glass demand scheduling system
TRANSCRIPT
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US
20070112451A1
( 1 9 ) United S t a t e s
( 1 2 ) Patent
Application
Publication ( 1 0 ) P u b .
N o . :
US 2 0 0 7 / 0 1 1 2 4 5 1 A 1
C l a y t o n e t a l .
( 4 3 )
P u b .
D a t e :
May 7 , 2007
( 5 4 )
( 7 5 )
( 7 3 )
( 2 1 )
( 2 2 )
( 6 3 )
GLASS DEMAND SCHEDULING SYSTEM
I n v e n t o r s :
B y r o n
C l a y t o n ,
S a g a m o r e
H i l l s ,
OH
( U S ) ; P a u l
D o r s c h , W a r r e n , OH U S )
C o r r e s p o n d e n c e
A d d r e s s :
TAROLLI, SUNDHEIM,
COVELL &
TUMMINO . L . P .
1300
EAST NINTH STREET,
SUITE 1700
CLEVEVLAND, OH 4 1 1 4 ( U S )
A s s i g n e e : GED
n t e g r a t e d
S o l u t i o n s , I n c .
A p p l .
N o . : 1 1 / 6 5 2 , 7 4 7
F i l e d :
J a n .
1 2 , 2007
R e l a t e d US.
p p l i c a t i o n
Data
C o n t i n u a t i o n - i n - p a r t o f
a p p l i c a t i o n N o .
1 0 / 7 5 1 , 3 8 2 ,
? l e d on
J a n .
5 ,
2 0 0 4 , noW
P a t . No.
7 , 1 6 7 , 7 6 7 , Which
i s
a c o n t i n u a t i o n - i n - p a r t
o f
a p p l i c a t i o n
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1 9 1 ,
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on
Aug. 2 2 ,
2 0 0 3 ,
noW a b a n d o n e d .
7 O
ammo uwsmzms >
22
P u b l i c a t i o n C l a s si ? c a t i o n
( 5 1 )
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G06F
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Us.
or.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700/100; 7 0 0 /1 5 7
( 5 7 ) ABSTRACT
A
method f o r o p t i m i z i n g m a t e r i a l How
a n d
e q u i p m e n t
u t i l i z a t i o n i n t h e f a b r i c a t i o n
o f
i n s u l a t i n g
g l a s s
u n i t s i n a
p r o d u c t i o n
o p e r a t i o n .
T h e m e t h o d i n c l u d e s c o m p i l i n g a
p l u r a l i t y
o f o r d e r s a n d c o n v e r t i n g t h e
p l u r a l i t y
o f o r d e r s i n t o
p r o d u c t i o n s c h e d u l e s f o r
o p e r a t i n g
p r o c e s s e s t h a t f a b r i c a t e
t h e
i n s u l a t i n g g l a s s u n i t s o v e r
a
p r e s c r i b e d
p e r i o d o f t i m e .
The method u r t h e r i n c l u d e s
r e l e a s i n g
t h e p r o d u c t i o n
s c h e d
u l e s
t o t h e p l u r a l i t y
o f
p r o c e s s e s u s e d t o f a b r i c a t e
i n s u l a t i n g
g l a s s
u n i t s .
T h e m e t h o d l s o i n c l u d e s m o n i t o r i n g
p r o d u c t i o n
o p e r a t i o n s d a t a p r o d u c e d a s a
r e s u l t
o f t h e r e l e a s i n g t h e
p r o d u c t i o n
s c h e d u l e s t o t h e
p l u r a l i t y o f
p r o c e s s e s
u s e d
t o
f a b r i c a t e
t h e
i n s u l a t i n g g l a s s u n i t s
a n d
p r o v i d i n g
r e p o r t s
u s e d
b y t h e
m o n i t o r i n g
p r o d u c t i o n
o p e r a t i o n s h a v i n g i m a g e
r e a d a b l e
i n d i c i a t h a t a r e imaged o r p r o v i d i n g r e a l - t i m e d a t a
f o r t r a c k i n g m a t e r i a l How t o , f r o m ,
a n d
t h r o u g h t h e p r o
c e s s e s u s e d i n t h e f a b r i c a t i o n o f i n s u l a t i n g g l a s s u n i t s .
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USYDMER mom’ END
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Fig.16A
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n
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US 2007/0112451A1
GLASS DEMAND
SCHEDULING
SYSTEM
CROSS
REFERENCE TO RELATED
APPLICATION
[ 0 0 0 1 ] The p r e s e n t a p p l i c a t i o n i s a C o n t i n u a t i o n - i n - P a r t
a p p l i c a t i o n o f c u r r e n t l y p e n d i n g US. p p l i c a t i o n S e r . N o . :
1 0 / 7 5 1 , 3 8 2 h a v i n g
a
? l i n g
d a t e
o f
J a n . 5 , 2 0 0 4 e n t i t l e d
“ G l a s s P r o d u c t i o n S e q u e n c i n g ” c l a i m i n g p r i o r i t y a s a Con
t i n u a t i o n - i n - P a r t o f US.
a p p l i c a t i o n
S e r . N o . 1 0 / 6 4 6 , 1 9 1 ,
e n t i t l e d
“ G l a s s
O p t i m i z a t i o n ” ? l e d
A u g .
2 2 , 2 0 0 3 . The
p r e s e n t a p p l i c a t i o n c l a i m s p r i o r i t y t o , a n d i n c o r p o r a t e s i n
t h e i r
e n t i r e t i e s
b o t h o f t h e
a b o v e - i d e n t i ? e d
a p p l i c a t i o n s f o r
a l l
p u r p o s e s .
FIELD
OF THE
INVENTION
[ 0 0 0 2 ] The
r e s e n t
i n v e n t i o n c o n c e r n s a
method and appa
r a t u s f o r c o n t r o l l i n g
p r o d u c t i o n
r u n s e q u e n c e s o f i n s u l a t i n g
g l a s s
u n i t s .
