NZ628192B - Black box for monitoring and tracing sensitive product processing - Google Patents

Abstract

Disclosed is a system (20) for providing production quality information relating to one or more products to a client device (26). The system (20) includes means for receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product. The image data and the data representative of the factor(s) are stored on a data storage medium (24) in association with a product identifier of the product. The system (20) further includes means for receiving a request identifying the product identifier and means for sending the image data and the data representative of the factor(s) to the client device (26) in response to the request. The factors are determined during production of the product. representative of at least one factor affecting the quality of a product. The image data and the data representative of the factor(s) are stored on a data storage medium (24) in association with a product identifier of the product. The system (20) further includes means for receiving a request identifying the product identifier and means for sending the image data and the data representative of the factor(s) to the client device (26) in response to the request. The factors are determined during production of the product.

Description

BLACK BOX FOR MONITORING AND TRACING SENSITIVE PRODUCT PROCESSING Field of Invention The present invention relates to a system, method and/or apparatus for improving product traceability. More particularly, the invention relates to improved product traceability using closed-circuit television (CCTV) in combination with other records.

Background to the Invention Some products have information about them collected and recorded as they are produced, processed, distributed, sold and sometimes even ultimately used or consumed. The ability to determine such information about a product is known as tracing the product. The degree to which a product’s history can be traced is termed product traceability. A high degree of product traceability may be important to many or all of the parties involved with a product in one way or another.

The ability to determine a product’s origin and details of its history are clear benefits of a highly traceable product. A significant advantage for producers, manufacturers, distributors and retailers of a highly traceable product include less costly and more effective problem identification and solving in the event that defects or issues are found with a product. In turn, consumers are more likely to trust a highly traceable product and will have confidence that it is safer or of better quality than similar products, and they benefit from the increased level of safety when using or consuming the product.

The quality of a product may be affected by factors or parameters during production stages such as manufacturing and packaging of a product. These factors may, for example, relate to the environment or circumstances in which the product is produced, such as room temperature, equipment temperature, humidity, air composition etc.

Monitoring these factors can be very important in order to produce a quality product. For example a person may actively review the factors in real time, or there may be a means to autonomously monitor the factors such that an alarm is sounded if one of the factors reaches an unsatisfactory level.

Occasionally, even if the circumstances under which a product is produced are well monitored, a problem may arise. In this case it is desirable to identify the cause of the problem, for reasons such as preventing future problems and verifying that the quality of other products or a whole batch of products is not compromised. Such problem identification may be particularly important in industries such as food or pharmaceuticals where human health may be at stake.

Existing solutions include alarms, as previously mentioned, for information that can be monitored by a machine (e.g. temperature, air humidity, air pressure, air composition, radiation levels, etc.). However, the various means to monitor or collect information often operate independently of each other. Furthermore, some information may be collected or recorded and saved while other information may not be logged (for example an oxygen level detector may sound an alarm if it detects an adverse level, yet may not keep a log of oxygen levels over time).

Furthermore, even when multiple types of means used to monitor useful information are all collecting and recording data, they often operate and store the data independently from one another. This can lead to delays during problem identification, especially if the problem is caused by a combination of factors, or by interactions between the types of information being monitored (e.g. low temperature and high humidity may each alone fall within allowed limits, but together may cause condensation, which may be a problem in certain settings).

Finally, it may be difficult to link recorded data with a particular batch of product or even a particular product unit (i.e. unit of product as intended for individual sale to the consumer).

Some products, and often those that are traced with a high degree of precision, require the consumer to have a high level of trust and confidence in the quality of the product. This is often the case for products that, if defective, can be particularly dangerous or unhealthy. An example of such a product is infant milk powder.

Purchasers of infant milk powder are very conscious of quality and safety, as infants may be particularly vulnerable to the effects of a defective milk powder product.

Object of the Invention It is an object of the invention to provide an improved method, system and/or apparatus of collecting, storing and/or presenting multiple types of information about a batch of product or an individual product unit.

