EP1041006A2 - Method and device for monitoring a (cigarette) making and packaging plant - Google Patents

Abstract

The method involves detecting the quantity of finished or partially finished products such as cigarettes or cigarette packet products in stores by continuous or cyclic measurement. The amount to be produced is compared with the amount already produced. the amount already produced reaches a critical amount, the production units are set back in succession, run empty and finally switched off. Any stores are emptied so as to give the desired amount of products. An Independent claim is included for a method of controlling a production and packing line. An apparatus is also claimed.

Description

The invention relates to a method for controlling a manufacturing and packaging system for cigarettes or similar products from manufacturing units, such as (cigarette) manufacturing machine (Maker), packaging machine (packer), possibly film wrapping machine, if necessary pack packer (bar packer) and if necessary Carton packer (cartoner) to manufacture and ready to ship Packaging products - cigarettes - a certain, limited Quantity - target quantity. The invention further relates to a facility for performing the method.

The manufacture of cigarettes (or cigarillos) increasingly requires a quick, economical adaptation to different Products. These differences can be qualities of cigarettes, different brands, equipment, etc. concern. Often there are only a limited number of a variety or brand or equipment To manufacture quantities.

So far, the manufacturing and packaging system has only been rough the number of (cigarette) packs to be manufactured adjusted, with overproduction in the safe range. This is often not deductible and ultimately has to be destroyed.

The invention is based, in particular the complete task Manufacturing and packaging system for cigarettes control that limited quantities - target quantities - are produced can, without the production with too large overproductions connected is.

a) die sich im Herstellungs- bzw. Verpackungsprozess befindliche Menge an ganz oder teilweise fertiggestellten Produkten - z.B. Zigaretten und/oder Zigarettenpackungen - werden einschließlich von sich in Speichern befindlichen Produkten - durch permanente oder zyklische Messungen erfasst und mit der zu produzierenden Sollmenge einerseits sowie einer bereits produzierten Istmenge andererseits verglichen,

b) bei Erreichen einer kritischen Istmenge, die zusammen mit den im Herstellungs- bzw. Verpackungsprozess vorhandenen Produkten die herzustellende Sollmenge ergeben, werden nacheinander die aufeinanderfolgenden Fertigungseinheiten heruntergefahren, leergefahren und schließlich abgeschaltet, wobei etwaige Speicher ebenfalls leergefahren werden, derart, dass bei Stillstand der Fertigungs- und Verpackungsanlage die gewünschte Sollmenge produziert ist.

To achieve this object, a first method according to the invention has the following features:

a) The amount of fully or partially finished products in the manufacturing or packaging process - e.g. cigarettes and / or cigarette packs - including products in storage - are recorded by permanent or cyclical measurements and with the target quantity to be produced on the one hand and a on the other hand, the already produced actual quantity is compared,

b) when a critical actual quantity is reached, which together with the products in the manufacturing or packaging process result in the target quantity to be produced, the successive production units are shut down, emptied and finally switched off, with any memories also being emptied, such that when the Manufacturing and packaging system, the desired quantity is produced.

Monitoring the storage of cigarettes and cigarette packs as well as the other manufacturing units of the "line" by known organs, such as sensors, buttons, counters etc., so that the current production status practically at all times recorded and then further measures are taken can.

Alternatively, the object can be achieved according to the invention by that taking into account the target quantity to be manufactured the performance of the individual production units, the reject production known as empirical value and taking into account a current, unexpected faulty production each manufacturing unit the required for the target quantity Material, especially packaging material is provided.

The manufacturing process of the entire manufacturing and packaging system is evaluated via a common central computer and displayed on a connected screen.

There is another special feature of the method according to the invention in that before the target quantity of products is reached - Cigarettes / packs of cigarettes - on every manufacturing unit existing material, especially packaging material, with regard to the reusability for the next one Product type checked and displayed on a screen.

According to the invention, the target quantity to be produced can be derived from a result from product-related specifications, but alternatively also from an existing inventory of certain material, for example of tax stamps for cigarette packs. The target quantity can correspond to the number of tax stamps available.