BACKGROUND
ART
[ 0 0 0 3 ]
WindoW m a n u f a c t u r e r s t y p i c a l l y
r e c e i v e o r d e r s
t h a t
i n c l u d e a v a r i e t y o f d i f f e r e n t s i Z e s and y p e s
o f
WindoWs
a n d / r p a t i o d o o r s . The
i f f e r e n t
s i Z e s and y p e s
o f WindoWs
a n d / o r p a t i o d o o r s r e q u i r e d i f f e r e n t s i Z e s a n d
t y p e s
o f
i n s u l a t i n g g l a s s
u n i t s
( I G s )
t h a t
a r e a s s e m b l e d i n t o a f r a m e
or sash t o
for m
a
completed
WindoW
or a t i o
door
a t one or
more
g l a Z i n g l i n e s .
The WindoW
a n u f a c t u r e r s s e p a r a t e and
g r o u p t h e o r d e r s
f o r
t h e
I G s
i n t o r e g u l a r o r p l a n ne d p r o d u c
t i o n
r u n s .
The
r e g u l a r o r
planned r o d u c t i o n r u n s a r e sched
uled
t o
be manufactured i n
a c e r t a i n sequence
on
a c e r t a i n
f u t u r e
d a t e , u s u a l l y W i t h i n o n e to t h r e e b u s i n e s s d a y s a h e a d .
[ 0 0 0 4 ] V a r i a b l e s
i n
t h e m a n u f a c t u r i n g p r o c e s s
r a r e l y
a l l o W
t h e
r e g u l a r p r o d u c t i o n r u n s
t o
b e m a n u f a c t u r ed
i n t h e
e x a c t
p l a n n e d s e q u e n c e .
F o r
e x a m p l e , r u s h o r d e r s f o r
i m p o r t a n t
customers
and remake o r d e r s t h a t
occur
When
IGs break
a r e
o f t e n
p r i o r i t i z e d ,
c h a n g i n g
t h e
s e q u e n c e o f
t h e
p r o d u c t i o n
r u n s . The o p e r a t i o n a l s t a t u s o f
machines
used t o make t h e
components
of
h e
IGs m ay
a l s o c a u s e t h e sequence
of
h e
r e g u l a r o r p l a n n e d p r o d u c t i o n
r u n s
t o
b e
a l t e r e d .
F u r t h e r ,
demand u c t u a t i o n s , s u c h a s a s h o r t a g e
at one of
h e g l a Z i n g
l i n e s
may c a u s e t h e
s e q u e n c e o f
t h e r e g u l a r o r
p l a n n e d
production r u n s
t o
be a l t e r e d . A s a r e s u l t , a s u p e r v i s o r of an
IG p r o d u c t i o n
l i n e m u s t
c o n s t a n t l y
m o n i t o r e a c h o f t h e
m a n u f a c t u r i n g
v a r i a b l e s
a n d
m o d i f y t h e
s e q u e n c e o f
t h e
p r o d u c t i o n r u n s a c c o r d i n g l y .
[ 0 0 0 5 ]
C u r r e n t m e t h o d s e m p l o y e d b y
I G
s u p e r v i s o r s
f o r
m o n i t o r i n g I G
m a n u f a c t u r i n g
v a r i a b l e s a n d m o d i f y i n g p r o
d u c t i o n r u n s e q u e n c e s
a r e s l o W ,
i n a c c u r a t e
and
c o n f u s i n g .
The e x i s t i n g m e t h o d s t y p i c a l l y r e l y o n
i n f o r m a l
communi
c a t i o n s ,
s u c h
a s
Word
f
m o u t h , h a n d W r i t t e n
documents
and
manual d a t a e n t r y .
Use o f
t h e s e n o n - a u t o m a t e d
f o r m s o f
communication f t e n c o n f u s e o p e r a t o r s ,
t i e up
a c h i n e s
and
d e l a y
s t a n d a r d
m a n u f a c t u r i n g
p r o c e d u r e s .
U s e
o f
t h e s e
i n f o r m a l comm unication methods
c a u s e p r o d u c t i o n
e f ? c i e n
c i e s t o
d r o p even f u r t h e r W h i l e
neW
employees a r e b e i n g
t r a i n e d o r neW machines a r e being
commissioned.
[ 0 0 0 6 ]
The g l a s s
l i t e s t h a t
a r e needed
t o c o n s t r u c t t h e IGs
a re s e p a r a t e d a n d g r o u p e d
i n t o
s c h e d u l e d p r o d u c t i o n
b a t c h e s
o r r u n s . For each r o d u c t i o n b a t c h ,
t h e
g l a s s l i t e s a r e f u r t h e r
g r o u p e d a n d a r r a n g e d
t o
b e
c u t
f r o m l a rge
s t o c k g l a s s
s he e t s
t o a c h i e v e t h e h i g h e s t y i e l d . The
p r o c e s s
o f
g r o u p i n g
a n d
May 7 ,
2 0 0 7
a r r a n g i n g g l a s s l i t e s
t o
b e c u t f r o m
s t o c k
g l a s s s h e e t s
t o
a c h i e v e
t h e h i g h e s t y i e l d
i s c a l l e d
g l a s s o p t i m i Z a t i o n .
[ 0 0 0 7 ] G l a s s
o p t i m i Z a t i o n i s
u s u a l l y
p e r f o r m e d b y a com
p u t e r e x e c u t i n g a c o m p u t e r p r o g r a m . The
o u t p u t
f r o m t h e
g l a s s o p t i m i Z a t i o n p r o c e s s
i s
a c o n t r o l program
t h a t
i s s e n t
t o a c o m p u t e r - c o n t r o l l e d c u t t i n g
t a b l e .