Alternatively, it is an object of the invention to address at least some of the foregoing problems or at least provide the public with a useful choice.

Summary of the Invention It would be advantageous if there was a means to store multiple types of information collected during production such that it can be accessed easily in relation to a particular batch of product or particular product unit.

While products such as infant milk powder usually undergo rigorous quality checking processes during manufacture, consumers may benefit from increased confidence in the quality of products. It would therefore be advantageous if, when making the decision to purchase a particular unit of product that would have significant negative consequences if it were defective, the purchaser could access information to suggest that the particular unit of product or the batch as a whole is not defective. It would be further advantageous if this information included a collection of information.

Preferred aspects of the invention are set forth in the appended claims. Particular embodiments are described below in non-limiting terms.

According to a first embodiment of the invention there is provided a method of providing production quality information relating to one or more products to a client device, the method comprising: receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factor(s) being determined during production of the product; storing the image data and the data representative of the factor(s) on a data storage medium in association with a product identifier of the product; receiving a request identifying the product identifier; and sending the image data and the data representative of the factor(s) to the client device in response to the request.

Preferably, the method comprises identifying the product identifier of the product during production of the product.

Preferably, the method comprises determining the factor(s) and generating the data representative thereof.

More preferably, the step of identifying the product identifier occurs substantially at the same time as the step of determining the factor(s).

Preferably, the image data and the data representative of the factor(s) are associated in such a way as to be stored and retrievable together.

Preferably, the method comprises combining the image data with the data representative of the factor(s) before performing the step of storing the data, such that the combined image data and data representative of the factor(s) are stored as a combination, and the step of sending the data to a client device comprises sending the combination.

In some embodiments the data representative of factor(s) affecting the quality of a product is in the form of data relating to the environment in which the product is produced, the data being selected from one or more of: air temperature, air humidity, air composition, equipment temperature, machine parameters and/or machine settings.

In some embodiments the image data may comprise CCTV pictures or other video forms.

Preferably, the step of combining the image data with the data representative of the factor(s) comprises combining at least some of the data with the CCTV pictures or video by overlaying the data onto the CCTV pictures or video such that the data overlaid on a given CCTV picture or video frame is data that was collected at the time at which the CCTV picture or video frame was collected.

In some embodiments, further data representative of the actual quality of a product may be collected such as data specific to individual product units such as photographs or X-ray images.

Preferably, the product identifier identifies the product or a group thereof specifically, for example a batch number, serial number or product unit identification means by which an individual product unit is identifiable. Alternatively, the product identifier identifies the product indirectly, for example by identifying the time and place a product was produced, or the worker or equipment that produced it.

In some embodiments, the method comprises receiving the request identifying the selected product identifier from a mobile device, for example a mobile phone or a tablet computer.

According to a second embodiment of the invention there is provided a system for providing production quality information relating to one or more products to a client device, the system comprising: means for receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factors being determined during production of the product; means for storing said image data and the data representative of the factor(s) on a data storage medium in association with a product identifier of the product; means for receiving a request identifying the product identifier; and means for sending the image data and the data representative of the factor(s) to the client device in response to the request.

Preferably, the system comprises means for identifying the product identifier of the product during production of the product.

Preferably, the system comprises means for generating the data representative of the factors.

Preferably, the system comprises means to store together the image data and the data representative of the factors in association with each other such that they are stored and retrievable together.

Preferably, the system comprises means for combining the image data with the data representative of the factors before storing the data, such that the combined image data and data representative of the factors are able to be stored as a combination, and the data is able to be sent to a client device as the combination.

In some embodiments the image data may comprise CCTV pictures or other video forms.

Preferably, the system comprises means for combining at least some of the data with the CCTV pictures or video by overlaying the data onto the CCTV pictures or video such that the data overlaid on a given CCTV picture or video frame is data that was collected at the time at which the CCTV picture or video frame was collected.

