Integrated manufacturing system

Abstract

A manufacturing system utilizes a common database structure and product definition to achieve true integration of multiple systems. The production definition includes an item and specification to define material or resources used in or related to a manufacturing process. The item identifies the material or resources, and the specification describes its performance specifications. Multiple manufacturing systems each utilize the same common database structure and product definition for processing data. These systems may include an Environmental, Health, Safety & Training system to manage environmental and health aspects of the manufacturing process. A New Product Development system may also be integrated with the common database to facilitate and automate the process of developing new products. The true integration of manufacturing systems allows full communication among the systems and automates many functions, such as generating reports and monitoring of hazardous materials and agents.

Claims

What is claimed is:

1. A plant-level manufacturing system for integrating together an enterprise-level system, a process control system, and other sub-systems, the plant-level manufacturing system comprising:

a) database means for storing and managing data in a common database describing material used and created in the manufacturing process, the database means comprising:

i) item means for storing items, each of the items identifying physical properties of the material;

ii) specification means for describing a plurality of sets of performance specifications of the material; and

iii) database linking means for linking one or more of the sets of performance specifications to one of the items;

b) interface means for linking the enterprise-level system and the process control system to the database means, the interface means comprising:

i) means for transferring data between the enterprise-level system and the plant-level manufacturing system;

ii) means for transferring data between the process control system and the plant-level manufacturing system; and

iii) means for transferring data from the process control system to the enterprise system; and

c) integration means for linking other sub-systems within the plant-level system to the items and the performance specifications in the common database and for allowing both the sub-systems and the plant-level system to utilize the same items and the same performance specifications in the common database.

2. The plant-level manufacturing processing system of claim 1 wherein the database means further comprises container means for specifying sets of containers in which the material is to be purchased, manufactured, or sold and for linking one or more of the sets of containers to one of the performance specifications.

3. The plant-level manufacturing processing system of claim 1 wherein the interface means further comprises means for linking a maintenance management system to the common database and for transferring data between the maintenance management system and the plant-level manufacturing system, the maintenance management system comprising means for scheduling preventive maintenance for equipment used in the manufacturing process.

4. The plant-level manufacturing processing system of claim 1 wherein the interface means further comprises means for linking a lab information management system to the common database and for transferring data between the lab information management system and the plant-level manufacturing system, the lab information management system comprising means for receiving a request for a lab test of material and for sending results of the lab test on the material.

5. The plant-level manufacturing processing system of claim 1 wherein the interface means further comprises means for linking a finite scheduling system to the common database and for transferring data between the finite scheduling system and the plant-level manufacturing system, the finite scheduling system comprising means for receiving a master schedule and for generating in response a finite schedule.

6. The plant-level manufacturing processing system of claim 1 wherein the interface means further comprises means for linking a process historian system to the common database and for transferring data between the process historian system and the plant-level manufacturing system, the process historian system comprising:

a) means for gathering detail data describing events in the manufacturing process from the process control system

b) means for summarizing the detail data; and

c) means for transmitting the summarized data to the plant-level system.

7. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a quality certification system to the items and the performance specifications, the quality certification system comprising:

a) means for setting up tests to be performed on material defined by the items and their related performance specifications;

b) means for creating a many-to-many relationship between the tests and combinations of the items and the related performance specifications; and

c) means for storing results of the tests.

8. The plant-level manufacturing system of claim 7 wherein the quality certification system further comprises:

a) means for generating a certificate of analysis based upon the results of the tests; and

b) means for determining and reporting whether the results of the tests are within predefined limits.

9. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a production management system to the items and the performance specifications, the production management system comprising means for scheduling and reporting production of material defined by the items and the performance specifications.

10. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a purchasing system to the items and the performance specifications, the purchasing system comprising means for creating a first set purchase orders based upon the items and the performance specifications and for receiving a second set of purchase orders from the enterprise-level system.

11. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a customer order system to the items and the performance specifications, the customer order system comprising means for creating a first set customer orders based upon the items and the performance specifications and for receiving a second set of customer orders from the enterprise-level system.

12. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a material control system to the items and the performance specifications, the material control system comprising means for analyzing an inventory to perform inventory transactions.

13. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a quality-based costing system to the items and the performance specifications, the quality-based costing system comprising means for calculating product costing, for financial reporting, and for operational analysis.

14. The plant-level manufacturing processing system of claim 1 wherein the integration means further comprises means for linking a financial and administrative management system to the items and the performance specifications, the financial and administrative management system comprising means for organizing and arranging financial data related to the manufacturing process.

15. A health, safety, and training system integrated to a plant-level manufacturing system for managing health, safety, and training aspects of a manufacturing process, the health, safety, and training system comprising:

a) integration means for using a common data repository with the plant-level manufacturing system so that both the health, safety, and training system and the plant-level manufacturing system share the same item data within the repository, the item data describing material used and created in the manufacturing process;

b) the common data repository comprising database means for storing and managing the item data, the database means comprising item means for storing items, each of the items identifying physical properties of the material and health, safety, and training information related to the material;

c) human interface means for linking employee identification data with health and safety factors related to job requirements in order to determine preventive action for employees to alleviate effects of the health and safety factors, the human interface means comprising:

i) means for storing sets of employee identification data in the common database;

ii) means for storing sets of job requirements in the common database and for linking the sets of job requirements with the sets of employee identification data;

iii) means for storing sets of health and safety factors in the common database and for linking the sets of health and safety factors with the sets of job requirements; and

iv) means for storing sets of preventive action data in the database and for linking the sets of training data with the sets of health and safety factors; and

d) means for linking the preventive action data with the employee identification data to determine a preventive action plan for a particular employee.

16. The health, safety, and training system of claim 15 wherein the means for storing sets of job requirements comprises:

a) job location means for storing characteristics of job locations related to the health and safety factors; and

b) job type means for storing characteristics of job functions related to the health and safety factors.

17. The health, safety, and training system of claim 15 wherein the means for storing sets of health and safety factors comprises:

a) means for storing expected exposure to the items based upon the job requirements; and

b) means for storing expected exposure to agents based upon the job requirements.

18. The health, safety, and training system of claim 17 wherein the means for storing expected exposure to agents comprises:

a) means for storing expected exposure to noise;

b) means for storing expected exposure to a particular machine which requires specialized training.

19. The health, safety, and training system of claim 15 wherein the means for storing preventive action data comprises:

a) means for storing required medical exams based upon the health and safety factors; and

b) means for storing required employee training based upon the health and safety factors.

20. An environmental system integrated to a plant-level manufacturing system for managing environmental aspects of a manufacturing process, the environmental system comprising:

a) integration means for using a common data repository with the plant-level manufacturing system so that both the environmental system and the plant-level manufacturing system share the same item data within the repository, the item data describing material used and created in the manufacturing process;

b) the common data repository comprising database means for storing and managing the item data, the database means comprising item means for storing items, each of the items identifying physical properties of the material and environmental information related to the material; and

c) environmental means for managing physical properties of the material which are incidental to the environment, the environmental means comprising:

i) identification means for storing environmental factors of the material in the common database;

ii) tracking means for recording usage and production of the material in the common database; and

iii) reporting means for outputting data from the common database related to the usage and production of the material.

21. The environmental system of claim 20 wherein the identification means comprises means for storing information relating the material which includes flammability, combustibility, or carcinogenic.

22. The environmental system of claim 20 wherein:

a) the identification means comprises means for storing a CAS-level profile of the material;

b) the tracking means comprises means for recording usage of particular hazardous elements of the material based upon the CAS-level profile; and

c) the reporting means comprises means for outputting data related to the usage of the particular hazardous elements of the material based upon the CAS-level profile.

23. The environmental system of claim 20 wherein the identification means comprises means for storing a Material Safety Data Sheet related to the material.

24. The environmental system of claim 20 wherein the reporting means comprises means for generating a SARA report based upon the material.

25. A system integrated to a plant-level manufacturing processing system for managing the development of new products, the system comprising:

a) integration means for utilizing a common database with the plant-level manufacturing system, the database comprising database means for storing and managing experimental data describing material to be used and created in the manufacturing process for the new product, the database means comprising:

i) item means for storing experimental items, each of the items identifying physical properties of the material; and

ii) specification means for describing a plurality of sets of experimental performance specifications of the material and for linking one or more of the sets of performance specifications to one of the items;

b) communication means for electronically directing work flow related to the development of the new product; and

c) commercialization means for converting the experimental data into product data for commercial production of the new product.