The l a s s o p t i m i Z a
t i o n
s o f t W a r e
o u t p u t s
a computer program h a t o p t i m i Z e s one
o r more p r o d u c t i o n b a t c h e s c o n t a i n i n g p a t t e r n s o f l i t e s
a r r a n g e d
on
s t o c k g l ass
s h e e t s . The c u t t i n g
t a b l e
a u t o m a t i
c a l l y s c o r e s t h e g l a s s a c c o r d i n g t o
e a c h
p a t t e r n .
Each
p r o d u c t i o n b a t c h n o r m a l l y c o n t a i n s o n e o r more l a s s l a y o u t
p a t t e r n s t h a t
p r o v i d e
a l o W e r y i e l d t h a n
d e s i r a b l e .
[ 0 0 0 8 ] These LoW Y i e l d
P a t t e r n s o r
LoW Y i e l d
S h e e t s
s i g n i ? c a n t l y r e d u c e
t h e y i e l d
o f e n t i r e p r o d u c t i o n
b a t c h e s
r e s u l t i n g
i n h i g h e r m a n u f a c t u r i n g
c o s t s d u e
t o
W a s t e d g l a s s .
W a s t e
i s p a r t i c u l a r l y
e x p e n s i v e
When
m a n u f a c t u r i n g
W i n
d o W s f r o m i n c r e a s i n g l y p o p u l a r
s p e c i a l t y
g l a s s e s s u c h
a s
LoW-E
o r
s e l f - c l e a n i n g m a t e ri a l s .
[ 0 0 0 9 ] T o d a y ,
t h e r e a r e s e v e r a l e x i s t i n g
m e t h o d o l o g i e s
u s e d
t o
i n c r e a s e
g l a s s
y i e l d s .
U n f o r t u n a t e l y , e a c h m e t h o d
p r e s e n t s one
o r
more problems t o
m a n u f a c t u r i n g
o p e r a t i o n s .
The
m e t h o d s and
t h e i r
r e s u l t i n g
p r o b l e m s a r e
d e s c r i b e d
b e l o W .
[ 0 0 1 0 ] a ) S t a n d a r d d i m e n s i o n e d l i t e s
c a l l e d
? l l e r l i t e s
can
be
i n t r o d u c e d t o s c h e d u l e d p r o d u c t i o n b a t c h e s
t o
? l l - i n u n u s e d s p a c e
on h e s t o c k g l a s s
s h e e t s . The
l a s s
o p t i m i Z a t i o n s o f t W a r e
d e t e r m i n e s Where ? l l e r l i t e s can
b e
i n s e r t e d When c r e a t i n g
t h e i n i t i a l
programmed
p a t
t e r n s . Because
? l l e r s a r e i n s e r t e d p r i o r t o t h e a c t u a l
m a n u f a c t u r i n g p r o c e s s , t h e number a n d t y p e
o f ? l l er
l i t e s
r ar el y
meet
a c t u a l
p r o d u c t i o n d e m a n d . Too f e W
? l l e r
l i t e s
s t a r v e p r o d u c t i o n l i n e s
W h i l e
t o o
many
l l e r s
c r e a t e
s t o r a g e a n d
q u a l i t y p r o b l e m s .
[ 0 0 1 1 ] b )
A d d i n g d i f f e r e n t
s i Z e s
o f
l a r g e
s h eets
c a n b e
s t o c k e d t o i n c r e a s e y i e l d .
[ 0 0 1 2 ] T h i s a l l o W s
t h e
g l a s s o p t i m i Z a t i o n s o f t W a r e
t o
p i c k
t h e
s i Z e
o f s t o c k s he e t s t h a t p r o d u c e t h e b e s t y i e l d . A l t h o u g h
t h i s
method
n h a n c e s y i e l d , i t
al so
i n c r e a s e s i n v e n t o r y
s p a c e
a n d c o s t s W h i l e d e c r e a s i n g t h r o u g h p u t
( m o r e g l a s s
s i Z e s t o
s h u t t l e
i n a n d o u t ) .
[ 0 0 1 3 ] c )
C e r t a i n c u t t i n g t a b l e s
a l l o W
t h e
s i Z e s
a n d
t y p e s
o f
l i t e s
from
LoW Y i e l d S h e e t s t o b e m a n u a l l y
e n t e r e d a t t h e c u t t i n g t a b l e c o n t r o l l e r W i t h t h e s i Z e s and
t y p e s o f
o t h e r
o f
s e l e c t e d l i t e s ,
t h e n
r e - o p t i m i Z e d
t o
i n c r e a s e y i e l d s .
[ 0 0 1 4 ] A l t h o u g h
t h e s e f e a t u r e s
p r o v i d e
? e x i b i l i t y a n d
i n c r e a s e y i e l d , t h e y
al so
c a u s e t h e
c u t t i n g t a b l e
t o
r e m a i n
i d l e
d u r i n g
t h e m a n u a l
e n t r y
p r o c e s s .
[ 0 0 1 5 ]
T h i s g r e a t l y
r e d u c e s p r o d u c t i o n t h r o u g h p u t
a n d
e f ? c i e n c y .
SUMMARY OF THE INVENTION
[ 0 0 1 6 ] I n a c c o r d a n c e
W i t h
o n e e x e m p l a r y embodiment
o f
t h e c l a i m e d i n v e n t i o n
i s
a method
f o r
o p t i m i Z i n g m a t e r i a l
How and e q u i p m e n t
u t i l i Z a t i o n
i n t h e f a b r i c a t i o n o f i n s u l a t
i n g
g l a s s
u n i t s i n
a
p r o d u c t i o n o p e r a t i o n . T h e m e t h o d
c o m p r i s e s c o m p i l i n g
a
p l u r a l i t y o f
o r d e r s
a n d c o n v e r t i n g t h e
p l u r a l i t y o f
o r d e r s
i n t o p r o d u c t i o n
s c h e d u l e s
f o r o p e r a t i n g
a
p l u r a l i t y
o f p r o c e s s e s
t h a t
f a b r i c a t e
t h e
i n s u l a t i n g g l a s s u n i t s
-
8/19/2019 Glass Demand Scheduling System
19/28
US 2007/0112451A1
o v e r
a p r e s c r i b e d p e r i o d o f t i m e . The method f u r t h e r
i n c l u d e s r e l e a si n g t h e
p r o d u c t i o n
s c h e d u l e s t o t h e p l u r a l i t y
o f p r o c e s s e s u s e d t o f a b r i c a t e i n s u l a t i n g g l a s s
u n i t s .
