GB2574810A

GB2574810A - Automated process management system

Info

Publication number: GB2574810A
Application number: GB201809924A
Authority: GB
Inventors: Charles Handsaker Joseph
Original assignee: Elements Tech Platforms Ltd
Current assignee: Elements Tech Platforms Ltd
Priority date: 2018-06-18
Filing date: 2018-06-18
Publication date: 2019-12-25
Also published as: GB201809924D0

Abstract

A method for automated recording of process data for one or more steps in a process, comprising; generating a process checklist 10 comprising a plurality of process steps 11 to be completed sequentially; where each step includes prescribed details of at least one item 13 involved in said step, and each item has an associated identification protocol ID 23; obtaining information related to the item in a step by an interaction 30 between the identification protocol ID and a monitoring device 20 as said process step is performed; wherein said information is one or more of time information, location information and the ID of the at least one item of said step; automatically recording one or more of said time, location and ID information for the item in a process information database; automatically checking 31 the performed step off the checklist when the step is completed. The identification protocol ID may be a near-field communication (NFC) tag, and the monitoring device may be enabled for active NFC. The process may be a manufacturing, scientific or testing process.

Description

Automated Process Management system

Field of Invention

This invention relates to an automated process management system using an identification protocol and a device for reading the protocols. The process may be a manufacturing, scientific or testing process.

Background of Invention

A process describes a series of sub-divisions such as actions, steps or operations that are performed sequentially to produce an output. The manufacturing industry relies on the strict and repeatable performance of processes to create products for their customers.

Processes can vary wildly in time to complete, complexity, number of steps, and number of inputs amongst a host of other factors. This means that the success of a process can also vary based on the individual and combined performance of tasks. Because of this, it is preferential to record details relating to a process and the constituent steps of the process. Furthermore, in manufacturing processes that create products to ISO standards it is vital to document the manufacturing process, to provide evidence that certain procedures and tests have been performed to the required ISO standard.

Processes can be recorded in a number of ways, from the most basic recording of a process through handwritten notes; through to fully instrumented manufacturing lines that automatically digitise and record every aspect of a process. Though a fully instrumented manufacturing line may appear to be the gold standard for recording a process, the cost and disruption required to install such instruments makes it a prohibitive option for smaller manufacturers.

One method of recording a process is by creating a checklist, prescribing the constituent features required to perform each sub-division of a process. Such features may include the required tools and equipment, required components and materials, required training, and target output. Nixon (US20140282257A1) describes a method whereby such a system is implemented in a process control environment, with said checklist displayed on a user interface device such as a mobile phone and tasks are checked off, or completed, manually by the operator.

However, in an environment whereby staff are expected to wear gloves for safety purposes, manually ‘checking off’ items on a digitally held checklist can become a cumbersome and slow task, requiring users to take off gloves to operate a touch sensitive digital screen. An alternative to this process is to automate the ‘checking off’ procedure by using an identification medium such as Radio Frequency Identification (RFID), bar codes, and matrix bar codes (such as QR codes) to trigger an item within a checklist. Thus providing a means by which items on a digital checklist can be completed by users wearing appropriate Personal Protective Equipment in a factory in environment.

Asset Tracking using Identification Protocols

In the adjacent field of asset tracking, manufacturers utilise identification protocols to track the movement of assets around a factory, and across a supply chain. Bar codes provide a basic method of asset tracking, whereby users scan a printed bar code with a bar code scanner, identifying a unique identification code corresponding to a record for said asset in a database. Information about the interaction is then logged, and in some cases, information relating to the asset is provided to the user (US20130240621A1; US7258266B1; US20130032634A1). This allows users to ‘check’ items to record their location or timestamp in a process such as a supply chain.

RFID has provided an improved method of asset tracking, by providing a further automated system whereby RFID tags can be identified by RFID scanners at a proximity of up to 12m, allowing assets to be tracked across a facility and across a supply chain (US7504949B1; US746623B2). However, whilst RFID and bar codes (including matrix bar codes) provide a cheap method of identifying who last contacted the asset, and in some cases where the asset was last contacted; all three options require a separate printer to write the identification medium, to the technology required to read the technology.

