the following one;

- using an expert system to analyse the status variables and to develop a monitoring set-up able to make the information acquisition conditions less ambiguous and more efficient;

- equipping the work cell with the sensors strictly necessary to acquire the variables determined during the two previous steps, and with microprocessors connected to the sensors and synchronized with each other so as to memorize the time of detection (timestamp) and to perform simple operations;

- determining the duration of each elementary operation as the difference between two timestamps;

- randomising the data acquired so that the operator cannot be recognised;

- encrypting the data and results to ensure security and corporate privacy.

The characteristics and advantages of the invention are clarified by the following detailed description of preferred embodiments thereof, with reference to the accompanying drawings, wherein: Fig. 1 schematises the procedure for measuring activity times according to the invention;

Fig. 2a shows a first assembly to be used in the procedure according to the invention;

Fig. 2b illustrates another example of the first assembly in Fig. 2a;

Fig. 3a shows a second assembly to be used in the procedure according to the invention;

Fig. 2b illustrates another example of the second assembly in Fig. 3a; and Fig. 4 sets out a system for implementing the procedure for measuring activity times according to the invention.

In this document, the measures, values, shapes, and geometric references (such as perpendicularity and parallelism), when used with words like“about” or other similar terms such as“approximately” or“substantially”, are to be understood as except for measurement errors or inaccuracies due to production and/or manufacturing errors and, above all, except for a slight divergence from the value, measure, shape, or geometric reference which it is associated with. For example, if associated with a value, such terms preferably indicate a divergence of no more than 10% from the value itself.

Furthermore, when used, terms, such as“first”,“second”,“higher”,“lower”,“main� ��, and“secondary” do not necessarily identify an order, relationship priority, or relative position, but they can simply be used to distinguish different components more clearly from one another.

The measurements and data provided in this text are to be considered as performed in ICAO International Standard Atmosphere (ISO 2533), unless otherwise indicated. Unless otherwise specified, as is apparent from the following discussions, it is considered that terms such as“processing”,“computer science”,“determination”, “calculation” or similar, refer to the computer action and/or processes or similar electronic computing devices that manipulate and/or transform data represented as physical, such as electronic quantities of registers of an information system and/or memory, other data similarly represented as physical quantities within computer systems, registers or other devices for storing, transmitting or displaying information. With reference to the figures, the reference number 1 globally denotes the procedure for measuring activity times according to the invention.

It is designed to monitor and identify, conveniently automatically, the execution of an activity carried out by one or more operators 1a through a system of sensors able to recognise and monitor the differentiating elements. Specifically, it is designed to monitor and identify an activity that can be carried out in a work environment (e.g. a room, workstation, or warehouse) and/or with the help of working tools, such as a screwdriver or pallet truck, etc.

The procedure 1 is applicable, for example, to cells or lines in which the operations can be carried out either by operators 1 a, manually or using special tools, or by machinery.

It should be noted that in this document the term “operator” identifies a natural person, machine, and/or robotic device or other figure/device capable of carrying out an activity.

An operator 1 a may comprise an operator identifier. Said identifier is preferably designed to differentiate the operators based on the activities/tasks that they can and/or are qualified to perform.

The procedure 1 comprises a system 10 (Fig. 4).

The system 10, and therefore the procedure 1 , may be designed to detect and identify the movements of an operator 1 a.

The system 10 and the procedure 1 may detect the movements of an operator 1 a directly, i.e. by identifying the“absolute” movements (i.e. not connected to objects) of the operator 1 a by means of, for example, GPS or another system of geolocation associated with at least one operator 1 a.

The system 10 and the procedure 1 can, preferably, detect the movements of an operator 1 a directly, i.e. by identifying the movements of the operator 1 a in relation to a reference 1b such as the work environment and/or the work tools.

The system 10 may comprise at least one reference tag 11 designed to be attached to a reference 1 b; and at least one acquisition block 12 designed to record at least part of the movements of an operator 1 a conveniently based on said tags 1 1 .

The tags 1 1 may be designed to be associated - specifically, attached (and preferably integrally) - to the reference 1 b as shown in Figs. 3a, 3b, 4.

They can be used to define an area (Fig. 4) inside of which an operator 1 a needs to move during an activity and/or the mode of use (gripping or movements as illustrated in Fig. 3a) and/or the activation of a work tool (Fig. 3b).

One or more tags 1 1 may be associated with each reference 1 b.

At least one of the tags 1 1 associated with a reference 1 b can comprise an identification code for the tag 1 1 and, therefore, for the reference 1 b.

The tags 1 1 can be active and, therefore, designed to emit a signal, for example Bluetooth or NFC.