The
production s c h e d u l e s a r e a c c e s s i b l e t o u s e r s through a
c o m p u t e r
n e t W o r k .
The method
a l s o
i n c l u d e s
m o n i t o r i n g
p r o d u c t i o n o p e r a t i o n s d a t a p r o d u c e d
a s
a
r e s u l t
o f t h e
r e l e a s i n g t h e p r o d u c t i o n s c h e d u l e s t o t h e p l u r a l i t y
o f
p r o
c e s s e s
u s e d
to f a b r i c a t e t h e i n s u l a t i n g g l a s s u n i t s and
p r o
v i d i n g
r e p o r t s u s e d
b y t h e m o n i t o r i n g
p r o d u c t i o n
o p e r a t i o n s
h a v i n g i m a g e r e a d a b l e i n d i c i a t h a t
a r e i m a g e d
f o r p r o v i d i n g
r e a l - t i m e d a t a
f o r t r a c k i n g
m a t e r i a l
How
t o ,
f r o m , a n d
t h r o u g h t h e p r o c e s s e s
u s e d i n
t h e f a b r i c a t i o n
o f i n s u l a t i n g
g l a s s u n i t s .
[ 0 0 1 7 ]
I n a c c o r d a n c e
W i t h a n o t h e r e x e m p l a r y e m b o d i m e n t
o f t h e c l a i m e d
i n v e n t i o n
i n c l u d e s c o m p u t e r - r e a d a b l e media
h a v i n g c o m p u t e r - e xe c u t a b l e i n s t r u c t i o n s f o r p e r f o r m i n g
a
m e t h o d
o p t i m i Z i n g m a t e r i a l How a n d e q u i p m e n t u t i l i Z a t i o n
i n
t h e f a b r i c a t i o n
o f i n s u l a t i n g g l a s s u n i t s i n
a
p r o d u c t i o n
o p e r a t i o n , t h e i n s t r u c t i o n s
c o m p r i s i n g
t h e
s t e p o f
p r o d u c i n g
a
p l u r a l i t y
o f
p r o d u c t i o n
s c h e d u l e s
f o r
e q u i p m e n t a n d
a s s e m b l y
o p e r a t i o n s
u s e d
t o
f a b r i c a t e
WindoWs a n d
WindoW
components o v e r a p r e s c r i b e d
p e r i o d o f
t i m e . The i n s t r u c
t i o n s f u r t h e r c o m p r i s e r e l e a s i n g t h e
p r o d u c t i o n
s c h e d u l e s t o
t h e e q u i p m e n t
a n d
a s s e m b l y o p e r a t i o n s u s e d t o f a b r i c a t e
WindoW a n d WindoW
o m p o n e n t s .
The
r o d u c t i o n
s c h e d u l e s
a r e a c c e s s i b l e t o u s e r s
through
a
computer netWork.
The
i n s t r u c t i o n s a l s o c o m p r i s e c a l c u l a t i n g p r o d u c t i o n
o p e r a t i o n s
d a t a a s s o c i a t e d W i t h t h e p r o d u c t i o n s s c h e d u l e s . The c a l c u
l a t i n g o f
h e
p r o d u c t i o n
o p e r a t i o n s i n c l u d e s
u s i n g
i n f o r m a
t i o n from c o n t i n u o u s r e a l - t i m e d a t a c o l l e c t e d from t r a c k i n g
m a t e r i a l a n d c o m p o n e n t s t h r o u g h t h e e q u i p m e n t a n d a s s e m
b l y
o p e r a t i o n s u s e d
t o f a b r i c a t e WindoW and WindoW
com
p o n e n t s .
[ 0 0 1 8 ]
I n a c c o r d a n c e W i t h
y e t
a n o t h e r e x e m p l a r y e m b o d i
ment
of
t h e
c l a i m e d i n v e n t i o n
i s
a
method
f o r
c o n t r o l l i n g
p r o d u c t i o n s c h e d u l e s
o f n s u l a t i n g g l a s s
u n i t s ,
c o m p o n e n t s ,
a n d m a t e r i a l s i n e q u i p m e n t a n d a s s e m b l y o p e r a t i o n s
com
p r i s i n g
t h e s t e p s o f c o m p i l i n g a
p l u r a l i t y
o f n e W , r e m a k e ,
a n d r u s h o r d e r s
u s e d
t o
f a b r i c a t e
i n s u l a t i n g
g l a s s u n i t s
a n d
c o n v e r t i n g t h e
p l u r a l i t y o f
o r d e r s
i n t o
p r o d u c t i o n s c h e d u l e s
f o r
o p e r a t i n g
a
p l u r a l i t y
o f e q u i p m e n t a n d a s s e m b l y
o p e r a
t i o n s t h a t
f a b r i c a t e
t h e i n s u l a t i n g
g l a s s
u n i t s
o v e r
a p r e
s c r i b e d
p e r i o d
o f t i m e . The method
f u r t h e r
i n c l u d e s r e l e a s
i n g t h e p r o d u c t i o n
s c h e d u l e s
t o t h e p l u r a l i t y
o f
e q u i p m e n t
a n d a s s e m b l y o p e r a t i o n s t h a t f a b r i c a t e i n s u l a t i n g
g l a s s
u n i t s ,
t h e
p r o d u c t i o n
s c h e d u l e s
b e i n g
