GB2291514A

GB2291514A - A production controller.

Info

Publication number: GB2291514A
Application number: GB9414129A
Authority: GB
Inventors: Patrick Kelly
Original assignee: Individual
Current assignee: Individual
Priority date: 1994-07-13
Filing date: 1994-07-13
Publication date: 1996-01-24
Anticipated expiration: 2014-07-13
Also published as: BE1007047A6; GB9414129D0; GB2291514B

Abstract

A production controller (1) has a case tracking processor (2) which automatically triggers and implements the events to move cases along process tracks. There may be a very large number of cases and the events are automatically initiated. There may be a number of different parallel tracks for each case. Real-time data is inputted from a network system (4) and transaction data is automatically uploaded from a transaction processing system (20). The case tracking processor operates in a batch process mode to move each case along to the next stage at the correct time. In each batch process a fixed record (31) is referred to and this may cause the processor to go into loops to move the case along to the next stage. <IMAGE>

Description

"A Production Controller" The invention relates to the control of a large number of sequences of events, and more particularly to simultaneous control of a large number of sequences. Each sequence may be referred to as a 'production process" or as a case for the controller to direct. To avoid confusion with terms used to describe operation of the controller, the term "case" is used in this specification.

Many controllers, known as process controllers, have been developed for control of particular processes, for example, European Patent Specification No. EP-B-0033228 describes an industrial control system which has a number of remote units connected by a communications link. The system appears to be satisfactory for control of a single, albeit complex, industrial process. However, available controllers generally do not have the facility to control a large number of processes or cases and the tendency has been to provide dedicated controllers for specific cases.

An example of a situation where simultaneous control of a large number of cases is desirable is a mechanical engineering plant where progress of a large number of subassembly lines must be monitored and controlled. Another is where production and distribution of drugs are monitored to provide traceability for the end user.

According to the invention, there is provided a production controller comprising : a case tracking processor having in excess of 10 MB of memory, in excess of 1 GB of non-volatile storage capacity, and a multi-processor circuit; a transaction processor connected to the case tracking processor by a high speed data transfer link; a network system connected to the case tracking processor by a parallel data bus, and comprising a plurality of printers and workstations; a set of definition records of stages in process tracks to be followed by cases, the records being stored in the case tracking processor; a set of variable and fixed data records stored in the case tracking processor in a relational database structure; a means in the case tracking processor for receiving data relating to cases from the network system, for automatically filtering the data into fixed and variable categories, for updating fixed data records and variable data records for cases, the records being related together in a relational database structure; a real-time interface for automatically updating the case fixed and variable data records on reception of update data from the network workstations and scanners and transaction data transmitted from the transaction processor; and an output interface connected to a production device; a means in the case tracking processor for operating in batch mode to sequentially read a record for each case in turn, and to activate an event for that case according to the stage at which the case is located in the tracking process, the event being driven by commands in the relevant stage definition record and data read from the records.

Ideally, the case tracking processor comprises means for automatically retrieving a fixed data record for each case in turn, for reading from said record the stage for the case and the time duration since the last event, and means for automatically determining from said data if a subprocess involving access to the relevant stage definition record is required.

In one embodiment, the fixed record has a stored key for access to the relevant stage definition record.

Preferably, the case tracking processor comprises means for automatically retrieving data from the related variable data records for the case according to information read in the stage definition record, and means for determining if an event is to be activated according to data read from the fixed and variable records and the stage definition record.

In another embodiment, the case tracking processor comprises means for activating an event by generating a log file of printing instructions under direction of commands in the stage definition record during batch runtime, and means for prompting operator input of a print instruction for printing in accordance with the log file.

In a still further embodiment, the case tracking processor comprises means for automatically updating the variable records upon completion of an event.

Ideally, the fixed record comprises data relating to a plurality of stages, and the case tracking processor comprises means for carrying out a plurality of subprocesses for a case before passing on to the next case fixed record.

In another embodiment, fixed data is initially inputted at an interface connected to a data verifier and an automatic retrieval device for retrieving correct data related to an inputted data item.