Near Field Communication (NFC) provides an alternative to these technologies, that can be read, written and rewritten using a standard mobile phone. NFC is therefore a useful tool for transferring data between objects and devices. NFC has been used as an alternative medium for asset tracking (US20130190897A1; GB2550326A; CN105225044A; CN20331122411), providing a more secure and less corruptible method of accessing data from an item to a reader device. Furthermore, due to it’s compatibility with mobile devices such as smart phones, it can be written, read and rewritten using a single device, unlike other identification protocols.

Whilst asset tracking provides a method for the movement of assets to be traced, these methods have been seldom used to capture the manufacturing process that creates said assets.

Process Tracking using Identification Protocols

Data relating to an item can be identified through the interaction between a user device and an NFC tag integrated within a given item (US9258033B2). Said interaction can provide an identification code, and a timestamp for the interaction between the tag and smart device, that could be added to a process history or timeline.

Using a similar process, NFC tags can be used to add events to the history of an item (W02012100009A1; US7259675B2; US20030023408A1), thus providing a detailed description of a process. This method however, requires specific tags to carry information relating to a specific event that may or may not have a specific geolocation (W02012100009A1), or may require additional input from a reader/writer device to create an event (US7259675B2; US20030023408A1).

For a pre-defined process such as a manufacturing process, the process can be prescribed as a series of sequential steps. Furthermore, said steps can be deconstructed into a series of checks making up a checklist. This allows an automation of the logging of a process and it’s constituent events, by the utilisation of an identification protocol interaction such as an NFC interaction, to trigger the checking off events on a prescribed checklist. Thus providing a semi-automated method of checking off sequential items from a checklist held digitally.

For a process consisting of sequential steps, sequential interactions between an identification medium and a smart device could be used to trigger the start and end of a given step. In the example of an individual step of a manufacturing process, the start of said step may be triggered by the interaction between an identification protocol such as an NFC tag placed on an ID badge, and a read device such as an NFC capable mobile phone; subsequently, the end of said step may similarly be triggered by the interaction between an identification medium, and a read device.

A step may require a plurality of non-sequential of triggered checks, relating to a variety of required elements. These, for example, may be a specific user, specific equipment, or specific components; or a combination of features, each with a specific identification protocol that triggers a checking off.

A check may be triggered by a non-specific interaction, whereby no specific combination of identification protocol and read device is required; or said check may be triggered by a specific interaction that requires a specific device, identification protocol, or sub-group of identification protocols to trigger a check. Thus providing an element of quality assurance. In a real-life instance of requiring a specific user or equipment to be used to trigger a check, a specific reader device or identification protocol would be required.

In another real-life instance of requiring an identification protocol relating to a human operator, rather than another sub-group of items such as equipment or components, specific grouping of devices or identification protocols trigger the checking off.

According to the invention there is provided a method for automated recording of process data for one or more steps in a process, comprising the steps of: generating a process checklist comprising a plurality of process steps to be completed sequentially; where each step includes prescribed details of at least one item involved in said step, and each item has an associated identification protocol ID; obtaining information related to an item in a step by an interaction between the identification protocol and a monitoring device as said process step is performed; wherein said information is one or more of time information, location information and the identification protocol ID of the at least one item of said step ;automatically recording one or more of said time, location and ID information for the item in said step in a process information database where the information is stored; automatically checking the performed step off the checklist when the step is completed.

In a preferred embodiment of the invention, said performing and checking steps are repeated until all steps in said checklist are completed.

In an embodiment of the invention, all said performing and checking steps are completed sequentially. Alternatively, one or more of said performing and checking steps are completed in a non-sequential order. In a further embodiment of the invention, some of the steps will be completed sequentially, and some may be completed non-sequentially.

In an embodiment of the invention, one or more of said performing steps is comprised of a series of sub-steps, and at least one sub-step has an associated item. Preferably, one or more of said sub-steps of said performing steps are completed in a non-sequential order.

