WO2012121616A1 - Remotely identifiable boning workstations - Google Patents

Remotely identifiable boning workstations Download PDF

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Publication number
WO2012121616A1
WO2012121616A1 PCT/NZ2012/000033 NZ2012000033W WO2012121616A1 WO 2012121616 A1 WO2012121616 A1 WO 2012121616A1 NZ 2012000033 W NZ2012000033 W NZ 2012000033W WO 2012121616 A1 WO2012121616 A1 WO 2012121616A1
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WO
WIPO (PCT)
Prior art keywords
workstation
boning
transponder
tray
disassembly
Prior art date
Application number
PCT/NZ2012/000033
Other languages
French (fr)
Inventor
Christian John CHANDLER
Gregory William SIVEWRIGHT
David Richard Wright
Original Assignee
Scl Holdings Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Scl Holdings Limited filed Critical Scl Holdings Limited
Publication of WO2012121616A1 publication Critical patent/WO2012121616A1/en

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Classifications

    • AHUMAN NECESSITIES
    • A22BUTCHERING; MEAT TREATMENT; PROCESSING POULTRY OR FISH
    • A22BSLAUGHTERING
    • A22B5/00Accessories for use during or after slaughtering
    • A22B5/0064Accessories for use during or after slaughtering for classifying or grading carcasses; for measuring back fat
    • AHUMAN NECESSITIES
    • A22BUTCHERING; MEAT TREATMENT; PROCESSING POULTRY OR FISH
    • A22CPROCESSING MEAT, POULTRY, OR FISH
    • A22C17/00Other devices for processing meat or bones
    • A22C17/0073Other devices for processing meat or bones using visual recognition, X-rays, ultrasounds, or other contactless means to determine quality or size of portioned meat
    • A22C17/008Other devices for processing meat or bones using visual recognition, X-rays, ultrasounds, or other contactless means to determine quality or size of portioned meat for measuring quality, e.g. to determine further processing
    • AHUMAN NECESSITIES
    • A22BUTCHERING; MEAT TREATMENT; PROCESSING POULTRY OR FISH
    • A22CPROCESSING MEAT, POULTRY, OR FISH
    • A22C17/00Other devices for processing meat or bones
    • A22C17/10Marking meat or sausages