26. The system of claim 25 wherein the communication means comprises:

a) means for providing electronic-mail notification of tasks in the development process to a person responsible for the task; and

b) means for providing electronic-mail approval of the tasks in the development process.

27. The system of claim 25 wherein the communication means comprises means for generating and reporting checkpoints along the development process.

28. The system of claim 25 the commercialization means comprises means for changing the experimental item and the experimental specification into a commercial item and a commercial specification.

29. The system of claim 25 wherein:

a) the communication means comprises:

i) means for defining a sequence of events for completing the development process; and

ii) means for defining tasks and necessary skills to complete the events; and

b) the commercialization means comprises means for converting the experimental item and the experimental specification in the common database into a commercial item and a commercial specification to be utilized by the plant-level system in manufacturing the new product.

Description

FIELD OF THE INVENTION

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

The present invention relates to a plant-level system that utilizes a common database and product definition for integrating together various manufacturing systems. The present invention is particularly useful in, but is not limited to, the process industry.

BACKGROUND OF THE INVENTION

Process manufacturers have traditionally used a variety of systems for managing a manufacturing process. These systems may include an enterprise system, which may contain customer service, resource planning systems, and other centralized functions. The typical prior art enterprise systems are at a high level and are relatively removed from the actual manufacturing process. Typical resource planning systems may be accomplished by a material requirements planning system that tracks inventory and facilitates in planning for the inventory required in a particular production run.

Typical prior art environmental systems are often used to generate reports required by the government. By government regulations, manufacturers using hazardous materials must submit reports to the government that include, for example, amounts and types of hazardous material manufactured, processed, or otherwise used in the manufacturing process. Also, under right-to-know laws, employees have a right to know the types of hazardous material, if any, to which they are exposed. Environmental systems assist in managing this type of data and in generating reports.

Prior art health, safety, and training systems are typically used to track exposure of employees to hazardous materials and to determine preventative measures. The system may contain the various exposures and keep track of any employee exams or training. An employee who is exposed to hazardous materials may undergo periodic exams to determine if the exposure has caused any health problems. Employees may also have training regarding how to handle or work with hazardous materials, and the training is designed to minimize the potential for injury or exposure to the material.

Prior art low-level systems used in the manufacturing process may include area/unit control systems that interface and control the actual machinery on a shop floor in a manufacturing process. Workers on the shop floor may use data obtained with the enterprise system to determine inputs to the area/unit control system. For example, the enterprise system may indicate the quantity of a particular resource required in a manufacturing process. On the shop floor, a worker may obtain that quantity information and use it in the area/unit control system to adjust the manufacturing process to accommodate the desired quantity.

Between the prior art enterprise, area/unit control, and other manufacturing systems, there exists an information gap. These prior art systems operate independent of one another and typically use different product definitions in different and incompatible databases. For example, in traditional process manufacturing systems, the environmental and health, safety and training systems are stand-alone systems that operate independent of both one another and any other system used to control the manufacturing process. Accordingly, the systems are unable to efficiently communicate with one another or other manufacturing systems system. In order for these systems to communicate, either data must be manually reentered into one system from another or complex interface programs must be written to transfer data between the incompatible databases.

Another type of stand-alone system that may be used in a manufacturing process is a system for developing new products. When developing new products, particularly in the process industry, time to market can be critical in obtaining a competitive advantage. A company that is late in getting a product to the market may end up obtaining a much smaller portion of the market share, even though the company's product may be in no way inferior to the first product on the market. As a result, maintaining maximum efficiency in the development process is essential.

Traditionally, companies develop new products by shuffling papers or files from one person to another throughout the development process. Each person typically evaluates the product in his or her role within the company and then pass the "new product file" on to the next person. This process can be slow and inefficient due to the large interchange of paper documentation.

Alternatively, there is some availability of commercial product development systems, which provide electronic documentation of the development process and attempt to automate the process. These systems, however, are not integrated with a plant-level manufacturing system, which means that, once the new product is finalized and ready to be commercially produced, the information from the product development system must be entered into a manufacturing control system in order to set up the entire production run. These system, therefore, assist in new product development, but do not necessarily assist in determining parameters to be used in the plant-level system for manufacturing the new product.