a c c e s s i b l e
t o o p e r a t o r s a n d
management
t h r o u g h
a c o m p u t e r n e t W o r k a n d
m o n i t o r i n g
p r o d u c t i o n o p e r a t i o n s d a t a p r o d u c e d
a s a
r e s u l t
o f t h e
r e l e a s i n g
t h e p r o d u c t i o n s c h e d u l e s
t o
t h e
p l u r a l i t y o f
e q u i p
ment a n d
a s s e m b l y
o p e r a t i o n s a n d r e a l - t i m e f e e d b a c k i n f o r
m a t i o n . T h e
m o n i t o r i n g p r o d u c t i o n o p e r a t i o n s d a t a
i n c l u d e s :
m o n i t o r i n g
i n d i v i d u a l m a c h i n e p r o d u c t i o n r a t e s u s e d to
f a b r i c a t e t h e
i n s u l a t i n g g l a s s
u n i t s ; m o n i t o r i n g i n d i v i d u a l
machine c o m p l e t i o n r a t e s
u s e d t o
f a b r i c a t e t h e i n s u l a t i n g
g l a s s u n i t s ;
m o n i t o r i n g
i n d i v i d u a l k a n b a n
a r r i v a l
t i m e s h a v
i n g
a knoWn
amount
o f
m a t e r i a l
used to f a b r i c a t e t h e
i n s u l a t i n g g l a s s u n i t s ; m o n i t o r i n g i n d i v i d u a l
k a n b a n
c o n
sumption
r a t e s o f
t h e knoWn amount
o f
m a t e r i a l used to
f a b r i c a t e t h e
i n s u l a t i n g
g l a s s u n i t s ; a n d m o n i t o r i n g i n d i
v i d u a l machine s t a r t t i m e s u s e d to f a b r i c a t e t h e i n s u l a t i n g
g l s s
u n i t s . The method u r t h e r i n c l u d e s t h e
s t e p s
o f l e r t i n g
o p e r a t o r s a n d / o r management
s h o u l d
t h e m a t e r i a l s
s u p p l i e d
to
one
o r
more of t h e p l u r a l i t y
of
equipment o r assembly
o p e r a t i o n s
f a l l
b e l o W a
p r e s c r i b e d
m a t e r i a l
q u e u e t h r e s h o l d ,
May 7 ,
2 0 0 7
c r e a t i n g a m a t e r i a l n o t i c e c o n d i t i o n b a s e d
on
h e
m o n i t o r i n g
p r o d u c t i o n
o p e r a t i o n s
d a t a and a l t e r i n g one
o r more
o f
t h e
p r o d u c t i o n
s c h e d u l e s b a s e d on h e
m a t e r i a l n o t i c e
c o n d i t i o n .
[ 0 0 1 9 ] T h e s e a n d o t h e r o b j e c t s a n d a d v a n t a g e s o f t h e
s y s t e m c o n s t r u c t e d i n a c c o r d a nc e W i t h a n
e x e m p l a r y
embodiment
o f
t h e
i n v e n t i o n i s more c o m p l e t e l y d e s c r i b e d
i n c o n j u n c t i o n W i t h
t h e a c c o m p a n y i n g
d r a W i n g s .
BRIEF
DESCRIPTION
OF THE DRAWINGS
[ 0 0 20 ] F I G .
1
i s
a
s c h e m a t i c r e p r e s e n t a t i o n o f
a
WindoW
a n d / o r d o o r m a nu f a c t u r i n g
f a c i l i t y ;
[ 0 0 2 1 ]
F I G .
2 i s a s c h e m a t i c r e p r e s e n t a t i o n
o f
a
WindoW
a n d / o r d o o r m a n u f a c t u r i n g
f a c i l i t y
e q u i p p e d W i t h a s y s t e m
f o r c o n t r o l l i n g
p r o d u c t i o n r u n s e q u e n c e s o f
n s u l a t i n g g l a s s
u n i t s ;
[ 0 0 2 2 ] F I G .
3
i s
a
s c h e m a t i c
r e p r e s e n t a t i o n of a u s e r
i n t e r f a c e by means o f
Which a n
o p e r a t o r c o n t r o l s
p r o d u c t i o n
run
sequences;
[ 0 0 23 ] F I G .
4
i s
a
s c h e m a t i c
r e p r e s e n t a t i o n
of
a
u s e r
i n t e r f a c e by
means o f Which a n o p e r a t o r c o n t r o l s p r o d u c t i o n
run
sequences;
[ 0 0 2 4 ]
F I G . 5 i s a
s c h e m a t i c
r e p r e s e n t a t i o n of a u s e r
i n t e r f a c e by
means
o f
Which a n
o p e r a t o r
c o n t r o l s p r o d u c t i o n
run
sequences;
[ 0 0 2 5 ] F I G .
6
i s
a
How h a r t
t h a t i l l u s t r a t e s one
method
of
c o n t r o l l i n g p r o d u c t i o n r u n s e q u e n c e s ;
[ 0 0 2 6 ] F I G . 7 i s
a
s c h e m a t i c
r e p r e s e n t a t i o n
o f
a
c u t t i n g
s t a t i o n l o c a t e d W i t h i n a
WindoW o r
door
manufacturing
f a c i l i t y ;
[0027] FIG. 8
i s
a schematic
of
u s e r i n t e r f a c e by means
o f
Which
a n
o p e r a t o r
s e t s
up
c u t t i n g
o p e r a t i o n s
a t
t h e F I G .