Definitions

  • the invention relates in general to procedures for assembly or disassembly of items, and to means for maintaining an identity or link between the assembled item and each separated component, and is particularly related to although not limited to disassembly or boning of food animal carcasses into individual components within abbattoirs and meat works.
  • a “transponder” as used herein is a device capable of emitting a signal carrying unique transponder identifying data when it receives an interrogation signal or simply is exposed to a field of electromagnetic energy: radio frequencies or light.
  • the preferred transponder is a "RFID” or self-contained radio-frequency identification device which derives operating power from the field of energy and transmits its identifier code while energized.
  • RFID radio-frequency identification
  • the archetypal production line as put into practice by Henry Ford comprises a large number of vehicle units carried on a conveyor belt and passing in a strict sequence, while being assembled, through many processes each involving workers or robots.
  • This invention has been developed from a disassembly kind of production line, and furthermore one where processing may be carried out in parallel at different speeds, rather than expecting or enforcing a strict serial sequence with all steps being carried out at the same speed.
  • One end product having a commercial value is the resulting collections of different parts.
  • Another end product having a commercial value is information.
  • This invention is also concerned with gathering numerical data such as the weights of disassembled parts; each being reliably linked back to the item first entering the
  • a disassembly production line is at a meat packing works, where the carcasses of food animals are cut apart.
  • a carcass is cut into parts and finally into single items by a team of skilled persons.
  • the data that is recovered in this kind of disassembly production line may be used to (a) provide a link between an eventually retailed cut of meat and the source farm or the source animal; and (b) to provide weight and quality data that is linked to the particular animal from which the parts have been obtained in the boning room. Quality factors other than weight may also be recorded; such as appearance, marbling and colour, and after appropriate procedures, taste, flavour and texture.
  • the animal identifier would usually be the unique ear tag or similar that was used on the farm or feedlot from which the animal came. That data provides information that can be used in the course of breeding programs in which animals that produce better quality meat are selected. By analogy with the widely used artificial-insemination dairy bull selection programmes based on milk tests, the breeding values of beef sires can be determined and the best beef bulls can be used.
  • PROBLEMS TO BE SOLVED To provide a production system; either for assembly or for disassembly, wherein sequential processing is not required.
  • attributes such as weights of the different parts of each uniquely identified animal while they are being separated from the original carcass or other original object in a boning room.
  • attributes such as weights of the different parts of each uniquely identified animal while they are being separated from the original carcass or other original object in a boning room.
  • attributes such as weights of the different parts of each uniquely identified animal while they are being separated from the original carcass or other original object in a boning room.
  • An object of the present application is to provide a re-usable spatial location and unique identification means for parts during an assembly or disassembly process; more specifically to provide means for correlating a carcass with cuts made from the carcass and for recording other parameters; alternatively to provide a more flexibly operated disassembly or boning line by using remotely identifiable workstations, or at least to provide the public with a useful choice.
  • the invention provides a set of inter-related equipment for a process of assembly or disassembly of items on a production system, characterised in that the set of equipment includes more than one portable workstation on which either assembly from components or disassembly into components is carried out when the workstation is at a working position; each workstation including a transponder carrying workstation identity data; each transponder being capable of being interrogated by a nearest one of a plurality of interrogators located at specified positions, namely (a) one or more workstation loading positions, at each of which the workstation identity data is obtained from the transponder, forwarded to a computer system, and coupled within the computer system with an identifier for the item to be assembled or disassembled, and at (b) one or more working positions at each of which the workstation identity data is obtained from the transponder and forwarded to the computer system, and at (c) one or more workstation unloading positions at each of which the workstation identity data is obtained from the transponder and forwarded to
  • the computer system is further adapted to maintain a record of acquired data describing the or each identified component carried on or transferred to or from the workstation at one or more of the working positions within the production system; 100 said data being selected from a range including: weight, type, colour, shape, texture,
  • the production system is particularly adapted for the disassembly of a carcass of a meat animal into components and the computer system is particularly adapted for the collation and reporting of data describing the disassembly process and 105 describing the components thereby obtained.
  • each workstation comprises a receptacle within which the carcass or parts thereof may be disassembled; each workstation being equipped with a transponder capable when interrogated of emitting an unique identification code.
  • the workstation is a re-usable boning tray having an upper or 110 working side, edges, and an under side, and including a transponder.
  • the transponder is concealed within the under side of the tray.
  • the workstation is a tray made of a durable plastics material capable of being washed and sterilised for re-use.
  • the workstation includes at least one optically readable label mounted upon a 115 surface of the tray.
  • the invention provides a method for operating a boning room, characterised in that a computer or system of computers is provided with information from data input means identifying a single carcass on arrival at the boning room, and then is provided with information from data input means identifying one or more boning trays each
  • the computer or system of computers is capable of exporting information describing the parts of the identified carcass as exposed during disassembly to an external user.