Even though the manufacturing systems described above may be crudely interfaced together, they are not truly integrated. As a result, the systems have inefficiency that could only be resolved by true integration.

A need exists, therefore, for a truly integrated manufacturing system that utilizes a common database structure. In particular, a need exists for integrating environmental and health, safety and training systems within plant-level manufacturing system. There is an additional need, particularly in the process industry, for a new product development system that is completely integrated within the plant-level manufacturing system.

SUMMARY OF THE INVENTION

An integrated system provides an efficient solution to the problem of communicating between various manufacturing systems, because the entire integrated system is built around a unique and common product definition within the common database structure. A truly integrated system facilitates data transfer and automates many tasks, such as the generation of environmental reports and scheduling of exams and training for employees. Furthermore, a plant-level system fills the information gap between enterprise-level and process control systems.

The present integrated manufacturing system invention is an integrated manufacturing system invention that utilizes a common product definition as the basis for a truly integrated plant-level manufacturing system. In the present system, all of the integrated manufacturing systems use the same product definition and thus the same data format and data storage location. The product definition provides a link between any of the various manufacturing systems and provides for an efficient and more powerful use of the information contained in the product definition.

An item, specification, and container structure and relationship within a common database forms the unique product definition in the present integrated manufacturing system invention. Items may include the various resources used in a manufacturing process to produce one or more end products. Each item is linked to one or more sets of specifications. The specifications may include performance characteristics of the particular item, and these performance characteristics define the item. Each specification is linked to one or more containers. A container may indicate either the physical location where the particular item is stored or the type of packaging used to contain the material.

The manufacturing systems used in conjunction with the manufacturing process in the present integrated manufacturing system invention are linked to the product definition structure within the database. The data used by all of these systems is thus stored in a common location and in the same format. Data transfer between the systems occurs through the product definitions in the common integrated database. The common database is part of a distributed system that may be on multiple machines.

The present environmental invention utilizes a common database product definition as the basis for integrating an environmental system and a health, safety and training system to a plant-level manufacturing system. The integrated systems use the same product definition and thus the same data format. The product definition provides a link between any of the systems, which automates environmental and health, safety and training functions in the manufacturing process.

The use of a common database to integrate the systems allows information from many parts of the systems to be linked together through the product definition. This is particularly useful with the integrated health, safety and training system. Exposure to items within the product definition are linked to job locations, and job locations are linked to employees. Employees are thus effectively linked to exposure to items due to the jobs they perform. Based on this information, the present invention may automatically schedule exams and training for employees as preventative measures to the risk of exposure.

The present new product development invention utilizes a common product definition as the basis for integrating a new product development system to a plant-level manufacturing system. The new product development system uses the same product definition as the plant-level system and thus the same data format. The product definition provides a link between the new product development system and any of the various manufacturing systems that are also integrated with the plant-level system, which automates and documents the pipelined process of developing new products.

Furthermore, since data is stored in the common database product definition during new product development, the data required for commercially producing the product is automatically linked to the systems required to set up the production run. This feature saves considerable time between the finalization of the new product and the commercial availability of the product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a conceptual block diagram showing a plant-level system integrated with an enterprise and area/unit control systems.

FIG. 1B is a conceptual diagram showing a number of manufacturing systems integrated to a common database.

FIG. 1C is a preferred data flow diagram of an integrated manufacturing system.

FIG. 1D is a block diagram showing the product definition structure within a common integrated database.

FIGS. 2A-2B is an interconnected block diagram used to illustrate the meaning of the symbols in the data model and data structure diagrams.

FIG. 2C is a preferred data model of a Production Management module.

FIG. 2D is a preferred logical data model of a Product Process Definition module.

FIG. 2E is a preferred logical data model of a Purchasing module.

FIG. 2F is a preferred logical data model of a Customer Order module.

FIG. 2G is a preferred logical data model of a New Product Development (NPD) data model.

FIG. 2H is a preferred logical data model of Enterprise Level modules.

FIGS. 2I and 2J is a preferred logical data model of Environmental, Health, Safety & Training modules.