In some embodiments, the system comprises means for receiving the request identifying the selected product identifier from a mobile device, for example a mobile phone or a tablet computer.

According to a third embodiment of the invention there is provided an apparatus for providing production quality information relating to one or more products to a client device, the apparatus comprising: means for receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factors being determined during production of the product; means for storing said data on a data storage medium in association with a product identifier of the product; means for receiving a request identifying the product identifier; and means for sending the data to the client device in response to the request.

Further aspects of the invention, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention.

Brief Description of the Drawings One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which: Figure 1 is a flow chart illustrating a method according to an embodiment of the invention; Figure 2 is a flow chart illustrating a system according to another embodiment of the invention.

Detailed Description of Preferred Embodiments of the Invention Figure 1 shows a flow chart illustrating a method 10 according to an embodiment of the invention, and Figure 2 shows a flow chart illustrating a system 20 according to an embodiment of the invention, method 10 and system 20 being a method and system for providing production quality information relating to one or more products to a client device.

During the production of products, method 10 comprises step 11, receiving image data of the product being produced or the surrounds in which the product is produced, and step 2, receiving data representative of at least one factor affecting the quality of the product. Step 11 and step 12 may be performed simultaneously.

With reference to Figures 1 and 2, the system 20 comprises camera 21 which is a means to collect image data, for example a CCTV camera, the image data being in the form of pictures or video of the product being produced or the environment thereof, or any other useful pictures or video that may provide information representative of the quality of the product. In other preferred embodiments there may be multiple cameras which may take multiple pictures or video or combinations thereof.

In some embodiments the image data may comprise image or video of sensors or other apparatus that on their own provide an indication of the quality of a product. For example, in a scenario where a plurality of bags of product are produced as a batch, the bags may be counted as they are produced. The bag count may be shown on a display. If the number of bags counted in a batch is different to the planned number of bags for the batch, this indicates that the composition of the batch of product may be incorrect, as there may have been incorrect amounts of constituents added. In such an embodiment, image data collected of the bag count display, for example a CCTV recording in which the display is visible, would be representative of the quality of the product as it shows the bag count. This may be advantageous for collecting data that cannot be collected directly from the data source.

The image data collected by camera 21 is received by processing means 23, according to step 11 of method 10.

The system 20 also comprises sensors 22a and 22b, which in this embodiment collect temperature and humidity data of the environment in which the products are produced.

Temperature and humidity of the production environment are factors affecting the quality of certain products, for example food products and particularly infant milk formula products, and as such sensors 22a and 22b are means to collect such data representative of factors affecting the quality of the product.

Other factors affecting the quality of a product may be any properties of the environment or equipment that may have an effect on the quality of product, for example temperature of the equipment, air pressure, air composition, radiation levels, as well as factors that are not directly measureable with a sensor, such as the length of time since a machine has been cleaned, the total time a tool has been cutting, the time since new coolant was added or oil was changed, among many others.

The data collected by sensors 22a and 22b is received by processing means 23, according to step 12 of method 10.

In accordance with a preferred embodiment of method 10, in system 20 the camera 21 and sensors 22a and 22b all collect the production quality information simultaneously.

Step 13 of method 10 comprises combining of the image data with the data representative of the factors affecting the quality of the product, which in the system 20 is performed by processing means 23. Processing means 23 receives the image data (pictures or video) from camera 21, the data representative of factors affecting the quality of the product (temperature and humidity readings) from sensors 22a and 22b, and performs step 13 of method 10 overlaying or superimposing the temperature and humidity readings onto the image data to combine the data.

The result of step 13 as performed by system 20 is therefore a combination of the image data in the form of picture or video of the product units being produced, with the temperature and humidity also shown on the picture or video. Each picture or video frame preferably has temperature and humidity readings collected at or near the time the picture or video frame was collected.