Further preferably, said item is one or more of a component used in the manufacturing process, a worker working on the process, or a machine used in the process

In an example embodiment of the invention, said time information includes information on when the process step started and when the process step ended. Further preferably said location information includes details of the location of the item during the manufacturing step, and any changes that may occur during the step.

In an embodiment of the invention, the identification protocol ID is an NFC tag.

Further preferably, said monitoring device is a mobile device enabled for active NFC communication with the identification protocol ID.

Preferably, wherein the process checklist is stored in a server that is external to the monitoring device. Alternatively, the process checklist may be stored in said monitoring device.

In the preferred embodiment of the invention, each item has a different identification protocol ID. Alternatively, one or more items may have the same identification protocol ID.

In the preferred embodiment of the invention, said monitoring device can obtain the time, location and identification protocol information when the monitoring device is within 5 metres of the monitored item

Preferably, said process checklist is part of said process information database.

Brief description of the figures

Description of Figures

Figure 1 is a schematic block diagram showing a prescribed checklist on a database;

Figure 2 is a schematic block diagram showing the interaction between an identification protocol and a database;

Figure 3 illustrates a first embodiment of checking off events on a checklist;

Figure 4 illustrates a second embodiment of checking off events on a checklist

Figure 5 illustrates a checklist for a first embodiment of the invention;

Figure 6 illustrates a checklist for a second embodiment of the invention;

Figure 7 illustrates a checklist for a third embodiment of the invention.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.

Description of Invention

In the various embodiment of the invention that follow the invention is generally described with respect to a manufacturing process. A manufacturing process is one where an item is constructed or modified through the performance of a series of prescribed tasks. However, the invention may equally apply to a testing process, whereby records of inputs and testers are added to a process record to create a history of the process, or to a scientific process made up of a series of steps and procedures to be carried out in a prescribed order, for example.

Figure 1 illustrates a prescribed checklist 10 for a manufacturing process, that consists of a series of steps 11, with each step including details of items 13 to be checked off the list 10, that is held on a database 12. The items 13 may be checked sequentially, or non-sequentially, and may relate to an event, or to a user, or relate to a piece of equipment, such a piece of machinery or another component. In a preferred embodiment of the invention, the database 12 is held on an external server, but it may alternatively be held on an external computing device, or on an identification protocol reader 20 capable of reading the identification protocol 23.

Figure 2 illustrates how the identification protocols 23 interact with the database 12. Typically, the identification protocols 23 are NFC tags, that may be attached to the employee ID badge or to the machinery that is performing the process step, or to the component that is being worked on in the specific process step. At least one identification protocol 23 is placed in proximity of the performance of the process.

At least one reader device 20, communicates with the database 12 by means of a wireless network 22. Preferably the reader device 20 is a mobile telecommunications device, but may be a portable handheld device, or portable computing device, or any other mobile communication device. The reader devices and/or identification protocols may be found across a plurality of environments such as multiple factory floors, each providing input to a different step in a given process.

Near Field Communication

Preferably, the first short-range wireless communication protocol used for this method is a protocol such as Radio Frequency Identification (RFID) or Near Field Communication (NFC). These protocols enable two objects or devices to communicate by bringing them within close proximity of one another. It is typically utilised to transfer small amounts of information from one object to another, such as an identifier or short code.

NFC is a subset within the family of Radio Frequency Identification (RFID) technologies, and is specifically a subdivision of high-frequency RFID, operating at a frequency of 13.56Mhz which restricts the read length of the signal. However, because of the required proximity for communication, NFC has become a favoured method of secure peer-to-peer communication.

NFC information transfer occurs when two sensors, each containing an electromagnetic antenna are passed within a proximity small enough to establish an electromagnetic connection between the two sensors, which is less than 100mm and more typically less than 20mm.