1
c u t t i n g
s t a t i o n ;
[ 0 0 2 8 ] F I G S . 9 - 1 5
a re
s c h e m a t i c
d e p i c t i o n s
o f g l a s s
s he e t s
i l l u s t r a t i n g l a y o u t s
o f l i t e s
to
b e
c u t
from
t h e
s h e e t s
a t
t h e
c u t t i n g s t a t i o n ;
[ 0 0 2 9 ]
F I G S . 16A a n d 16B
a r e
? o W c h a r ‘ t s f o r
o p t i m i Z i n g
l i t e
l a y o u t s on g l a s s s h e e t s
o f
a
p r o d u c t i o n
r u n ;
[ 0 0 3 0 ] FIGS. 1 7 A and 17B
a r e
? o W c h a r t s
i l l u s t r a t i n g a
p r o c e s s f o r
m a n a g i n g a n d
o p t i m i Z i n g
m a t e r i a l How a n d
e q u i p m e n t u t i l i Z a t i o n
t h r o u g h
t h e p r o d u c t i o n p r o c e s s
o f
F I G . 2
i n
a c c o r d a n c e
W i t h t h e p r e s e n t i n v e n t i o n ; and
[ 0 0 3 1 ] F I G . 1 8 i l l u s t r a t e s a p r i n t i n g o p e r a t i o n f o r a p l u
r a l i t y
o f e p o r t s f o r
p r o v i d i n g i n f o r m at i o n
t o t h e
p r o d u c t i o n
p r o c e s s
o f F I G . 2
i n a c c o r d a n c e W i t h t h e p r e s e n t i n v e n t i o n .
DETAILED
DESCRIPTION
[ 0 0 3 2 ]
The
d i s c l o s e d
i n v e n t i o n
p r o v i d e s a n i n t e g r a t e d
s o f t W a r e
and
a p p a r a t u s
s o l u t i o n u s e d
i n
t h e
m a n u f a c t u r e o f
WindoWs a n d / o r d o o r s
f o r
d y n a m i c a l l y
m o n i t o r i n g
manu
f a c t u r i n g v a r i a b l e s a n d c o n t r o l l i n g
p r o d u c t i o n s e q u e n c e s
u s i n g c e n t r a l p r o d u c t i o n
c o n t r o l
W o r k s t a t i o n 1 0
( F I G . 2 ) .
[ 0 0 3 3 ]
F I G .
1
s c h e m a t i c a l l y
i l l u s t r a t e s a
WindoW a n d / o r
d o o r m a n u f a c t u r i n g f a c i l i t y
1 2 .
The f a c i l i t y 1 2 i n c l u d e s a
f r o n t end system o r t e r m i n a l 14 Where o r d e r s f o r WindoWs
a n d / o r d o o r s a r e e n t e r e d and
WindoW
a s s e m b l y i s s c h e d u l e d .
The r o n t end
s y s t e m 1 4 p r o v i d e s
o r d e r s 1 6 t o a n i n s u l a t i n g
g l a s s u n i t ( I G ) p r o d u c t i o n c o n t r o l t e r m i n a l
1 8 .
T h e o r d e r s
1 6
-
8/19/2019 Glass Demand Scheduling System
20/28
US 2007/0112451A1
may i n c l u d e r e g u l a r p r o d u c t i o n
o r d e r s
2 0 ,
r u s h o r d e r s
2 2 ,
and remake o r d e r s 2 4 . The rush o r d e r s
22
a r e o r d e r s
t h a t
a r e
p r i o r i t i z e d ,
u s u a l l y
due t o a c u s t o m e r demand. The remake
o r d e r s 24
a r e e n t e r e d
When an IG
5 , a component
of an G ,
o r a
?nished
WindoW
o r
door
58 i s damaged.
I n t h e
exem
p l a r y e m b o d i m e n t , r e m a k e o r d e r s
a re
p r o v i d e d d i r e c t l y t o
t h e
c e n t r a l
c o n t r o l W o r k s t a t i o n 18
by an e l e c t r o n i c
commu
n i c a t i o n 19
from
a g l a z i n g
l i n e
o r a WindoW component
p r o c e s s i n g
s t a t i o n ( F I G .
2 ) .
T h e r e g u l a r
p r o d u c t i o n
o r d e r s
2 0 a r e
o r d e r s
t h a t
have not been tagged a s a rush order or a
re-make o r d e r .
[ 0 0 3 4 ]
The
p r o d u c t i o n
c o n t r o l
t e r m i n a l 1 8 r e c e i v e s t h e
o r d e r s 16
a s
i n p u t and
c r e a t e s
a sequence of r u n s of
i n s u l a t i n g g l a s s u n i t s
t o
b e p r o d u c e d a t a n i n s u l a t i n g g l a s s
u n i t ( I G ) d e p a r t m e n t
2 6 .
I n t h e i l l u s t r a t e d
e m b o d i m e n t ,
t h e
I G d e p a r t m e n t i n c l u d e s s e v e r a l i n s u l a t i n g g l a s s c o m p o n e n t
p r o c e s s i n g
machines
o r s t a t i o n s t h a t c o n s t r u c t IG compo
n e n t s and assemble t h e
IG
components t o c r e a t e I G s . I n t h e
i l l u s t r a t e d e m b o d i m e n t ,
t h e
IG c o m p o n e n t p r o c e s s i n g
s t a
t i o n s
i n c l u d e a
g l a s s c u t t i n g
s t a t i o n
2 8 ,
a s p a c e r
f r a m e
p r o d u c t i o n
s t a t i o n
3 0 ,
a m u n t i n b a r
p r o d u c t i o n
s t a t i o n 3 2 , a
m u n t i n b a r a s s e m b l y
s t a t i o n
3 4 , a g l a s s
W a s h i n g s t a t i o n 3 6 ,
an
IG
assembly s t a t i o n 3 8 , an oven 4 0 , a g a s ? l l s t a t i o n 4 2 ,
a n d a
p a t c h i n g
s t a t i o n 4 4 . G l a s s l i t e s 4 6 , s p a c e r f r a m e s
4 8 ,
and muntin b a r s
5 0 a r e
c o n s t r u c t e d
a t
t h e g l a s s
c u t t i n g
s t a t i o n 2 8 , t h e s p a c e r f r a m e p r o d u c t i o n s t a t i o n 3 0 , a n d t h e
m u n t i n b a r
p r o d u c t i o n
s t a t i o n
r e s p e c t i v e l y .