  • the computer or system of computers is capable of monitoring 130 and reporting on the disassembly process.
  • the computer or system of computers is capable of placing carcass- related information describing one or a group of disassembled parts upon a data carrier at the completion of the boning process such as a label for a package.
  • Fig la A perspective view of a boning tray including a transponder according to the invention.
  • Fig lb An elevation view of a boning tray including a transponder according to the invention.
  • Fig lc A plan view of a boning tray including a transponder according to the invention.
  • Fig 2 is a diagram showing one possible layout of a boning "line” or production system according to the invention, where sequential processing is not a requirement.
  • the underlying concept of this invention is to create a uniquely identified, portable 155 workstation including a transponder.
  • the workstation can be moved around and worked on at a variety of places within the premises. Thanks to the transponder, it is possible for a suitably connected data management processor to maintain in its memory real-time record of where each workstation is at any time. Further, a workstation can be weighed or otherwise assessed from time to time, while being identified by means of the transponder at 160 each assessment. For instance the incremental loss of weight of each identified workstation from action to action can be related to the weights of parts removed. Even further, the origin of the object placed on the workstation at the beginning of a disassembly process can be correlated with the identity of workstation itself. It will be evident that the use of many such workstations at a site allows disassembly processes to proceed independently of each 165 other. The invention allows any combination of sequential steps to be performed by
  • the uniquely identified portable workstation is an approximately
  • This "identifiable, moveable boning tray” is the core component of this invention. It may be moved about a boning room and weighed from time to time, or left in one place. Rather than referring to a "boning line” wherein every tray moves in a strict sequential order, this Example describes 175 a "boning system” where trays, which comprise “portable workstations” may at least to some extent be processed out of order. The supervising computer system keeps track.
  • FIG. 1 A boning tray 100 according to the invention is shown in Figs la, lb and lc.
  • Fig la is a perspective view of the tray from above and to one side;
  • Fig lb is an elevation view with the transponder projected on to the surface, and
  • Fig lc is a plan view of the working
  • a typical tray might conveniently be 800 mm in width, 400 mm in depth, and the sides 107 of the tray might be 15-75 mm high- not necessarily all the same height - as at 102.
  • the trays are stackable, and the sides are sloped so as to form part of a stack.
  • the transponder shown as dashed lines in Fig la is not normally visible from above, and need not be placed in the exact centre of the tray although
  • transponder 105 is embedded is exaggerated.
  • the underside of preferred trays is provided with a pattern of ridges (not shown) so as to provide strength without excessive mass and to assist in sliding over a wet surface.
  • One ridge that holds the transponder may be made wider.
  • the internal transition from floor to walls is smoothly rounded
  • the boning tray is constructed of a tough material capable of withstanding impacts from knives while boning is carried out, yet capable of being cleaned and sterilised for re-use.
  • Suitable materials include (without limitation) high-density polyethylene and various types of NylonTM.
  • Metal such as stainless steel is a possibility for
  • the transponder environment must be made transparent to rado- frequency fields. Tray materials could be coloured if that is useful, such as for operator relief or to relate groups of trays with each other. Dimensions of the boning tray should take note of convenience for the operators as well as the containment function.
  • one or more internal ridges may be included in the top of the tray for the purpose of
  • Each moveable boning tray includes a unique tray identification means 105 capable of being read remotely.
  • a central cavity 103 underneath the tray may be filled with a non-conductive material 104 and a conventional or possibly a heat-resistant
  • each unique number is repeated in a human-readable marking or an optically readable marking 106, for convenience.
  • Each preferred transponder holds for example a permanent 64-bit substantially unique 210 digital code, which may include error- sensing bits. This code is capable of distinguishing any one boning tray from any other.
  • Fig 1 shows a rectangular transponder, any convenient shape is acceptable.
  • a compatible nearby reading means or interrogator (Fig 2: 123), concealed within a top surface of any working position, emits short range radio signals capable of interrogating the transponder 105 at a certain frequency and power in the 215 conventional manner, as well known to those skilled in the relevant arts, and subsequently reads and reports the information carried within returned signals which specifically identify the individual boning tray and which are sent by cables or wireless means (shown as dotted lines 122 A in Fig 2) to the computer system 122.
  • the short-range transponder reading means or interrogator 123 is placed near the base of the tray at the loading point 110 (see 220 Fig 2), at each work station 111 , at each weigh station, optionally at each work station, and optionally at packing stations 114— 117; wherever the tray needs to be identified.
  • Use of wireless signals has the advantage over optical identification that it does not require an unobscured, well-lit and properly oriented target and a clean lens to actually see the target.
  • the transponder in each tray is well protected although it should be made of a type that is 225 resistant to sterilisation temperatures. Then, as long as the computer system 122 has been initially provided with information from 110 as to which tray is filled with which carcass or part thereof, the identity of cuts either in or taken from that tray is available.
  • optical label, name, target 106 or targets may also be mounted upon one or more external or internal surfaces.
  • Some kinds of optical target include redundancy in the
  • preferred targets resemble two-dimensional bar-codes and may use Hamming or other error correction methods to overcome the "noise" inherent in partially obscured labels, as is known to those skilled in the arts.
  • a plain bar code could be used. After all, each tray and its label(s) will be cleaned after each use. Both optical labels and wireless transponders may