NFC sensors can be programmed to cause a smart device to run a series of commands, such as open a web page or app. One such use is for NFC sensors to be attached to, or embedded within business cards; with the sensor running a command to open the website or social media page of the individual described on the business card. Another such use is for a NFC sensor to be attached to a given object; when a mobile device is passed within proximity of the sensor on the object, a command is communicated to cause the opening of a record relating to the object within a database.

An alternative embodiment may utilise a different form of RFID or short-range wireless communications protocol, which allows data to be transferred from an object or device to a device capable of actively capturing data.

Figure 3 shows how the interactions are checked off a checklist 10 using a first embodiment of the invention. Each interaction 30 between an identification protocol 23 and a reader device 20 triggers an item 13 to be checked off 31 the checklist 10.

As shown in figure 4, the manufacturing process checklist 10 comprises a series of steps 11, and each separate step has a start and an end, these will be triggered sequentially by the interaction 30 between a mobile device 20 capable of reading the identification protocol 23 and the identification protocol 23.

A suitably enabled mobile device 20 communicates with the database 12 over a wireless network 13 to access the checklist 10

Each step 11 of the process 10 is started by an NFC interaction 30 between an NFC tag 23 and a mobile phone 20; and is ended by a sequential NFC interaction 30 between an NFC tag 23 and a mobile device 20.

Figure 5 shows a checklist 550, that has three separate sequential steps 501, 502, 503. Steps 501, 502 and 503 each have a start 510, 512, 514 and an end 511, 512, 514. In the process given by checklist 550 each item on the checklist 550 is checked off sequentially, that is start 510 and end 511 of step 501, then start 512 and end 513 of step 502, then start 514 and end 215 of step 503, and so on until the process is completed.

The checklist of figure 5 may be used in the following scenario. One device (such as a mobile phone, or other portable device), will be logged into the process checklist 550, and the device is passed across the manufacturing process. Staff working on the process will use ID protocols, in this case, an NFC tag on an ID badge to trigger the sequential items on the checklist, that is the start and stop stages for each of the steps 501,502, 503.

In this example of the invention, a single ID protocol (e.g. an NFC tag) will be used to identify each step of the process (and the start/stop within each step). The ID protocol is passed along between the workers on the process, and each worker of members of staff will have a suitable device to check the ID protocol. The worker/staff member will interact their device with the ID protocol to trigger the item to be checking off of the process checklist 550.

In this example of the invention, the checking of all of the items 510, 511, 512, 513, 514, 515 on the checklist 550 can be triggered by the interaction between any ID protocol and any device.

Figure 6 is an example of the invention that uses non-sequential checking of the items from a process checklist 650, using specific ID protocols. The checklist has steps 601,602 and 603. Each of the steps includes multiple different items, in the figure each step includes 4 items, but any number of items may be included in each step, and each step may also include different numbers of items

This figure illustrates how the checklist 650 can be used for non-sequential checking of process items in two alternative scenarios. The first is using a single identification protocol reader device 20, that will read multiple ID protocols associated with the steps of the checklist-in some cases two steps may have the same ID protocol, but at least two steps in the process will be provided with a different ID protocol. The alternative scenario is the all the process steps use the same ID protocol (as described in figure 5) but there are multiple different identification protocol reader devices 20 that will be used through the process.

As illustrated each step 601,602, 603 has a plurality of items 611,612, 613, 614, (four items in the illustration, but there may be any number of two or more items in each step) the items may include details of components needed for the process and equipment to be used for that process step. In this example, the items in each step may includes details of the components to be used in the step, details of equipment that is used in the step, and/or details of the stop/start time of the step in the process.

Each of the items 610,611,612, 613, can be checked off in any order independent of the ordering in the checklist step.

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Figure 7 is a further example of a process checklist 750. In this example there are three process steps, 701, 702, 703. Each process step includes a start item, 710, 710’, 710” and an end item 711, 71T, 711”. Each step also includes details of components 712, 713, 714, 715, 716 that are used in the steps 701, 702, 703 of the process. Like the example of figure 6, this example can be used for non-sequential checking of process items in two alternative scenarios. The first is using a single identification protocol reader device 20, that will read multiple ID protocols associated with the steps of the checklist-in some cases two steps may have the same ID protocol, but at least two steps in the process will be provided with a different ID protocol. The alternative scenario is the all the process steps use the same ID protocol (as described in figure 5) but there are multiple different identification protocol reader devices 20 that will be used through the process.