Fig. 1

eine Fertigungs- und Verpackungsanlage für Zigaretten im schematischen Grundriss,

Fig. 2

eine schematische Darstellung einer Steuerungseinrichtung für eine Anlage gemäß Fig. 1,

Fig. 3

ein Fließbild über die Mengensteuerung der Anlage,

Fig. 4

eine Grafik über den Funktionsablauf bei der Fertigung und Verpackung der Zigaretten,

Fig. 5

ein weiteres Diagramm über die Ermittlung von Materialbedarf,

Fig. 6

ein Diagramm über den Verfahrensablauf bei Beendigung der Produktion einer Charge,

Fig. 7

ein Beispiel für eine Bildschirmanzeige.

Further special features of the invention are explained in more detail below with reference to the drawings. It shows:

Fig. 1

a manufacturing and packaging system for cigarettes in a schematic floor plan,

Fig. 2

1 shows a schematic illustration of a control device for a system according to FIG. 1,

Fig. 3

a flow diagram about the quantity control of the plant,

Fig. 4

a graphic of the functional sequence in the manufacture and packaging of the cigarettes,

Fig. 5

another diagram about the determination of material requirements,

Fig. 6

a diagram of the process flow at the end of the production of a batch,

Fig. 7

an example of an on-screen display.

The embodiment shown in the drawings relates a manufacturing plant for cigarettes, a so-called Line. This consists of manufacturing units, namely for example from a cigarette manufacturing machine, namely a maker 10, a packaging machine connected to this, a packer 11, a subsequent film wrapping machine 12, a packaging machine for manufacturing Containers from several packs of cigarettes, i.e. a packer 13 and a cartoner 14, which holds the packaging containers, ie cigarette sticks, packed in a shipping box.

The cigarettes made by the maker 10 are made by one Cigarette conveyor 15 with a cigarette store 16 Packer 11 fed. This can be, for example a hinge-lid packer, i.e. a packaging machine for the production of folding boxes. The packer 11 is a Cutting memory 17 assigned, so a device for recording a larger stock of pre-made blanks for the hinged box. The blank store 17 also has conveying members on for feeding stacks of blanks to the packer 11.

The (cigarette) packs manufactured by the packer 11 are via a pack conveyor 18 of the film wrapping machine 12 supplied. Its job is to put the cigarette packs in to wrap an outer foil or plastic blank. Out The finished cigarette packs become pack groups formed in the area of the bar packer 13 with a packaging be provided and thus a cigarette stick usually result in ten packs of cigarettes. These cigarette sticks are the cartoner by a bar conveyor 19 14 fed. This transfers finished shipping boxes 20 a plurality of cigarette sticks to a conveyor 21. Im Area of the pack conveyor 18 between the packer 11 and the Foil wrapping machine 12 is a pack store 22 to accommodate a larger number of cigarette packs (without outer wrapping).

The manufacturing units described must be supplied with material become. Sufficient tobacco is to be supplied to the maker 10, also cigarette paper in the form of wrapped Lanes, namely bobbins. Furthermore, the maker 10 is also to feed filter attachment paper wrapped in the form of bobbins, so that the manufactured cigarettes are in the range of one Filter attachment machine 23 supplied with the appropriate material can be. The other manufacturing units are packaging material also in wound paths, i.e. as Deliver bobbins. This applies to the manufacture of a Cigarette packs of the type collapsible box usual collar, furthermore for an inner covering, a so-called inner liner the cigarette group and for the outer wrapping made of foil or Cellophane. For this purpose, a central warehouse 24 is provided, in which the bobbins 25 of different materials, for example are stored on pallets. A suitable conveyor, for example, a common material conveyor 26 is along a conveyor track 27 between the bearing 24 and the individual Manufacturing units can be moved for the delivery of the bobbin material upon need.

In the example shown, the bearing 24 can be constructed that filter attachment paper 28, collar material 29, inner liner material 30, film material 31 and cigarette paper 32 in the area the conveyor track 27 for takeover by the material conveyor 26 are positioned, each in a favorable relative position to the assigned manufacturing unit.