Step 14 of method 10 comprises storing the data in association with a product identifier of the product or a group of products that was produced at the time the data was collected. The product identifier either identifies the product or group thereof directly, for example a batch number, serial number or other product unit identification means by which an individual product unit is identifiable. Alternatively, the product identifier identifies the product indirectly, for example by identifying the time and place a product was produced, or the worker or equipment that produced it.

In preferred embodiments the product identifier is identified during production of the product, for example if the product identifier is a serial number encoded in a QR code, then a preferred system would comprise a QR code reader and a preferred method would comprise reading the QR code to identify the serial number. The product identifier may also be data that is stored and/or combined with image data or data representative of factors affecting the quality of a product.

Processing means 23 of system 20 performs step 14 of method 10 by storing the combined data (which in this particular embodiment is in the form of picture or video with overlaid temperature and humidity readings) in data store 24. The combined data is stored in association with the product identifiers that the data relates to, for example the product identifiers of the products that were produced at the time the data was collected. This improves traceability of the products because, for a given product, the temperature and humidity of the environment in which that product was produced can be found by referencing the product identifier in the data store.

The data may be stored in association with the product identifier by, for example, storing the data with a file name including the product identifier or in a database in the same data entry as the product identifier.

In some embodiments a processing means such as processing means 23 of system 20 may be a single server configured to perform the steps 13 and 14 of method 10, although in other embodiments there may be multiple components. For example in some embodiments there may be a device that receives a video feed from a CCTV camera as well as the temperature and humidity readings from temperature and humidity sensors, and overlays the temperature and humidity readings in real time on to the CCTV video and outputs the combination of video footage and corresponding temperature and humidity readings as a processed video feed according to step 13 of method 10. In such an embodiment the processed video feed may then be received by a device such as a computer or server which processes and stores the processed video feed in a data store according to step 14 of method 10. The same device may then be involved in performing step 15 of method 10 as will be described below.

Step 15 comprises receiving a request from a client device identifying a product identifier. In a preferred embodiment this step is performed by website 25 of system 20 accessible by client device 26. The step involves the server 23 searching data store 24 for data (which in this example is in the form of combined image data and data representative of factors affecting the quality of a product) that is associated with the identified product identifier. For example, the server 23 may search for a file name or data entry that includes the identified product identifier.

In one embodiment, the product identifier is generated by scanning the QR code of the relevant product.

After receiving the relevant data from the server 23 including the combined image data and other data, the website 25 sends the combined data to the client device 26, in this preferred embodiment in the form of a video or other collection of image data, either embedded in a document or webpage or a software application, or as a single file or collection of files.

In many embodiments the client device is a computer or mobile device within the organisation that produces the products, however in some embodiments the client device may be a client device operated by a member of the public, for example a customer or potential customer seeking information on the product. In some embodiments a customer may be in possession of the product, and the product may comprise product identification means, for example a product identifier in the form of a number printed on the product or other means such as a QR code within which the product identifier is encoded. The customer may obtain the product identifier and make a request for the product quality information from their client device by identifying the product identifier, and be provided with the image data and data representative of factors affecting the quality of the product in response, for example as previously described with reference to Figures 1 and 2.

In addition to receiving product quality information and increasing their confidence in the quality of the product, the consumer is also reassured that a particular product unit is genuine. The invention therefore helps to reduce counterfeiting. Along with the product quality information, the website can confirm that the product is known and in the system, and is therefore not a counterfeit product.

The invention provides multiple ways for counterfeit products to be identified.

For example, a manufacturer or distributer may provide product identification means on all their products, so that a consumer will be able to identify counterfeit product units by the lack of a product identification means.

Additionally, if a product comprises a product identification means, a consumer may identify that it is a counterfeit product unit by a lack of response from the website, or a warning/notification from the website that the product unit is not known to the manufacturer/distributer or not authentic, and may therefore be counterfeit.