FIGS. 3A-3H represent a preferred database layout structure of an integrated manufacturing system.

The following drawings are preferred data flow diagrams, organized and identified by module, for a system that implements an integrated manufacturing system.

COMMON SYSTEM FUNCTIONS MODULE (PSCS)

System Support Set-Up (CSSS)

FIG. 4: System Parameter Maintenance (CS01).

FIG. 5: User Maintenance (CS02).

FIG. 6: Shop Calendar Maintenance (CS03).

FIG. 7: Currency Exchange Rate Maintenance (CS04).

FIG. 8: UOM Conversion Factor Maintenance (CS05).

Functions Maintenance (CSFM)

FIG. 9: Facility Maintenance (CS06).

FIG. 10: Enterprise Facility Maintenance (CS27)

FIG. 11: Agency Maintenance (CS07)

FIG. 12: Vendor Maintenance (CS09)

FIG. 13: Employee Maintenance (CS10)

FIG. 14: Container Maintenance (CS12)

FIG. 15: Procedure Maintenance (CS13)

FIG. 16: Process Line Maintenance (CS14)

FIG. 17: Enterprise Process Line Maintenance (CS28)

FIG. 18: Customer Bill-To Maintenance (CS15)

FIG. 19: Customer Ship-To Maintenance (CS16)

FIG. 20: Session Constant Maintenance (CS22)

FIG. 21: Electronic Mail User Maintenance (CS23)

FIG. 22: Inventory Location Maintenance (CS24)

FIG. 23: Procedure Code Where Used (CS25)

FIG. 24: Electronic Mail Message Maintenance (CS26)

Product Relationship (CSPR)

FIG. 25: Customer/Item/Spec Maintenance (CS18)

FIG. 26: Item/Spec/Vendor Maintenance (CS21)

ENVIRONMENTAL MODULE (PSEN)

EHST Setup (ENES)

FIG. 27: Job Type Maintenance (EN20)

FIG. 28: Environmental Location Maintenance (EN21)

FIG. 29: Physical Agent Maintenance (EN22)

Compliance Quantities (ENCQ)

FIG. 30: CQ Inquiry (EN10)

FIG. 31: CQ Source Maintenance (EN11)

Release Management (ENRM)

FIG. 32: Unplanned Release Maintenance (EN03)

FIG. 33: Agency Notification Maintenance (EN05)

Waste Management (ENWM)

FIG. 34: Waste Shipping Request Maintenance (EN07)

FIG. 35: Waste Profile Maintenance (EN09)

FIG. 36: Biennial Summary Maintenance (EN14)

Employee Exposures (ENEE)

FIG. 37: Employee Job/Location Maintenance (EN16)

FIG. 38: Job/Location Exposure Maintenance (EN17)

FIG. 39: Employee Exposure Inquiry (EN18)

FIG. 40: Item Exposure Maintenance (EN19)

HEALTH MODULE (PSHL)

FIG. 41 illustrates the employee-exposure relationship and how a preferred system links employees with required training and medical exams.

Medical Surveillance (HLMS)

FIG. 42: Medical Exam Maintenance (HL01)

FIG. 43: Employee Exam Maintenance (HL02)

FIG. 44: Exam Schedule Maintenance (HL03)

FIG. 45: Medical Result Maintenance (HL08)

FIG. 46: Employee Work Restriction Maintenance (HL09)

FIG. 47: Dispensary Visit Maintenance (HL10)

FIG. 48: Incident Maintenance (FT04)

FIG. 49: Safety Statistics Maintenance (FT05)

FIG. 50: Occupational Illness and Injury Incidents Maintenance (FT06)

Training (TR)

FIG. 51: Training Course Maintenance (TR01)

MATERIALS MANAGEMENT MODULE (PSMM)

Purchasing (MMPR)

FIG. 52: Blanket Purchase Order Maintenance (MM01)

FIG. 53: Purchase Requisition Maintenance (MM02)

FIG. 54: Purchase Order Maintenance (MM03)

FIG. 55: Vendor Return Maintenance (MM04)

Customer Orders (MMCO)

FIG. 56: Customer Order Maintenance (MM40)