The process of manufacturing the cigarettes until the manufacture of the finished shipping cartons filled with cigarette sticks 20 will continuously and from time to time monitored and recorded. To 2 is a control unit 33 for this purpose Manufacturing unit or machine unit with a central line 34 connected. A central computer 35 is in turn connected to these connected. In addition, computers are in the area of (Material) warehouse 24 and connected in the shipping area, namely a storage PC 36 and a shipping PC 37. The latter is located in the area of the cartoner 14 or the conveyor 21. Data can be supplied to the central computer 35, in the present case Trap by laptop 38. The control units 33 are the maker 10, the filter attachment machine 23, the packer 11, the Pack storage 22, the bar packer 13 and the cartoner 14 assigned.

The production control with regard to a certain production quantity according to a first embodiment performed that a small amount to the required production Safety margin is added, for example between 5% and 10% and that the quantity specification thus formed - Target quantity - serves as an input variable. The actual manufacturing, so the total production is larger than the target quantity, taking into account scrap production or Faulty productions of every manufacturing unit or unit. The control shown as an example takes into account on the one hand the expected wrong production and on the other hand one unexpected wrong production. This results in an actual one Wrong production. The expected wrong production results from the data of the individual manufacturing units and units, which are available and saved due to the constant company evaluation are. The unexpected wrong productions are caused by Monitoring or querying the production data of the individual Manufacturing units and aggregates determined during production. The production data constantly becomes from the two data the system determines taking into account the quantity specification, namely, that at the end of production and manufacturing the target quantity has been reached.

The number of cigarettes to be produced results from the Target quantity and the actual wrong productions of the whole Line. The cigarette production may have to do that during the manufacturing and packaging process changing data adjusted, namely increased or reduced.

Taking into account the data mentioned, namely the target quantity and the expected, that is, known, misproduction, the required material of each manufacturing unit is at the beginning made available for production. The unexpected Incorrect production leads to a change in the provision of material, in particular the subsequent request and subsequent delivery of material for individual manufacturing units.

As explained using the flow diagram in FIG. 3, it is assumed that that the quantity specification - target quantity - 5,000 units is, for example 5,000 cigarettes or packs. Due to queries in the area of manufacturing units the respective additional manufacturing requirement for units is determined. The individual manufacturing units are shown schematically as Rectangles shown. On the left side of each manufacturing unit 10, 11, 12, 13, 14 is a bar symbol for additional claims 39 on material. On the opposite Page is symbolic based on horizontal Stripes depicting the wrong production, namely in the extended Line the actual misproduction resulting from the expected misproduction 40 (dashed line) and the unexpected Incorrect production 41 composed.

It is assumed that the carton packer 14 is the end machine in the line an actual (total) faulty production of 50 Units delivered and that these are the expected misproduction 40 corresponds, so not unexpected wrong production is incurred. As a result of the way the carton packer works an (expected) additional demand for 50 units has been determined. The upstream bar packer 13 must have a usable production deliver from 5,050 units.

For the rod packer 13, an expected incorrect production of 50 units plus an unexpected misproduction of 100 units assumed. On the one hand, this means that the preceding manufacturing unit, i.e. the film wrapping machine 12, deliver a usable quantity of 5,200 units got to. In addition, there is an additional requirement 39 for packaging material required, for the unexpected wrong production of 100 units.

The film wrapping machine 12 has an entire one in this example Wrong production of 60 units. There is one against it assumed incorrect production 40 out of 140 units. Because the previous one Manufacturing unit, namely the packer 11, according to the actual Incorrect production is loaded, the pack 11 deliver a quantity of 5,260 units.

For the packer 11 it must also be taken into account that a given, assumed misproduction of 100 units given is. It is also an unexpected, additional one Incorrect production 41 out of 290 units to be considered. On the one hand, this means that the Maker 10 due to the Performance of the packer 11 additional cigarettes for 390 units must deliver, a total of 5,650 units.