  • 235 be used on the same tray, because it may be convenient to have a human-readable or an optically readable label on each tray.
  • This invention makes much use of quality indicators such as weights because one objective is to return meat quality information, coupled to each animal passing through the meat processing plant, back to the farmer or feed lot operator that supplied the stock, so that 240 breeding selection and performance data including feeding data can be returned.
  • the system would weigh the boning tray loaded with a carcass to be dismembered, and then would weigh each cut separately, and perhaps also weigh the trimmings, so that the business can be monitored more accurately.
  • Some examples of the available quality-describing information that may be tied to one 245 animal, and later used for farm quality control or for breeding value purposes by application of the transponder-equipped tray workstations of the invention are:
  • Samples may be cooked and tasted under a suitably controlled environment, or
  • Some examples of the process or performance information that may be tied to one workstation by application of the transponder-equipped tray workstations of the invention 255 are:
  • the invention also provides a method for maintaining identity of a disassembled carcass using a plurality of separately identified boning trays. This method may involve several steps, such as first receiving identification of a single carcass, being carried to the area of the boning line or lines on a conveyor hook by means of a unique identifier on the hook, and read out to a remote information processor. That identifier may be another transponder.
  • the invention includes the step of identifying one or more boning trays 100 as previously described in this section as becoming (at 110 in Fig 2) loaded with parts of the identified single carcass to the remote computer system here shown as 122, via data cables 122 A.
  • the hook identifier (not shown) for the whole or partial carcass is coupled to or linked to the tray identifiers within a database or comparable means within a digital computer or network
  • each tray transponder During the process of converting the contents of each boning tray into salable cuts and waste, there is no particular reason to continuously read each tray transponder, although any
  • boxes 111 represent separate working positions, herein called boning stations, with a worker likely to be at each one. Each working position is provided with an interrogator 123, typically within the top surface. Each boning station 111 may receive loaded boning trays (the "workstations" of the invention) directly from the 285 loading point 110, and may also receive trays from other stations as suggested by arc 119. There is no required specific order of tray movements, since the tray contents will be positively identified at the end stage, when packing occurs.
  • a loop 113 represents an optional sequencer intended to present any one boning tray 100 at any one packing station (114, 115, 116 or 117), or present each tray to every packing station in sequence. It
  • Each weighing station (such as the one at position "111 A” in Fig 2) is provided with an interrogator 123, typically within the surface.
  • the computer system having already registered the boning tray and its initial weight at 110, will be able to calculate the weight of the contents at the weighing station such as 111 A, which serves as one indication of the
  • weight a measuring device for which is represented symbolically by 120 at working position 111 A
  • means may be provided at one or more stations 111 to assess colour, shape, and marbling.
  • a colour image may be recorded in a standardized way using well-known digital camera (121)
  • the stored image would be associated in the computer system with the uniquely numbered boning tray and in turn the originating animal.
  • Means to assess texture and consistency may require a mechanical device that reports the amount of force needed to indent the cut, or may accept an operator comment.
  • Taste and flavour may be assessed by a person or persons after processing (cooking) a sub-sample, or may be
  • the quality data would be reported (such as by report 124 upon a data carrier such as paper or as an electronic file) to the organization that raised the animals, such as a farmer or a feedlot manager. That data, which comprises phenotypic information, may be used to establish the relative genetic quality of the sire and dam of the animal that was
  • 315 processed, for breeding selection purposes. It may also be used to show whether the animals were properly fed.
  • Each packing station may include transponder-reading or interrogator means 123 appropriate for the tray recognition system in use.
  • the interrogator is located within a tabletop surface.
  • the tabletop surface may also include weighing means 120.
  • 320 When each boning tray is presented at a specific packing station (one of 114, 115, 116 or 117), identification of the boning tray to the remote information processor is established by the embedded transponder through an interrogator at that packing station so that a customised label at that packing station can be prepared from the currently stored data for that workstation, using a programmable printer for each packed item. For instance that label
  • 325 may include the identity of the corresponding disassembled carcass. It may be that a single packing station sorts and processes only one kind of cut from a boning tray 100, or that one packing station is capable of discriminating between a variety of cuts and labelling them separately, for later sorting of the packed items.
  • the label that is actually printed may comprise indicia printed directly onto a container, or 330 it may be printed on to a separate self-adhesive label that is then stuck onto a plastic bag or whatever is used to hold each packed item.
  • the weight and type of each packed item is also printed onto the label in human-readable form.
  • the indicia as printed at the packing station on the boning line may be read directly by a person, such as a customer in a retail shop. However it is 335 likely that one class of item at the boning line might be packed in bulk and only later be unpacked into a number of individual items on a retailer's shelf so that aspect of maintained identity is beyond the control of those operating the meat packing process. In that case, a standardised marking such as a one or two dimensional bar code may be used, and later translated into a number of individual customer labels.
  • the invention can be applied to other assembly or disassembly chains, such as food preparation, electronics manufacture, and so on, where a "job" is kept together on a remotely identifiable tray.
  • the preferred identification system is robust and fully compatible with the intended 360 working environment.