FIG. 57: Customer Order Line Assignment (MM41)

FIG. 58: Customer Return Maintenance (MM42)

Inventory (MMIN)

FIG. 59: Inventory Inquiry (MM20)

FIG. 60: Record Inventory Transaction (MM21)

FIG. 61: Item Transfer (MM22)

FIG. 62: Record Lot Split and Merge (MM23)

FIG. 63: Item Lot Tracking and Tracing (MM24)

FIG. 64: Browse Inventory Transaction (MM25)

FIG. 65: Cycle Count Class Assignments (MM30)

FIG. 66: Cycle Count Results (MM31)

FIG. 67: Cycle Count Schedule Maintenance (MM32)

Receiving (MMRC)

FIG. 68: Purchased Item Receipt/Rejection (MM10)

FIG. 69: Customer Return Receipt (MM11)

FIG. 70: Historical Receipts/Corrections (MM13)

Shipping (MMSP)

FIG. 71: Customer Shipment Maintenance (MM50)

FIG. 72: Waste Shipment Maintenance (MM52)

FIG. 73: Report Shipment Pick List (MM53)

PRODUCTION MANAGEMENT MODULE (PSPM)

Production Planning (PMPP)

FIG. 74: Production Order Maintenance (PM01)

FIG. 75: Production Scheduling (PM02)

FIG. 76: Detail Production Resource Netting (PM04)

FIG. 77: Campaign Launch (PM05)

FIG. 78: Process Line Downtime Maintenance (PM30)

Production Execution (PMPE)

FIG. 79: Record Production Results (PM10)

FIG. 80: Record Miscellaneous Production (PM11)

FIG. 81: Record Process Line Events (PM12)

FIG. 82: Correct Production Recording (PM13)

Production History (PMPH)

FIG. 83: Production Statistics (PM20)

FIG. 84: Process Line Utilization (PM21)

NEW PRODUCT DEVELOPMENT MODULE (PSPD)

FIGS. 85A-85B are an example of a customized new product development pipeline that may be constructed by a New Product Development module. Design Request (PDDR)

FIG. 85C: Create/Submit A Request (PD03)

FIG. 86: Browse A Request (PD04)

Request Maintenance (DRMN)

FIG. 87: Update A Request (PD05)

FIG. 88: Project Milestones (PD08)

FIG. 89: Request Status (PD09)

FIG. 90: Maintain Profile (PD10)

FIG. 91: Maintain Definition (PD11)

FIG. 92: Revision History (PD12)

FIG. 93: Design Request Comments (PD17)

FIG. 94: Financial Analysis (PD19)

Experimental Solutions (DRES)

FIG. 95: Experimental Solutions (PD06)

FIG. 96: Commercialize Queue (PD13)

FIG. 97: Commercial Scale Up (PD21)

FIG. 98: Commercialize P-Types (PD22)

Request Custom Reports (DDRP)

FIG. 99: Design Request Reports (PD14)

FIG. 100: Browse Design Request Reports (PD24)

Work Queue Management (DRWQ)

FIG. 101: Priority Detail (PD07)

FIG. 102: Project Leader Work Queue (PD23)

Raw Materials (PDRM)

FIG. 103: Environmental Summary (PD02)

Parameter Maintenance (PDPM)

FIG. 104: Status Maintenance (PD15)

FIG. 105: Design Category Maintenance (PD16)

FIG. 106: Business Group Maintenance (PD18)

FIG. 107: Report Template Maintenance (PD20)

PRODUCT MANAGEMENT MODULE (PSPR)

Item Maintenance (PRIM)

FIG. 108: Item Maintenance--General Information (PR01)

FIG. 109: Item Maintenance--Physical Hazards and Precautions (PR02)

FIG. 110: Item Maintenance--Health Hazards (PR03)

FIG. 111: Item Maintenance--Compliance Quantities (PR04)

FIG. 112: Item Maintenance--Transportation Data (PR05)

FIG. 113: Item Maintenance--Molecular Formulation (PR06)

FIG. 114: Item Maintenance--Control and Safety Measures (PR07)

FIG. 115: Item Maintenance--User Defined Fields (PR17)

Item/Spec Maintenance (PRSM)

FIG. 116: Item/Spec Control Formula Maintenance (PR08)