T h e
g l a s s l i t e s ,
s p a c e r f r a m e s ,
and muntin b a r
g r i d s
50
a r e
a s s e m b l e d
to
form
I G s
a t
t h e
IG a s s e m b l y s t a t i o n 3 8 .
The I G s
a r e f e d
t h r o u g h
t h e
o v e n / p r e s s 4 0 ,
Which p r e s s e s t h e
IG
to a
p r e d e t e r m i n e d
t h i c k n e s s
a n d h e a t s t h e
a d h e s i v e /
e a l a n t t h a t
s e c u r e s t h e
l i t e s
t o t h e s p a c e r f r a m e . The
IGs
a r e then ? l l e d
W i t h an n e r t
g a s
at t h e g a s ? l l s t a t i o n 42 and a t c h e d at t h e
p a t c h i n g
s t a t i o n 4 4 . A n IG d e p a r t m e n t
s u p e r v i s o r
4 5 i s
r e s p o n s i b l e
f o r
m a n a g i n g
e a c h o f
t h e
IG
c o m p o n e n t
p r o
c e s s i n g s t a t i o n s t o e n s u r e t h a t
demands f o r
I G s
by a
g l a Z i n g
department 60
a r e
m e t .
[ 0 0 3 5 ]
T o
s i m p l i f y
t h e d i s c l o s u r e o f h i s
i n v e n t i v e
method
and
a p p a r a t u s , t h e
t e r m g l a Z i n g
i s
to b e i n t e r p r e t e d a s
i n s t a l l i n g a g l a s s l i t e
o r IG
i n any WindoW
o r
door
compo
n e n t
and
h e term
s a s h i s t o be n t e r p r e t e d a s
any WindoW
o r
d o o r
component t h a t
s u r r o u n d s
a
g l a s s l i t e .
[ 0 0 3 6 ] Once
a t c h e d ,
t h e
? n i s h e d
I G s
a r e
p l a c e d
on c a r t s
54 i n a s t a g i n g a r e a
5 6 .
The
c a r t s
54 i n t h e s t a g i n g a r e a 56
f o r m
a
v i s u a l
k a n b a n s y s t e m
5 5 ,
p r o v i d i n g
p r o d u c t i o n
p e r s o n n e l
W i t h a v i s u a l s i g n a l i n g s y s t e m b y m o n i t o r i n g t h e
number o f c a r t s i n t h e s t a g i n g a r e a a s s i g n e d
t o an
assembly
l i n e i n a
g l a Z i n g
d e p a r t m e n t 6 0 . More s p e c i ? c a l l y , t h e I G s
a r e
taken
from
t h e
c a r t s
54 and
a r e
assembled
With
WindoW
s a s h and f r a m e s o r
d o o r s i n
t h e g l aZ i n g d e p a r t m e n t
6 0 to
c o n s t r u c t c o m p l e t e d WindoWs a n d / o r
d o o r s
5 8 .
Assembly
o f
an
IG
t o a WindoW
o r
door
sash
and/or a frame
i s broadly
r e f e r r e d t o
h e r e i n
a s g l a Z i n g .
The
g l a Z i n g d e p a r t m e n t 6 0
i n c l u d e s s e v e r a l d i s c r e t e
g l a Z i n g
l i n e s 6 2 .
[ 0 0 3 7 ]
F I G .
2 i l l u s t r a t e s a
WindoW
a n d / o r d o o r manufac
t u r i n g
f a c i l i t y
1 2 eq u i p p e d W i t h a s y s t e m 6 4 f o r c o n t r o l l i n g
p r o d u c t i o n
r u n s e q u e n c e s o f i n s u l a t i n g g l a s s
u n i t s .
I n t h e
e m b o d i m e n t
i l l u s t r a t e d
b y
F I G . 2 , t h e
p r o d u c t i o n
c o n t r o l
t e r m i n a l 1 8 r e c e i v e s o r d e r s e l e c t r o n i c a l l y
as
i n d i c a t e d by
arr oW 66 from h e f r o n t end s y s t e m
1 4 .
The o n t r o l t e r m i n a l
1 8 e l e c t r o n i c a l l y s e n d s and
e c e i v e s
i n f o r m a t i o n
to
and from
t h e g l a s s c o m p o n e n t p r o c e s s i n g m a c h i n e s
a s
i n d i c a t e d b y
May 7 ,
2 0 0 7
arroW 6 8 . The
f r o n t
end system 14 and
t h e
c o n t r o l t e r m i n a l
1 8 r e c e i v e demand n f o r m a t i o n e l e c t r o n i c a l l y
f r o m t h e
g l a Z
i n g l i n e s
a s
i n d i c a t e d
by
a r r o W s
7 0 , 7 2 r e s p e c t i v e l y . T h i s
information i n c l u d e s a nu m b er of runs 74 i n a
queue 76
f o r
e a c h
g l a Z i n g
l i n e .
The
c o n t r o l t e r m i n a l
1 8
a l s o r e c e i v e s
remake
r e q u i r e m e n t i n f o r m a t i o n
from
t h e g l a Z i n g l i n e s
as
i n d i c a t e d
by
arroW
7 8 .
A d d i t i o n a l remake i n f o r m a t i o n may
be
provided
from one o r mo re of t h e
s t a t i o n s
i n t h e IG
d e p a r t m e n t .
[ 0 0 3 8 ] I n
t h e e x e m p l a ry e m b o d i m e n t , t h e
p r o d u c t i o n c o n
t r o l t e r m i n a l
18 s
a c o n t r o l l e r o r a n c i l l a r y computer n c l u d
i n g
a programmable d e v i c e
i n
communication
W i t h
a p r o
grammable d e v i c e 8 0 l o c a t e d a t e a c h
WindoW
component
p r o c e s s i n g
s t a t i o n
and a
programmable d e v i c e
82 l o c a t e d a t
t h e p l u r a l i t y o f g l a Z i n g l i n e s .