As an alternative or in addition, they can be passive, such as an RFID, a bar/QR code or another optical recognition element. The tags 1 1 are preferably, conveniently passive RFID tags.

The acquisition block 12 can be personal and, thus, able to be associated, conveniently exclusively, to an operator 1 a. It may comprise said identifier of the operator 1 a.

The system 10 preferably comprises at least one block 12 for each operator 1 a. The acquisition block 12 may be attached to the part of the operator that moves during movements so as to be move with it.

The block 12 can be attached, conveniently integrally, to an operator 1 a.

It can, preferably, be worn and, for example, consists of a piece of clothing such as a shoe (Fig. 2a) or a glove (Fig. 2b). It should be noted that an operator 1 a can wear several acquisition blocks 12.

It should be specified that the acquisition block 12, where associated with an operator 1 a that consists of a piece of machinery and/or a robotic device, may consist of a component of the operator 1 a or of a component attached to it.

The acquisition block 12 may comprise the identifier of the operator 1 a.

The acquisition block 12 may be designed to detect and, specifically, to acquire at least one tag 1 1 so as to cause a variation in the distance between the tag 1 1 and the block 12. It is, thus, designed to detect the movements of the operator 1 a based on the relative movements between the tag 1 1 and the acquisition block 12 and, thus, between the reference 1 b and the operator 1 a.

The acquisition block 12 may comprise detection means 121 for the tags 1 1 ; and a control card 122 designed to detect a change in the distance between the tag 1 1 and the block 12 based on the tags 1 1 detected by the detection means 121 .

The acquisition means 121 are designed to acquire the position of the tag 1 1 in relation to the means themselves 121 .

The acquisition means 121 are designed to acquire the identification code of the tag

1 1 . They may comprise a camera and/or an RFID reader.

The control card 122 is designed to determine the distance between the detection means 121 and the tags 1 1 enabling the identification of the movement of the operator 1 a in relation to the reference 1 b.

The acquisition block 12 may comprise at least one inertial sensor 123 designed to detect the movements of the operator 1 a or of a part thereof (for example, an arm). The inertial sensor 123 may be an accelerometer and/or a gyroscope.

The acquisition block 12 may comprise at least one clock 124 designed to measure the passing of time at least during the acquisition of at least one tag 1 1 making it possible to measure the duration of the movements of an operator 1 a and, in particular, the time that has passed between one initial movement and one final movement of an activity, i.e. the duration of the activity.

The acquisition block 12 may comprise a power source (e.g. a battery) of the same acquisition block.

The acquisition block 12 may comprise a storage medium for data that is acquired. The system 10 may comprise an activity database that associates each activity with an initial movement and a final movement, identifying, respectively, the beginning and end of the activity.

The activity database divides a process (for example of production) into activities, which are then divided into the movements of the operator 1 a.

It may associate each activity with an intermediate movement between the initial and final movements; and, conveniently, an order for executing the movements. The activity database can associate each activity with an identification code of at least one tag 1 1 , i.e. of one reference 1 b to be used or wherein to carry out said activity. Optionally, the activity database can associate each activity with at least one identifier of the operator 1 a so as to identify which and how many operators 1 a are needed to carry out the activity.

In some cases, the activity database can associate each activity and, specifically, each movement with a theoretical time, i.e. the time in which the activity and/or movement should be performed.

The system 10 may comprise a job database in which the activities performed, conveniently associated with an activity code, are listed.

The activity code is preferably a random code generated by the system. It may, thus, make it possible to avoid tracing back to the execution order of the activities and, for example, to the operator 1 a performing this activity.

The job database can associate each job (conveniently identifiable using a job code) with one or more activities performed (extracted from said activity database) and, conveniently, an activity execution order.

The job database can associate each activity performed with an actual time, i.e. the time in which an activity is actually performed.

The job database can, additionally, associate each activity performed with at least one identifier of an operator 1 a.

The job database can, additionally, associate each activity performed with at least one identification code of a reference 1 b.

The system 10 may comprise a control unit of the system 10 and, thus, of the procedure 1 .

The control unit may comprise a memory for one or more of said databases.

The control unit may be physically/structurally separated from the acquisition block 12 and, for example, constitute a server. Alternatively, it is integrated in the acquisition block 12.

The control unit can be in data connection, preferably wireless, with at least one acquisition block 12 and, specifically, with the control card 122.

The control unit can receive at least the change in distance between the acquisition block 12 and at least one tag 1 1 (specifically, all of them), detected by the detection means 121 , from one or more acquisition blocks 12, as well as, conveniently, the identifier of the acquisition block 12 i.e. of the operator 1 a.

In addition, the control unit can receive at least one, and, specifically, all of: the identification code of the tag 1 1 ; the length of the movements detected by the clock 124; and movements of the operator 1 a detected by the inertial sensor 123, from at least one acquisition block 12.