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which : Fig. 1 is a diagrammatic view of a production controller of the invention; Fig. 2 is a flow chart illustrating the manner in which the controller operates; Fig. 3 is a diagrammatic view showing progress of a particular case; and Fig. 4 is a flow chart illustrating both batch and real-time processing steps.

Referring to the drawings, and initially to Figs. 1, there is shown a production controller of the invention, indicated generally by the reference numeral 1. The production controller 1 comprises a case tracking processor 2 which has a multi-processor circuit, 5 GB of disk capacity and 5 GB of tape capacity. There is also a 50 MB memory connected to the multi-processor circuit.

For satisfactory operation of the processor 2, at least 10 MB of memory and 1 GB of storage capacity are required.

The case tracking processor 2 is connected to a number of asynchronous terminals 3. Further, the processor 2 is connected by a high speed 32-bit network link 5 to a network system 4. The network system 4 has a local area network cable 6 to which are connected 64-bit bus workstations 7 and laser printers and scanners 8. A repeater 9 connects the cable 6 to a wide area network comprising a network server 10 and various workstations 11 and printers 12. By appropriate use of repeaters 9, the wide area network may be extended, depending on the operator location and requirements.

A dial-up system 15 comprises a pair of modems 16 and a workstation 17 for dial-up communication with the case tracking processor 2.

A transaction processing system 20 comprises a host computer 21 connected to various terminals 22 via a terminal server 23. The host computer 21 is connected by a k/bit leased line to a cluster controller 24. The cluster controller 24 is connected to a pair of processors 25 and is connected to the case tracking processor 2 by a synchronous and data link control link 26. There are various ports 27 and 28 on the case tracking processor 2 for connection to X25 and X400 networks.

The main inputs for the system 1 are provided through the various workstations 7 and 11 in the network system 4 via the dial-up system 15 and via the transaction processing system 20 and the scanners 8. The inputs from the network system 4 are inputted in real-time and can include any data relating to cases which are handled by the system 1.

Of course, production stage sensors could also provide inputs. The case tracking processor automatically filters the input data into variable and fixed categories.

A case may be a manufacturing production line or any case or process for which the events are suitable for automation. The inputs which are provided by the transaction processing system 20 are batch uploads of transaction data which are generated during a batch transaction process of the host computer 21.

The outputs of the system 1 are provided on the various terminals which are connected to the workstations and host computers, and very importantly, at the various laser printers 8 and 11. Indeed, the documents which are printed by the system 1 form an integral part of the events of the cases which are being tracked and are not simply for information purposes. Therefore, the production controller 1 is particularly suitable for cases where documentation is very important, such as pharmaceutical production lines.

The core of the case tracking operations are carried out by the case tracking processor 2. The basis of these operations is the real-time reception of input data for the cases, and batch processes which are carried out for case tracking. In this specification, the term "case tracking" means not simply monitoring of progress of cases, but also the actual implementation of the processes by activating the necessary events.

A batch process carried out by the processor 2 is indicated by the numeral 30 in Fig. 2. The process 30 involves the multi-processor circuit carrying out one or more operations for each case in turn. As illustrated in Fig. 2, the work for the first case "case 1" involves the circuit accessing a fixed data record 31 for that case.

This data record contains summary data for the case including the last event which took place and the duration of time elapsed since that event. In addition, there is a key which provides the address for access to additional, variable data records and stage definition records, described below. For case 1, the multi-processor circuit has determined that in view of the last event and the time duration since the last event, no further action is required and it is not even necessary to access other data on the disk. However, for case 2, because of the time duration since the last event, the circuit automatically refers to a stage definition record 33 for the particular stage at which the case is at. In this embodiment there are 100 stages numbered 001 to 100 and any case may follow one or any sub-set of these 100 stages.Each stage has a definition record 33 which provides the circuit with the necessary information for initiating an event for that stage. As shown in Fig. 2, the circuit accesses variable data records 34 after the stage definition record 33 in order to determine whether or not an action should be triggered. A relational database structure is used by the circuit to access the different records efficiently. For example, in a pharmaceutical production case, the particular stage may relate to a quality control check, however, this would be dependent on whether or not sufficient samples have already been taken, which latter data is stored in the variable data records 34.Depending on the data which is retrieved from the variable data records 34, the circuit generates document files in step 35 for case 2 and subsequently updates the variable data records 34 in step 36 to include the fact that these events have taken place. Another example is transmission of a scanned image with a superimposed message from a production facility to a distributor.

