Method and apparatus for sequentially collecting and analyzing real time data with interactive monitoring
A system, comprising a plurality of slave devices collecting real time data from process stations, a master device receiving the collected data from the plurality of slave devices, wherein the master device polls the plurality of slave devices in a predetermined order and an analysis device processing the collected data and producing output data as a function of the collected data.
1. A method, comprising the steps of:
collecting real time material information from a production line;
analyzing the real time material information to determine a material cost;
collecting real time operator information from the production line;
analyzing the real time operator information to determine an operator cost;
collecting real time equipment information from the production line;
analyzing the real time equipment information to determine an equipment cost;
collecting real time indirect cost information from the production line;
analyzing the real time indirect cost information to determine an indirect cost;
determining an actual production cost as a function of the material cost, the operator cost, the equipment cost and the indirect cost; and
generating cost comparison data as a function of the actual production cost and a scheduled production cost;
wherein the real time equipment information includes equipment failure data, and further comprising the steps of:
transmitting the equipment failure data to a maintenance post;
determining a response time for maintenance personnel to respond to the equipment failure data as a function of the transmitted equipment failure data and a repair time entered by the maintenance personnel in response to the equipment failure data.
2. The method of claim 1 , further comprising the steps of:
determining an actual operation efficiency as a function of the actual production cost and the real time equipment cost; and
generating efficiency comparison data as a function of the actual operation efficiency and a scheduled efficiency.
3. The method of claim 1 , wherein the analyzing of the real time material information step includes a comparison of the real time material information with stored material information.
4. The method of claim 1 , wherein the analyzing of the real time operator information step includes a comparison of the real time operator information with stored operator information.
5. The method of claim 1 , wherein the analyzing of the real time equipment information step includes a comparison of the real time equipment information with stored equipment information.
6. The method of claim 1 , wherein the combining step includes a comparison of the real time information with stored part information.
7. The method of claim 1 , further comprising the steps of:
analyzing the real time equipment information and the real time operator information as a function of time; and
generating a real time operator efficiency of an operator.
8. The method of claim 7 , wherein the real time operator efficiency is generated for at least two operators in a production unit.
9. The method of claim 7 , wherein the real time operator efficiency is generated for at least two operators in a service unit.
10. The method of claim 7 , wherein generating the real time operator efficiency step includes a comparison of the real time operator information with stored operator information to determine a deviation of the operator cost from a scheduled operator.
11. The method of claim 2 , wherein determining the actual operation efficiency step includes an analysis of the material cost, the operator cost, and the equipment cost.
12. The method of claim 11 , wherein determining the actual operation efficiency step further includes an analysis of an energy cost.
13. The method of claim 11 , wherein the material cost is a function of the operator cost and the equipment cost.
14. The method of claim 11 , wherein the operator cost is a function of the material cost and the equipment cost.
15. The method of claim 11 , wherein the equipment cost is a function of the material cost and the operator cost.
16. A method, comprising the steps of:
collecting real time operator information;
collecting real time equipment information;
analyzing the operator information and the equipment information as a function of time; and
generating a productivity report based on the time analyzed operator information and equipment information,
wherein the real time equipment information includes equipment failure data, and further comprising the steps of:
transmitting the equipment failure data to a maintenance post;
determining a response time for maintenance personnel to respond to the equipment failure data as a function of the transmitted equipment failure data and a repair time entered by the maintenance personnel in response to the equipment failure data.
17. The method of claim 16 , wherein the function of time is based on one of a production unit and a service unit.
18. The method of claim 17 , wherein the production unit is a manufactured item.
19. The method of claim 17 , wherein the service unit is a completed service task.