For the subsequent delivery of packaging material to the packer 11 (during the production process) other considerations come up to carry. The demand 39 for the packer 11 is in itself determined by the unexpected incorrect production 41, i.e. with 290 Units charged. However, since the subsequent manufacturing unit, namely the film wrapping machine 12, a "material credit" of 40 units, the packer is 11 material only to be delivered later for 250 units.

The Maker 10 is through the following manufacturing units with a production of 5,650 units. It is believed, that an expected misproduction 40 out of 200 units given is. In addition, there are 230 units of unexpected Bad production 41. This means that the production of cigarettes is a total of 6,080 units to the performance of the Makers 10 and all subsequent manufacturing units take into account, so that at the end the quantity specification of 5,000 is reached.

Due to the preloads from the subsequent production units must have 10 material, namely tobacco and cigarette paper and filter paper for 480 units during the Manufacturing process can be delivered later.

4, 5 and 6 show the block diagrams the processes during production to determine the demand values as well as to end the manufacturing process.

Fig. 4 shows an overview of the manufacturing process, wherein in the functions or measures are shown in individual fields are.

According to field 42, at the start of batch production, the Central computer 35 entered the mark to be manufactured and the Quantity specification, i.e. the demand to be produced, including a low safety margin. Then the production program begins.

The (initial) amount of packaging and other material of each manufacturing unit. For this purpose, the stored, average or expected wrong productions retrieved for each manufacturing unit or unit. In In connection with the quantity specification, the material quantity, in particular the amount of packaging material calculated in accordance with field 44 become. Corresponding information is sent to the warehouse PC 36 transmitted and accordingly the material to the individual manufacturing units made available.

This calculation cycle is used during batch production repeated several times or continuously, for all production units this line. In each case, the ascertained Changes to the specifications and assumptions taken into account. This requires the manufacturing units through sensors and other supervisory bodies with regard to the production process and especially with regard to those in the line fully or partially finished products monitored become. In particular, in the manufacturing units and existing (known) sensors and probes in the memories, which record the respective level and corresponding data deliver to the central computer 35.

To record the fully or partially manufactured quantities the present result according to field 45 after each calculation cycle determined again by query and calculation. It will first by querying the number of packs in the manufacturing process detected. Furthermore, the amount of memory of cigarettes in the cigarette store 16, the amount of packs recognized in the pack store 22. After all, that too Detects packs that have left the cartoner 14 and are filled as "good packs" in the shipping carton 20.

A calculation is made from this query data in accordance with field 46 carried out, namely the present total production determined from the queries according to field 45. The calculated total production is compared with the target quantity according to field 47. If the total production does not (yet) reach the target quantity the need calculation for the individual manufacturing units repeated, in accordance with that shown in Fig. 5 Procedure. However, if the quantity specification has been reached or exceeded, the shutdown of the production line initiated in accordance with the steps shown in Fig. 6.

5 shows the calculation sequence for determining the Material requirements, especially packaging material for the individual manufacturing units.

According to field 47, machine-specific data are requested, namely the production output of Maker 10, Packer 11, film wrapping machine 12, bar packer 13 and cartoner 14. Des further faulty productions of the aforementioned manufacturing units determined, namely the actual faulty production from the known (assumed) wrong production and the unexpected wrong production. From this data according to field 47 the consumption of material or packaging material for the individual manufacturing units calculated according to field 48. According to Field 49 is then made a comparative calculation the actual consumption of material or packaging material in relation to the "good packs" in the area of Cartoner 14 the average consumption of material the production unit concerned (with the expected wrong productions) also the good packs in the area of the cartoner 14 compared. If the first comparison number is larger If the second is, another calculation is made according to field 50 employed, namely for packaging or other material of the relevant manufacturing unit. To this The purpose is the incorrect production of the machine in question, for example the maker 10, and the subsequent manufacturing units 11, 12, 13, 14 added up and from this the one to be requested Material determined for the relevant manufacturing unit. Appropriate information is given to the warehouse. This calculation is done sequentially for all manufacturing units performed the line.