As indicated by the arrow 37, the controller then returns to the fixed data record for the next case, namely, case 3. The steps between accessing the fixed data records for case 2 and case 3 may be regarded as a sub-process or loop 32. Such a loop may take any particular form as defined by the stage definition record 33 and indeed there may be a number of loops for each case, there being one possible loop for each of a number of stages at which the case is simultaneously located. This is described in more detail below.

Further, an important aspect of generation of document files in step 35 is that a log file is generated containing all of the printing instructions and data which are necessary. This log data is then ready for use in printing of a document, however, this cannot be printed until a user instruction is received. Thus, the production control is automatic up to the stage of the operator inputting an instruction to print the necessary documents. This provides versatility for the operator.

As also indicated in Fig. 2, for case 4 a different subprocess 40 is carried out whereby only the stage definition record and the variable data records 34 are accessed. No event takes place takes place because of the data which is in the variable data records 34. As indicated by the arrow 37, the circuit then proceeds to the next case, and so on. The sub-processes or loops for the cases 2 and 4 are indicated by the numerals 32 and 40, respectively and a different type of loop 45 is now described for case i. Again, the stage definition and variable data records 33 and 34 are accessed. However, in this case, no event takes place and there is only the generation of an operator output signal in step 46. This may indicate that the circuit is not prepared to automatically initiate the next event and requires operator interaction.

The circuit then proceeds through each case in turn for the batch process 30 carrying out none, one, or a number of loops for each case. As shown diagrammatically for case j, there is a loop 32 carried out for a stage indicated as stage k and a loop 45 carried out for a stage 1. By processing in this manner, the multi-processor circuit of the case tracking processor 2 is able to handle each case in turn in an extremely effective manner and a very large degree of versatility is provided by the manner in which a number of different sub-processes can be carried out for each case. This allows not only the tracking of a large number of cases, but the tracking of a number of different stages for each case. This is illustrated in Fig. 3 whereby a case indicated as case m proceeds through stages 01, 02, 03, 04, 05 and then branches out into two parallel tracks.One track has stages 10 and 11 and ends at stage 11. The other track has stages 20 and 21 and then branches out into two further tracks beginning with stages 30 and 40 respectively. While the case is at any of the stages, a batch process is carried out to move it onto the next stage. For example, batch process A moves the case from the stage 01 to stage 02. On the other hand batch process E moves the case from stage 05 to the stages 10 and 20.

While the case is at both stages 10 and 20 in parallel, a batch process F has two loops, one for each of these stages to move it on or otherwise as the case may be. The diagram of Fig. 3 shows the complexity of individual cases and the simplicity with which they are handled by the case tracking processor 2.

Operation of the system 1 is shown in more detail in Fig.

4 which provides more detail for an individual case. The case illustrated is case m and as previously described there is a fixed data record 31, a stage definition record 33 and a number of variable data records 34. The number of variable data records 34 depends on the complexity of the case. The circuit of the case tracking processor 2 refers to a real-time clock 50 in addition to accessing the stage definition record 33 and this helps to provide the necessary information as to which data records 34 should be accessed.

The variable records provide a pattern of information which in this embodiment is a series of Y's and N's which are the format for data inputting by an operator. A pattern of Y's and N's can provide the necessary information for the controller to activate an event or to simply proceed to the next case.

As indicated in Fig. 4, an interactive input 52 is required for printing in step 51 to take place using the log file which was generated in step 35. Thus, in practice the system 1 may operate in a "background mode" on an on-going basis, where the only instruction required of an operator is an instruction to proceed with a batch process. Indeed, this instruction may be automated by a program which automatically initiates the batch process at pre-set times.