FIG. 117: Item/Spec Cost Maintenance (PR10)

FIG. 118: Item/Spec Maintenance (PR11)

FIG. 119: Item/Spec Substitute Maintenance (PR12)

FIG. 120: Item/Spec Container Maintenance (PR13)

FIG. 121: Item/Spec Process Code Maintenance (PR15)

FIG. 122: Item/Spec Where Used (PT16)

FIG. 123: Item/Spec Planning Data Maintenance (PR20) QUALITY CERTIFICATION MODULE (PSQC)

FIG. 124: Quality Certification (QC01)

SYSTEM INTERFACE FUNCTIONS MODULE (PSSI)

FIG. 125: Inbound Error Correcting (T010)

FIG. 126: Outbound Error Correcting (T030)

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. This embodiment is described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural or logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

I. INTRODUCTION

FIG. 1A illustrates conceptually the integration of an enterprise-level system 100, a plant-level system 101 and a process control system 102. The enterprise-level system 100 is a high-level system that contains many of the traditional functions performed in a manufacturing system, which may include, for example, material requirements planning. An example of a commercially available enterprise-level system is the MAC-PAC System developed by Andersen Consulting, the assignee of the present invention.

The process control system 102, also referred to as an area/unit control system, is a low-level system that interfaces an actual manufacturing process or system in order to control production. The system further includes a plant-level system 101 which contains various plant-level systems, only a few of which are shown in FIG. 1A. The plant-level system 101 provides the capability to further refine data from the enterprise-level system, facilitates data transfer, and is a communications link between the enterprise-level and process control systems. On the process control side, the plant-level system 101 may summarize data. All three of these systems are integrated together through a common database structure.

FIG. 1B further illustrates the system by showing the integration of various manufacturing systems. A common database structure 108 is at the heart of the system and integrates together the various manufacturing systems. Integration of systems is distinct from interfacing and provides for a higher level of communication, versatility, and data processing capability. Integration means that the various manufacturing systems are linked to a common database that uses a uniform structure for storing and processing data. The system preferably stores data in a single database structure that all of the manufacturing systems may access. The common database, or data repository, is part of a distributed system that may be on multiple machines. An interfaced system, in comparison, may have the same data stored in different locations and in different, often incompatible, database structures. By using a common database structure, integration of systems thus solves many data processing problems in the manufacturing industry.

FIG. 1B illustrates manufacturing systems that may be integrated together in the common database 108. The systems shown are either typical or desired systems for manufacturing, and the integration techniques used with these systems may be extended to other systems without departing from the scope of the invention. For example, as described below, a new product development system may also be integrated into the manufacturing system.

Customer service and logistics system 103 is a typical enterprise-level system that performs such functions as tracking and maintaining inventory, accounting, generating purchase orders, processing customer orders, and managing the distribution of goods. Resource planning system 104 performs traditional material requirements planning functions. Management system 105 defines and maintains resources within the system. Product management system 117 includes a new product development system.

Plant operations system 106 may contain the following functions. Quality certification system 109 may set up tests to be performed on resources identified by the system, stores the results of those tests, and may generate a certificate of analysis. Production management system 110 may schedule and report production of materials identified by the system. Maintenance management system 111 may schedule preventative maintenance for equipment used in the manufacturing process. Laboratory information system 112 may coordinate lab tests and results of those tests for materials used in the manufacturing process. Process historian system 113 may gather data from the process control system describing events in the manufacturing process, summarize the events, and store the summary. Purchasing system 114 may generate and organize purchase orders for material used in the manufacturing process. Materials control system 115 may analyze inventory and perform inventory transactions. Financial and administrative management system 116 may perform various accounting functions. Process definition system 118 is used to set up manufacturing formula and process.

Environmental, health, safety & training (EHST) module 107 is also integrated into the system. This module manages and processes data related to environmental and health aspects of the manufacturing process and is particularly useful in process manufacturing that involves hazardous materials or agents. An agent may be a potentially harmful intangible, such as noise. Since this module is integrated with the system, it may automatically track hazardous materials and perform functions such as generating reports of hazardous materials as required by government regulations. The health portion of the module may perform functions such as scheduling of training or medical exams for employees who work with or may otherwise be exposed to hazardous materials. The integration again provides the system with the capability to automatically schedule and track the required training and exams for employees. The integration also enables the use of thresholds and automatic collection of data and reporting of usage of hazardous materials to governmental agencies.