If due to the queries shown in connection with FIG. 4 and calculations the total production equal or greater is as the quantity specification, the shutdown process according to Fig. 6 initiated.

First, the Maker 10 is shut down. This means, that the supply of the material - tobacco, cigarette paper and Filter paper - interrupted and the Maker 10 in terms of Production is "run dry" and finally switched off. The cigarette store 16 downstream of the maker is under Maintaining the working speed of the following Manufacturing units run empty. The fill level of the cigarette store 16 is constantly queried. If the cigarette store is emptied, the operating state for the subsequent packer 11 "Empty run" initiated. If due to appropriate Query the packer 11 is empty, this manufacturing unit switched off.

The pack storage 22 is at full working speed empty. The fill level is also monitored here. If the pack storage 22 is empty, for the following film wrapping machine 12 the operating state "Empty run" initiated.

The filling status of the film wrapping machine 12 is then queried. If this production unit is empty, the shutdown takes place. At the same time, the bar packer 13 is in the operating state "Empty driving changed. If a query shows that the cartoner 14 has run empty, the end of production given. All production units are switched off. Remnants of packaging material are automatically removed. This is checked by a query. A ready message will appear on given the central computer 35. This shows the end of production on.

The above-described monitoring of the entire manufacturing and packaging system in relation to those already manufactured Products or partially finished products enabled another, advantageous control of the production quantity or a target quantity to be produced. It is assumed that sufficient material for the individual production units of the line, in particular packaging material is available or is requested as needed. Instead of continuous consideration of known, expected and unexpected Faulty productions become an already manufactured quantity of products (Cigarette packs / cigarettes), i.e. an actual quantity, continuously or by cyclical polling - for example at intervals of 10 s. - juxtaposed, namely under arithmetic Consideration of that in the manufacturing and packaging system existing material or taking into account the Completely or partially finished products. This result is compared to the target quantity. If the actual quantity produced together with those in the manufacturing and packaging system The shutdown process is the result of existing products initiated for the manufacturing and packaging system, first by shutting down and finally shutting it down of the maker up to the last production unit.

The predetermined target amount can be determined in different ways be determined, in particular also by necessary consumption Materials. In particular, it may be necessary Pack cuts of certain equipment and / or tax stamps completely to consume and then the one to be manufactured To set the target quantity.

Finally, there is a special feature of FIG. 7, namely from the representation on a connected to the central computer 35 Screen, for example of the laptop 38. The display provides information about the stock and type or possible use the material of a manufacturing unit, namely the Packers 11. The information refers to the upcoming Change of product type, for example a change of brand. It is the packaging materials processed in the pack 11 specified, namely cuts, film web (for the inner wrapping the cigarette group) and material webs for manufacturing of collar blanks. The screen shows that the products "blanks" and "inner wrapping" for the next one Brand are not suitable. When switching off the manufacturing and Packaging system are therefore these two packaging materials exchange. In contrast, the material for the Collar also used for the next execution of the packs become.

The material is always complete, but the smallest possible Units made available to the manufacturing units at Example using pallets with a specified amount of packaging material.

Reference symbol list:

10th

Maker

11

packer

12th

Foil wrapping machine

13

Bar packer

14

Cartoner

15

Cigarette conveyor

16

Cigarette store

17th

Cutting memory

18th

Pack conveyor

19th

Bar conveyor

20th

Shipping carton

21

Conveyor

22

Pack storage

23

Filter attachment machine

24th

camp

25th

Bobine

26

Material conveyor

27

Conveyor track

28

Filter paper

29

Collar material

30th

Inner liner material

31

Foil material

32

Cigarette paper

33

Control unit

34

Central line

35

Central computer

36

Warehouse PC

37

Shipping PC

38

Laptop

39

Demand

40

expected misproduction

41

unexpected wrong production

42

field

43

field

44

field

45

field

46

field

47

field

48

field

49

field

50

field

Claims (13)