The control unit may comprise a user interface.

The interface may be input and/or output.

The operation of the system 10, described above in structural terms, defines the procedure 1 for measuring activity times.

The procedure 1 is designed to be controlled by the control unit.

The procedure 1 may comprise a recording step 2 wherein the acquisition block 12 acquires, and thus identifies, the movements of an operator 1 a.

In the recording step 2, the detection means 121 detect one or more tags 1 1 and, as the operator 1 a performs a task, the control card 122 detects a change in the distance between the tags 1 1 and the block 12 that identifies the movements of the operator 1 a.

In addition, in the recording step 2, the clock 124 can measure the passing of time during said acquisition of at least one tag 1 1 making it possible to measure, for example, the execution time of each of the movements and/or the time passed between two movements.

In addition, in this step 2, the inertial sensor 123 may detect the movements of the operator 1 a enabling the control card 122 to detect the movements of the operator 1 a based on both the tags 1 1 and the movements detected by the sensor 123.

The data acquired by the acquisition block 12 can be stored, at least temporarily, in the storage medium for data acquired.

At this point, the procedure 1 may comprise a sending step 3 to send data acquired by the acquisition block 12 to the control unit.

In this step, once the data connection between the block 12 and the control unit is established, the acquisition block 12 sends the data acquired in the recording step to the control unit.

At this point, the procedure 1 may comprise a correlation step 4 wherein the movements recorded in said recording step 2 are correlated with at least the initial and final movements of each of the activities in the activity database so that if the initial movement and the final movement of at least one activity is identified from among the recorded movements, the activity is marked as performed.

Conveniently, in the correlation step 4, the movements recorded in the recording step 2 are correlated with the initial, final, and at least one intermediate movement so as to make it possible to identify an activity, in which the movements are all performed in the order desired, as performed.

Each activity marked as performed is, thus, saved in the job database and, conveniently, associated with an activity code.

The activity code is generated at random by the control unit.

The confrontation step 4 is performed by the control unit.

The procedure 1 may comprise an evaluation step 5 wherein a job database is created.

In the evaluation step 5, each activity performed is associated with an actual job time based on the data acquired by the clock 124 and, thus, on the execution times of at least the initial and final movements of said performed activity.

The actual time is preferably based on the execution times of at least the initial and final movements and at least one intermediate movement. Alternatively and/or in addition, the actual time is based on the execution times of at least the initial and final movements and on the time passed between said movements.

In the job database, each activity performed can be associated with at least one identifier of the acquisition block 12 (therefore, of the operator 1 a associated with the block 12) and/or at least one identification code of the tag 1 1 and, thus, of the reference 1 b (i.e. of the object used to perform the activity).

The evaluation step 5 is performed by the control unit.

The procedure 1 may comprise a comparison step 6 for comparing the data relating to the activity performed in the job database with the data of the activities in the activity database.

In particular, in the comparison step 6, the theoretical time and the actual time are compared, thus making it possible, for example, to understand if the activity performed had a different length to that programmed.

In the comparison step 6, at least one identifier in the job database can be compared with that/those in the activity database and associated with the same activity, thus making it possible to verify the correct allocation of the operators 1 a.

In the comparison step 6, the at least one identification code in the job database can be compared with that/those in the activity database and can be associated with the same activity, thus making it possible to verify the correct use of the job tools. The comparison step is, thus, concluded with the control unit that communicates, via said interface, the results of the above-mentioned comparisons.

The comparison step 6 is performed by the control unit.

The procedure 1 and, thus, the system 10 according to the invention, entail important advantages.

In fact, the procedure 1 and the system 10 for measuring activity times make it possible to precisely determine, in a simple and economical way, the execution of the activities necessary to complete a job.

In particular, by dividing the job into simple activities, the procedure 1 and the system 10 enable a precise monitoring of the job undertaken.

The identification of the initial and final movements also makes it possible to automatically identify (i.e. without the operator’s signal/action) the start of an activity. Another advantage is the fact that the procedure 1 and the system 10 involve an ideal use of the resources because they make it possible, for every single activity, to use both the staff most suitable to carrying it out and only the materials and/or tools strictly necessary.

A significant advantage is the fact that, by monitoring the actual times with which each activity performed is carried out, and, in particular, by comparing this datum with the theoretical times, the efficiency of every single job activity can be monitored. A not-insignificant advantage is the fact that the procedure 1 and, thus, the system 10 can be implemented completely automatically.

Variations may be made to the invention that fall within the scope of the inventive concept defined in the claims. All details may be replaced with equivalent elements and the scope of the invention includes all other materials, shapes, and dimensions.