In this example, the item starts 710, 710’, 710” and item end 711, 71T, 711” have to be checked off the checklist sequentially, but the components 712, 713, 714, 715, 716 that are used in the steps 701, 702, 703 can be checked off sequentially or consequentially.

In another embodiment of the invention, a plurality of identification protocol reader devices 20 are used, and a single identification protocol 23 is used to trigger Each check

In this one embodiment, one identification protocol reader device 20 is used, and a plurality of identification protocols 23 are used to trigger each check

In all of the examples of the invention discussed above, the process checklist 10, 550, may be uploaded to the identification protocol reader 20, alternatively, the process checklist 10, 550, may be held on external server, and continuously communicated with by identification protocol reader 20.

As described above, Near Field Communication (NFC) tags are used for the Identification protocol, Alternatively, the identification protocol may use Radio Frequency Identification (RFID).

The identification protocol ID 23 may be a bar code, in some cases a matrix bar code, or a QR code.

As discussed in the various examples given above, each step and associated check in each checklist 550, 650, 750 may be completed sequentially, or non-sequentially, or some items within each step may be completed sequentially, with the remaining items completed sequentially or non-sequentially. Sequential checks may relate to the start and end of a time period.

Furthermore, a step may be checked off by a single identification protocol interaction, or the step may be checked off by a plurality of identification protocol interactions.

Use Case Example

The proposed invention provides a method by which a structured and prescribed series of actions can be performed by a plurality of contributors, across a plurality of facilities.

Large manufacturers such as Original Equipment Manufacturers (OEMs) typically operate on sites consisting of a multiple of facilities and factories. Components may be manufactured across a succession of facilities, therefore resulting in high amounts of movement across a site. There is therefore a need for a method whereby the complex manufacturing process can be captured and standardised using a checklist, that can be performed in a quick and simple manner.

In the example of turbine blade manufacture by wax loss process, the manufacturing process typically consists of over one hundred steps, which are performed across multiple distinct phases, in multiple facilities. Each turbine blade interacts with a plurality of contributors, equipment, and added components and materials, making the tracking of this process complex and time consuming.

The described invention provides a method by which the process can be tracked using a quick and simple method, accurately and objectively providing data to a prescribed checklist to ensure that the procedure is performed in a standardised and repeatable manner. The described invention furthermore provides a method by which a large amount of detail about a succession of steps can be provided with minimal input from contributing users.

The proposed invention also provides a method by which a structured and prescribed series of actions can be performed by a plurality of contributors, supporting collaborative work across many facilities or environments which may be regional, national or international. In an increasingly globally collaborative workplace, supported by international communication networks, such an invention is necessary for ensuring the structured performance of prescribed processes and work flows.

In an example of a scientific study whereby several contributors work on a project, each contributor may be assigned a step of a process according to their specific expertise. Initial steps relating to an experimental procedure may be completed by a contributor in a laboratory, relating to the performance of testing procedures within a study. Upon completion of said experimental steps, another contributor in another facility may then perform a series of steps relating to the statistical analysis of the data obtained in said initial steps. Furthermore, a third contributor may use these statistical analyses to write up the procedure into an academical article. This provides a useful collaborative tool for national and international studies that are completed by a multitude of contributors contributing different skills and techniques, that are often situated at different institutions that are located globally.

In another example, the process may be cross disciplinary; whereby design work is followed by production of said design. In said example a series of initial steps may comprise of the design of a component in Computer Aided Design software, and a virtual test of the component by the same contributor. The design may then be sent to a second contributor, who may import the design and manufacture the designed component using a 3D printer positioned in a different facility.