Method for controlling a manufacturing and packaging system for cigarettes or similar products from manufacturing units, such as (cigarette) manufacturing machine (maker 10), packaging machine (packer 11), possibly film wrapping machine (12), possibly packer (bar packer 13) and possibly Carton packer (cartoner 14) for the manufacture and ready for dispatch packaging of products - cigarettes - a certain, limited quantity - target quantity -, characterized by the following features: a) The amount of fully or partially finished products in the manufacturing or packaging process - e.g. cigarettes and / or cigarette packs - including products in storage - are recorded by permanent or cyclical measurements and with the target quantity to be produced on the one hand and a on the other hand, the already produced actual quantity is compared, b) when a critical actual quantity is reached, which together with the products in the manufacturing or packaging process result in the target quantity to be produced, the successive production units are shut down, emptied and finally switched off, with any memories also being emptied, such that when the Manufacturing and packaging system, the desired quantity is produced. Method for controlling a manufacturing and packaging system for cigarettes or similar products with several manufacturing units, such as (cigarette) manufacturing machine (maker 10), packaging machine (packer 11), possibly film wrapping machine (12), possibly packer (bar packer 13) and possibly Carton packer (cartoner 14) for the manufacture and ready to ship packaging of products - cigarettes - a certain, limited quantity - target quantity -, characterized by the following features: a) on the basis of the quantity to be produced - target quantity - the need for material for each production unit is determined, in particular tobacco, cigarette and topping paper for the maker (10), packaging material for the packaging machines (11, 12, 13, 14), in particular under Consideration of incorrect production occurring at every production unit, b) the determined material, in particular packaging material, is sent to each manufacturing unit for processing, c) the production and packaging system is set up to manufacture the target quantity, plus a safety margin if necessary, and is switched off accordingly. Method according to claim 1 or 2, characterized in that the target quantity to be produced is determined on the basis of the material present in the area of a (selected) production unit, in particular on the basis of blanks. A method according to claim 1 or 2, characterized in that each manufacturing unit of the manufacturing and packaging system material, including packaging material, is made available at the start of the manufacturing process on the basis of the (known) average performance of the manufacturing unit in question, including the (known) expected incorrect production . A method according to claim 4, characterized in that the actual faulty production for each manufacturing unit during the manufacturing process is determined continuously or from time to time and is compared with the predetermined, expected misproduction and that in the case of (additional) unexpected faulty production corresponding to material, including packaging material, the manufacturing units additionally is made available. Method according to Claim 2 or one of the further claims, characterized in that for the maker (10) the total quantity of cigarettes to be produced is determined on the basis of the target quantity, possibly including a safety quantity, and taking into account the expected incorrect productions of each production unit, and in that changes in the total production of cigarettes to be produced are adjusted during the manufacturing process due to possible additional unexpected faulty productions of the individual manufacturing units. Method according to Claim 2 or one of the further claims, characterized in that the total production achieved is ascertained and compared to the target quantity several times during the production process by querying and calculating the performance of the individual production units, and in that the calculation cycles are repeated as long as the determined total production is lower than the target quantity. Method according to claim 7 or one of the further claims, characterized in that the completion of the manufacturing process is initiated when the total production is greater than or equal to the target quantity on the basis of the queries and calculations. Method according to Claim 2 or one of the further claims, characterized in that when the end of the production process is initiated, the production units and any memories are emptied in succession, the state of the production units or memories being determined by queries, starting with the maker (10), which shuts down immediately upon initiation of the termination process. Method according to claim 1 or one of the further claims, characterized in that packaging material is made available in the smallest transport units of a manufacturing unit, in particular as a pallet. Method according to claim 1 or one of the further claims, characterized in that in the case of an impending product change, in particular in the case of a brand change for cigarettes, before completion of the target quantity, the material present in the production and packaging system - residual material - with regard to the usability for the production of the new one Product or the new brand is checked, the result of the check is visually displayed to an operator on a screen. Device for carrying out the method according to one or more of claims 1 to 11, characterized in that measuring and control elements of the individual production units are connected to a central computer (35) and this is connected to a screen. Device according to claim 12, characterized in that each manufacturing unit is assigned a control unit (33) and this is connected to the central computer (35) via a central line (34).

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