Quality management by validating a bill of materials in event-based product manufacturing
View Patent ↗Providing quality management by validating a bill of materials in event-based product manufacturing. Some of the disclosed embodiments include a system and method for validating materials during manufacture of a product. Also disclosed are a method of validating that acceptable materials are being used on a machine during manufacture of a product, and one or more computer-readable media for storing a data structure representing a product specification in an event-based manufacturing system. The embodiments are operable in an intelligent manufacturing system including a process for converting raw materials to a product, a process control system including one or more sensors capable of generating an alarm in response to an event that results in one of waste, machine delay, or decrease product quality, a data logger associated with the process control system for obtaining event parameters associated with the event, a database on a server for recording event parameters obtained by the data logger, and a reporting system cooperatively associated with the database for reporting productivity parameters regarding the process derived at least in part from the event parameters.
1. A method for validating materials in a manufacturing control system controlling at least one machine for manufacturing a product, the method comprising:
obtaining, by the manufacturing control system, a bill of materials associated with the product, the bill of materials comprising a specification for manufacturing the product, the specification comprising one or more of the following: a machine setting and a material specification for a raw material to be used by the machine, wherein obtaining a bill of materials comprises obtaining a transitional bill of materials associated with a transition product to be manufactured by the machine during a grade change, and obtaining data comprises obtaining data associated with a raw material presently loaded in the machine;
obtaining, by the manufacturing control system, data associated with the raw material to be used by the machine in manufacturing the product; comparing the obtained data with the obtained bill of materials;
validating the raw material, in response to the comparing, to determine whether the raw material is valid for use in manufacturing the product, wherein obtaining data, comparing the obtained data, and validating the raw material occur during an initial manufacture of the product; and
modifying a production operation in the manufacturing control system based on the validating.
2. The method of claim 1 , further comprising prompting, in response to the comparing, a human operator to enter an override code to continue manufacturing.
3. The method of claim 2 , further comprising receiving, in response to the prompting, an override code from the human operator, wherein the override code comprises a justification to continue manufacturing.
4. The method of claim 3 , wherein the comparing results in a delay, and further comprising determining if the received override code corresponds to a type and duration associated with the delay.
5. The method of claim 1 , wherein obtaining data comprises:
obtaining at least one identifier associated with the raw material; and
obtaining data associated with each obtained identifier.
6. The method of claim 1 , further comprising authenticating the raw material in response to the comparing.
7. The method of claim 1 , further comprising identifying at least one replacement for the raw material in response to the obtaining a bill of materials.
8. The method of claim 1 , wherein modifying a production operation comprises invoking a setting change for the machine.
9. The method of claim 8 , wherein a computing device automatically performs the invoking.
10. The method of claim 8 , wherein invoking a setting change comprises changing a grade for the product.
11. The method of claim 1 , wherein the raw material comprises packaging for the product.
12. The method of claim 1 , wherein obtaining a bill of materials occurs via a network.