I n
t h e e x e m p l a r y e m b o d i m e n t ,
programmable d e v i c e s
80
a r e e l e c t r i c a l l y c o u p l e d
to con
t r o l l e r s
o f
WindoW c o m p o n e n t p r o c e s s i n g
s t a t i o n s
t h a t
i n c l u d e
c o m p a t i b l e m a c h i n e c o n t r o l l e r s . T h i s a l l o W s
t h e
s e q u e n c e
o f t h e s e WindoW
p r o c e s s i n g s t a t i o n s
t o
b e
a l t e r e d
a u t o m a t i c a l l y .
C o m p a ti b l e m a c h i n e s
a u t o m a t i c a l l y
r u n
t h e
n e x t p r o d u c t i o n r u n i n
t h e
s e q u e n c e , i f con?gured o r Auto
S e q u e n c i n g . S u c h WindoW c o m p o n e n t p r o c e s s i n g s t a t i o n s
i n c l u d e
t h e
g l a s s c u t t i n g s t a t i o n
2 8 , t h e s p a c e r
f r a m e p r o
d u c t i o n s t a t i o n 3 0 , t h e m u n t i n b a r p r o d u c t i o n s t a t i o n 3 2 , a n d
t h e o v e n
4 0 ,
i n t h e
e x e m p l a r y
e m b o d i m e n t .
N o n - c o m p a t i b l e
m a c h i n e s u t i l i Z e t h e s a t e l l i t e programmable
d e v i c e s
8 0 t o
a l e r t t h e o p e r a t o r
of
h e
neW
r o d u c t i o n r u n
s e q u e n c e .
Such
s t a t i o n s
may i n c l u d e a muntin
b a r a s s e m b l y s t a t i o n
3 4 , t h e
g l a s s W a s h i n g s t a t i o n
3 6 ,
a n IG s s e m b l y s t a t i o n 3 8 ,
a
g a s ? l l
s t a t i o n
4 2 , and
a
p a t c h i n g
s t a ti o n 4 4 .
[ 0 0 3 9 ]
R e f e r r i n g t o F I G S . 3 - 5 , t h e s t a t u s o f t h e r u n s
o f
I G s , t h e s t a t u s o f h e i n s u l a t i n g g l a s s c o m p o n e n t
p r o c e s s i n g
m a c h i n e s , a n d t h e q u e u e
o f
i n s u l a t i n g g l a s s u n i t s t o
b e
assembled a t each
g l a Z i n g l i n e
can be vieWed at t h e
p r o
duction c o n t r o l t e r m i n a l 18 o r W o r k s t a t i o n . The s c r e e n
i l l u s t r a t e d b y F I G . 3 p r o v i d e s t h e IG s u p e r v i s o r W i t h t h e
s t a t u s
o f c o m p l e t e
IG
p r o d u c t i o n r u n s , t h e s t a t u s
o f
r u n s
o f
IG
c o m p o n e n t s , and
t h e
s t a t u s
o f completed IG r u n s i n
q u e u e a t t h e g l a Z i n g l i n e s .
Column
400
p r o v i d e s
t h e
IG
s u p e r v i s o r W i t h t h e
o v e r a l l s t a t u s o f IG p r o d u c t i o n
r u n s .
Column 402
p r o v i d e s t h e IG s u p e r v i s o r W i t h t h e s t a t u s o f
r u n s
of muntin
b a r s t h a t
c o r r e s p o n d
to
each o v e r a l l
IG
p r o d u c t i o n
r u n . Column 0 4 p r o v i d e s
t h e IG u p e r v i s o r
W i t h
t h e s t a t u s
o f
r u n s
o f
g l a s s
l i t e s
t h a t
c o r r e s p o n d
t o e a c h
o v e r a l l IG
p r o d u c t i o n
r u n . Column
406 p r o v i d e s
t h e IG
s u p e r v i s o r W i t h
t h e
s t a t u s of
r u n s
o f
s p a c e r
f r a m e s t h a t
c o r r e s p o n d
to e a c h o v e r a l l IG r o d u c t i o n
r u n .
Column 408
p r o v i d e s
t h e
IG
s u p e r v i s o r W i t h t h e s t a t u s o f
t h e
IG
r u n s o f
a t t h e
g a s
? l l and
a t c h i n g s t a t i o n . Column
410 r o v i d e s t h e
IG
s u p e r v i s o r
W i t h
t h e
g l a Z i n g
l i n e
number
o r d e s c r i p t i o n
and
t h e s t a t u s o f e a c h
completed
IG
p r o d u c t i o n r u n
a t t h e
i d e n t i ? e d
g l a Z i n g
l i n e .
[ 0 0 4 0 ]
The s c r e e n o f F I G . 4 p r o v i d e s t h e
IG s u p e r v i s o r
W i t h t h e s t a t u s o f t h e
c o m p l e t e d IG
u n s i n t h e g l aZ i n g
queue
o f e a c h g l a Z i n g l i n e . On t h e s c r e e n i l l u s t r a t e d by
F I G .
4 ,
c o l u m n s
4 1 2 , 4 1 4 , 4 1 6 ,
4 1 8 p r o v i d e t h e
s t a t u s o f
e a c h
r u n
4 2 0
o f a s s em b l e d I G s i n t h e q u e u e s
422
o f g l a Z i n g l i n e s 1 ,
2 , 3 , a n d 4
r e s p e c t i v e l y .
T h e
s t i p h i n g
a n d c r o s s - h a t c h i n g
o f
F I G .
4 c o r r e s p o n d s to t h e
l e g e n d shoWn
i n
F I G .
3 .
[ 0 0 4 1 ]
The s c r e e n i l l u s t r a t e d b y F I G . 5 p r o v i d e s t h e IG
s u p e r v i s o r
W i t h
t h e stat us
o f e a c h p r o d u c t i o n
r u n 424 i n t h e
p r o d u c t i o n r u n
queue f o r
e a c h
WindoW
component
r o c e s s
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