glass demand scheduling system

8/19/2019 Glass Demand Scheduling System

1/28

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 ,

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J a n .

5 ,

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P a t . No.

7 , 1 6 7 , 7 6 7 , Which

i s

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( 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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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


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


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


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


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


o r d e r s

a n d c o n v e r t i n g t h e


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



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


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


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


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


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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glass demand scheduling system

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