Irrespective of the frequency of the batch processes, data is inputted to an interface of the processor 2 in realtime from the network system 4 via scanners and keyboards to update the data records 34 as indicated by step 54. In addition, data is uploaded from the transaction processing system 20 as indicated by 53 in Fig. 4. For both types of data inputting, the source of the input is automatically monitored in step 55 to provide a log of all inputs to the system for verification purposes. This step takes place by automatic identification of the source of each signal.

This is indicated by the password inputted.

In step 56, non-frequent fixed data amendment takes place.

It will be appreciated that amendment to the fixed data is not required frequently, however, it is important that it may be easily carried out when required. The fact that the case tracking processor automatically filters the data into variable and fixed categories is also important.

Steps 57 - 59 show the manner in which a fixed data record is generated in the first instance. The data is inputted in step 57 and there is automatic verification in step 58.

This takes place with reference to reference data which is stored. It also involves automatic retrieval of data to generate the data which is inputted to the record 31. For example, in a debt litigation system the automatic retrieval may take place to a geographical map database whereby the matter relating to the relevant Circuit Court is automatically retrieved on the inputting of the client address.

The invention is not limited to the embodiments hereinbefore described, but may be varied in construction and detail. For example, it is envisaged that instead of printers providing the outputs, any other suitable production device could be used instead, such as a pipeline valve or a conveyor for movement of raw material.

Claims

1. A production controller comprising a case tracking processor having in excess of 10 MB of memory, in excess of 1 GB of non-volatile storage capacity, and a multi-processor circuit; a transaction processor connected to the case tracking processor by a high speed data transfer link; a network system connected to the case tracking processor by a parallel data bus, and comprising a plurality of printers and workstations; a set of definition records of stages in process tracks to be followed by cases, the records being stored in the case tracking processor; a set of variable and fixed data records stored in the case tracking processor in a relational database structure;; a means in the case tracking processor for receiving data relating to cases from the network system, for automatically filtering the data into fixed and variable categories, for updating fixed data records and variable data records for cases, the records being related together in a relational database structure; a real-time interface for automatically updating the case fixed and variable data records on reception of update data from the network workstations and scanners and transaction data transmitted from the transaction processor; and an output interface connected to a production device; a means in the case tracking processor for operating in batch mode to sequentially read a record for each case in turn, and to activate an event for that case according to the stage at which the case is located in the tracking process, the event being driven by commands in the relevant stage definition record and data read from the records.

2. A controller as claimed in claim 1, wherein the case tracking processor comprises means for automatically retrieving a fixed data record for each case in turn, for reading from said record the stage for the case and the time duration since the last event, and means for automatically determining from said data if a sub-process involving access to the relevant stage definition record is required.

3. A controller as claimed in claim 2, wherein the fixed record has a stored key for access to the relevant stage definition record.

4. A controller as claimed in any preceding claim, wherein the case tracking processor comprises means for automatically retrieving data from the related variable data records for the case according to information read in the stage definition record, and means for determining if an event is to be activated according to data read from the fixed and variable records and the stage definition record.

5. A controller as claimed in any of claims 2 to 4, wherein the case tracking processor comprises means for activating an event by generating a log file of printing instructions under direction of commands in the stage definition record during batch run-time, and means for prompting operator input of a print instruction for printing in accordance with the log file.

6. A controller as claimed in any preceding claim, wherein the case tracking processor comprises means for automatically updating the variable records upon completion of an event.

7. A controller as claimed in any preceding claim, wherein the fixed record comprises data relating to a plurality of stages, and the case tracking processor comprises means for carrying out a plurality of sub-processes for a case before passing on to the next case fixed record.

8. A controller as claimed in any preceding claim, wherein fixed data is initially inputted at an interface connected to a data verifier and an automatic retrieval device for retrieving correct data related to an inputted data item.

9. A controller substantially as hereinbefore described, with reference to and as illustrated in the accompanying drawings.