Furthermore, even if a counterfeit product comprises a product identification means that refers to a genuine product, the consumer may be able to identify that a product is counterfeit by identifying any differences between the information provided by the website on the genuine product and the counterfeit product in question. For example, if a consumer makes a request for product quality information linked to a product identifier that a counterfeiter has added to a counterfeit product, the website may warn the consumer that the genuine product to which the product identifier refers has already been sold (or is expected to be sold elsewhere), and that any further products having that same product identifier are likely to be counterfeit.

In preferred embodiments the website receiving requests for product quality information will automatically identify that a request suggests the product in question may be counterfeit, and provide notification to the manufacturer/distributer so that appropriate action can be taken.

The invention also allows a manufacturer/distributer to provide warnings to consumers. For example, if a manufacturer identifies that a batch of products that have already been distributed or even sold to consumers are defective or unsafe, in addition to other appropriate action, the manufacturer can also issue a warning to any consumers requesting product quality information on the defective products, at the time they make the request. The manufacturer may provide instructions on the packaging of the products that the consumer should request product quality information immediately before consuming or using the product, so that they will receive any warning that has been issued.

There are therefore methods according to embodiments of the invention, of providing information relating to a product unit to a client device, which advantageously is in the form of image data of the product being produced or the surrounds thereof in combination with data representative of factors affecting the quality of the product.

There are therefore also systems according to embodiments of the invention, that at least comprise means to perform each step of the methods, for example means to receive image data, means to receive data representative of factors affecting the quality of a product, means to combine the image data and data representative of the factors, means to store the combined data in association with a product identifier, means to receive a request from a client device identifying the product identifier, and means to send the relevant combined data to the client device (e.g. website). The systems according to embodiments of the invention may also comprise additional components such as a means to collect the image data and/or data representative of factors affecting product quality, and/or identify the product identifier of a product during its production.

Where a method such as described above is carried out by one or more apparatus within a system according to the present invention, it will be clear that the apparatus will be an apparatus according to an embodiment of the invention. An example of such an apparatus could be a general purpose computer configured to perform method steps according to the embodiments described above.

The invention in preferred embodiments may be likened to a black box for an airplane – it may be a single system that collects, stores and can present various types of data representative of factors that could affect the quality of a product. If a problem occurs, either with a specific product unit or batch or at a specific time, the system can present the data collected at the relevant time for analysis.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of “including, but not limited to”.

The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.

Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.

Claims (28)

Claims 1.

1. A method of providing production quality information relating to one or more products to a client device, the method comprising: 5 receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factor(s) being determined during production of the product; storing the image data and the data representative of the factor(s) on a data 10 storage medium in association with a product identifier of the product; receiving a request identifying the product identifier; and sending the image data and the data representative of the factor(s) to the client device in response to the request. 15

2. The method as claimed in claim 1, wherein the method comprises identifying the product identifier of the product during production of the product.

3. The method as claimed in claim 1 or claim 2, wherein the method comprises determining the factor(s) and generating the data representative thereof.

4. The method as claimed in claim 3, wherein the step of identifying the product identifier occurs substantially at the same time as the step of determining the factor(s).

5. The method as claimed in any one of the preceding claims, wherein the image data and 25 the data representative of the factor(s) are associated in such a way as to be stored and retrievable together.

6. The method as claimed in any one of the preceding claims, wherein the method comprises combining the image data with the data representative of the factor(s) before 30 performing the step of storing the data, such that the combined image data and data representative of the factor(s) are stored as a combination, and the step of sending the data to a client device comprises sending the combination.

7. The method as claimed in any one of the preceding claims, wherein the data 35 representative of factor(s) affecting the quality of a product is in the form of data relating to the environment in which the product is produced, the data being selected from one or more of: air temperature, air humidity, air composition, equipment temperature, machine parameters and/or machine settings. 5

8. The method as claimed in any one of the preceding claims, wherein the image data comprises CCTV pictures or other video forms.