FIG. 1C is a data flow diagram that represents the preferred operation of a system that achieves integration of multiple manufacturing systems. Each of the steps shown in FIG. 1C may generally represent a complete system module. Since the system is fully integrated, the modules shown utilize the same product definition in the common database. Step 201 involves routines to set up data in the system and also comprises common system functions. The currency exchange rate conversation (CS04) is an example of a common system function, since currency exchanges are used throughout the system modules. Common system functions also interact with the enterprise-level system 215 via communication path 200. At step 202, a user may define a product as either commercial or experimental. The New Product Development (NPD) module manages experimental products. At step 203, the system sets up a design request and project requirements, which may be based on data entered by a user. At step 204, experimental product information is defined, and again the system utilizes the common database and product definition to represent this data.

Due to the integration of the NPD module with the system, data for an experimental product is stored in the same product definition in the common database as the other modules. One advantage of the integration of the NPD module is that, when the experimental product is ready for production, the system may reclassify it at step 216 as commercial and the data required for production is already in the database and ready to be used in producing the product. While the NPD module is particularly useful in the process industry, it may have applications in many other industries as well.

For commercial products, the system proceeds to step 205 to define and maintain commercially produced product information. The unique product definition utilized to maintain this information is further explained below. A number of manufacturing modules may interact with the product definition and operate on the data in the common database. At step 206, the system may set up data for purchasing and customer order information.

At step 210, the system may utilize the Environmental, Health, Safety & Training modules to manage health and environmental aspects of the manufacturing process. The environmental aspects may involve compiling data on any emissions of hazardous materials. Due to the integration of systems, the system may automatically monitor environmental aspects at step 210 and report emissions when they exceed predefined threshold limits. The health aspects may include monitoring and scheduling medical exams and training for employees who are exposed to hazardous materials or agents. The integration again provides the system with the power to automatically monitor these health aspects.

At step 208, the system may utilize the Production Management module to control the manufacture of commercial products. The system may interact with the process control system and units along communication path 212 to manage the production. At step 213, the system records quality results of the products produced at step 208. Other manufacturing systems may interact along communication path 211 with the modules monitoring the produced product. Finally, the system may ship the material or products to customers at step 214.

At step 209, the system may set up materials management functions. At step 207, the system may generate reports based on the data stored in the common database to manage the manufacturing process. The reports may include, for example, emissions of hazardous materials to be submitted to governmental agencies, medical exams and required training for employees, and lists of purchase orders.

II. THE INTEGRATED DATABASE

The common database which achieves integration of the manufacturing systems is built around a common database structure. FIG. 1D illustrates a preferred basic database structure and the integration of manufacturing systems to this structure. The basic preferred database structure 123 comprises the elements of an item 120, specification 121, and container 122. Item 120 identifies a material or resource used in, or related to, the manufacturing process. An item may either be a commercial or experimental item. Experimental items are used in conjunction with the New Product Development Module. Each item may by linked to one or more sets of specifications 121. Specification 121 comprises performance characteristics of an item. Each specification 121 may be linked to one or more containers 122. Container 122 specifies either a physical location of the material or a container in which material used in the manufacturing process is to be purchased, manufactured, or sold.

Common database structure 123 thus defines material in terms of its performance characteristics by creating an item/specification/container relationship. An item/specification relationship would be a sufficient structure for integrating manufacturing systems. The container element is included in a preferred database structure for additional processing power.

The implementation of a logical ownership concept in the system is an example of the usefulness of the container element in the preferred database structure. Logical ownership of material identifies the person or entity responsible for a particular amount of material. The integration utilized in the system allows a user to view inventory both by logical ownership and location. Table 1 includes a matrix as an example to illustrate this concept.

                  TABLE 1
    ______________________________________
    tank 1:    15 gal.                10 gal.
    tank 2:                6 lbs.      3 lbs.
    tank 3:               20 gal.      2 gal.
               owner 1    owner 2     owner 3
    ______________________________________