It will be further appreciated that, for clarity purposes, the described embodiments of the invention with reference to different functional units and processors may be modified or re-configured with any suitable distribution of functionality between different functional units or processors is possible, without detracting from the invention. For example, functionality illustrated to be performed by separate processors or controllers may be performed by the same processor or controller.

Hence, references to specific functional units are only to be seen as references to suitable means for providing the described functionality, rather than indicative of a strict logical or physical structure or organization.

Aspects of the invention may be implemented in any suitable form including hardware, software, firmware or any combination of these. The invention may optionally be implemented, at least partly, as computer software running on one or more data processors and/or digital signal processors.

Thus, the elements and components of an embodiment of the invention may be physically, functionally and logically implemented in any suitable way. Indeed, the functionality may be implemented in a single unit, in a plurality of units or as part of other functional units. Those skilled in the art will recognize that the functional blocks and/or logic elements herein described may be implemented in an integrated circuit for incorporation into one or more of the communication units.

Although the present invention has been described in connection with some example embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the scope of the present invention is limited only by the accompanying claims. Additionally, although a feature may appear to be described in connection with particular embodiments, one skilled in the art would recognize that various features of the described embodiments may be combined in accordance with the invention. In the claims, the term ‘comprising’ does not exclude the presence of other elements or steps.

Furthermore, although individually listed, a plurality of means, elements or method steps may be implemented by, for example, a single unit or processor. Additionally, although individual features may be included in different claims, these may possibly be advantageously combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. Also, the inclusion of a feature in one category of claims does not imply a limitation to this category, but rather indicates that the feature is equally applicable to other claim categories, as appropriate.

Furthermore, the order of features in the claims does not imply any specific order in which the features must be performed and in particular the order of individual steps in a method claim does not imply that the steps must be performed in this order.

Rather, the steps may be performed in any suitable order. In addition, singular references do not exclude a plurality. Thus, references to ‘a’, ‘an’, ‘first’, ‘second’, etc. do not preclude a plurality.

Claims

1. A method for automated recording of process data for one or more steps in a process, comprising the steps of:

generating a process checklist comprising a plurality of process steps to be completed sequentially;

where each step includes prescribed details of at least one item involved in said step, and each item has an associated identification protocol ID;

obtaining information related to an item in a step by an interaction between the identification protocol and a monitoring device as said process step is performed;

wherein said information is one or more of time information, location information and the identification protocol ID of the at least one item of said step;

automatically recording one or more of said time, location and ID information for the item in said step in a process information database where the information is stored;

automatically checking the performed step off the checklist when the step is completed.

2. A method according to claim 1 wherein said performing and checking steps are repeated until all steps in said checklist are completed.

3. A method according to claim 2 wherein one or more of said performing steps is comprised of a series of sub-steps, and at least one sub-step has an associated item.

4. A method according to claim 3 wherein one or more of said sub-steps of said performing steps are completed in a non-sequential order.

5. A method according to any preceding claim where said item is one or more of a component used in the process, a worker working on the process, or a machine used in the process

6. A method according to any preceding claim where said time information includes information on when the process step started and when the process step ended.

7. A method according to any preceding claim wherein said location information includes details of the location of the item during the process step, and any location changes that may occur during the step.

8. A method according to any preceding claim wherein the process is one or more of a manufacturing process, a scientific process or a testing process.

9. A method according to any preceding claim wherein the identification protocol ID is an NFC tag, card or sticker.

10. A method according to claim 9 wherein said monitoring device is a mobile device enabled for active NFC communication with the identification protocol ID.

11. A method according to any preceding claim wherein the process checklist is stored in a server that is external to the monitoring device.

12. A method according to any of claims 1 to 10 wherein said process checklist is stored in said monitoring device.

13. A method according to any preceding claim wherein each item has a different identification protocol ID.

14. A method according to any of claims 1 to 12 wherein an item is checked off said process checklist using a sub-group of identification protocols.

15. A method according to any preceding claim wherein said monitoring device can obtain the time, location and identification protocol information when the monitoring device is within 5 metres of the monitored item.

16. A method according to any preceding claim wherein said process checklist is part of said process information database.