9. The method as claimed in claim 8 when dependent on claim 6, wherein the step of combining the image data with the data representative of the factor(s) comprises 10 combining at least some of the data representative of the factor(s) with the CCTV pictures or video by overlaying at least some of the data representative of the factor(s) onto the CCTV pictures or video such that the overlaid data on a given CCTV picture or video frame is data representative of the factor(s) that was collected at the time at which the CCTV picture or video frame was collected.

10. The method as claimed in any of the preceding claims, wherein further data representative of the actual quality of a product is collected.

11. The method as claimed in claim 10, wherein the further data representative of the actual 20 quality of a product is data specific to individual product units such as photographs or X- ray images.

12. The method as claimed in any of the preceding claims, wherein the product identifier identifies the product or a group thereof specifically.

13. The method as claimed in claim 12, wherein the product identifier is a batch number, serial number or product unit identification means by which an individual product unit is identifiable. 30

14. The method as claimed in any one of claims 1-11, wherein the product identifier identifies the product indirectly.

15. The method as claimed in claim 14, wherein the product identifier identifies the time and place a product was produced, or the worker or equipment that produced it.

16. The method as claimed in any one of the preceding claims, wherein the method comprises receiving the request identifying the selected product identifier from a mobile device, for example a mobile phone or a tablet computer. 5

17. A system for providing production quality information relating to one or more products to a client device, the system comprising: means for receiving image data of the product being produced or the surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factors being 10 determined during production of the product; means for storing said image data and the data representative of the factor(s) on a data storage medium in association with a product identifier of the product; means for receiving a request identifying the product identifier; and means for sending the image data and the data representative of the factor(s) to 15 the client device in response to the request.

18. The system as claimed in claim 17, wherein the system comprises means for identifying the product identifier of the product during production of the product. 20

19. The system as claimed in claim 17 or 18, wherein the system comprises means for generating the data representative of the factors.

20. The system as claimed in any one of claims 17-19, wherein the system comprises means to store together the image data and the data representative of the factors in 25 association with each other such that they are stored and retrievable together.

21. The system as claimed in any one of claims 17-20, wherein the system comprises means for combining the image data with the data representative of the factors before storing the data, such that the combined image data and data representative of the 30 factors are able to be stored as a combination, and the data is able to be sent to a client device as the combination.

22. The system as claimed in any one of claims 17-21, wherein the image data comprises CCTV pictures or other video forms.

23. The system as claimed in claim 22, wherein the system comprises means for combining at least some of the data representative of the factor(s) with the CCTV pictures or video by overlaying at least some of the data representative of the factor(s) onto the CCTV pictures or video such that the overlaid data on a given CCTV picture or video frame is 5 data representative of the factor(s) that was collected at the time at which the CCTV picture or video frame was collected.

24. The system as claimed in any one of claims 17-23, wherein the system comprises means for receiving the request identifying the selected product identifier from a mobile 10 device, for example a mobile phone or a tablet computer.

25. An apparatus for providing production quality information relating to one or more products to a client device, the apparatus comprising: means for receiving image data of the product being produced or the 15 surroundings in which production of the product occurs, along with other data representative of at least one factor affecting the quality of a product, the factors being determined during production of the product; means for storing said data on a data storage medium in association with a product identifier of the product; 20 means for receiving a request identifying the product identifier; and means for sending the data to the client device in response to the request.

26. A method of providing production quality information relating to one or more products to a client device substantially as hereinbefore described with reference to any one of the 25 embodiments shown in the figures.

27. A system for providing production quality information relating to one or more products to a client device substantially as hereinbefore described with reference to any one of the embodiments shown in the figures.

28. An apparatus for providing production quality information relating to one or more products to a client device substantially as hereinbefore described with reference to any one of the embodiments shown in the figures. Receiving image data of the Receiving data representative of at product being produced or least one factor affecting the surrounds thereof quality of the product Combination of the image data with the data representative of the at least one factor Storing the data in association with a product identifier of the product Receiving a request from a client device identifying the product identifier Sending the data as the combination to the client device