Abstract

Uniquely identifiable, portable workstations are used in systems for assembly or disassembly of items. Interrogation devices, some being weighing machines, linked to a computer network can recognize workstations fitted with transponders. The example process is boning of a carcass or part thereof upon a portable, transponder-equipped boning tray. All the cuts in various trays retain a source identity established at the time that each tray is loaded. Recovered data includes: carcass quality, for referral to the farm; origin of cuts, for labeling, and process performance. Either sequential or non-sequential work practices are facilitated.

Description

TITLE: REMOTELY IDENTIFIABLE BONING WORKSTATIONS
FIELD
The invention relates in general to procedures for assembly or disassembly of items, and to means for maintaining an identity or link between the assembled item and each separated component, and is particularly related to although not limited to disassembly or boning of food animal carcasses into individual components within abbattoirs and meat works.
DEFINITIONS
A "transponder" as used herein is a device capable of emitting a signal carrying unique transponder identifying data when it receives an interrogation signal or simply is exposed to a field of electromagnetic energy: radio frequencies or light. The preferred transponder, according to present-day technical solutions, is a "RFID" or self-contained radio-frequency identification device which derives operating power from the field of energy and transmits its identifier code while energized. The concept is not limited to devices that use radio waves.
BACKGROUND
The archetypal production line as put into practice by Henry Ford comprises a large number of vehicle units carried on a conveyor belt and passing in a strict sequence, while being assembled, through many processes each involving workers or robots. This invention has been developed from a disassembly kind of production line, and furthermore one where processing may be carried out in parallel at different speeds, rather than expecting or enforcing a strict serial sequence with all steps being carried out at the same speed. One end product having a commercial value is the resulting collections of different parts. Another end product having a commercial value is information. This invention is also concerned with gathering numerical data such as the weights of disassembled parts; each being reliably linked back to the item first entering the
disassembly production line, or the efficiency at which work is carried out.
Since a computer network is used in the present invention to maintain knowledge of the position and status of each of a number of moveable, identifiable workstations, the information is easily gathered. Despite the emphasis on disassembly in the following Examples, the principles of the invention are equally applicable to supporting and monitoring a process for assembly wherein workers at individual moveable and identifiable workstations carry out the steps of assembly.
One specific application for a disassembly production line is at a meat packing works, where the carcasses of food animals are cut apart. In this application, within an area commonly known as a boning room, a carcass is cut into parts and finally into single items by a team of skilled persons.
The data that is recovered in this kind of disassembly production line may be used to (a) provide a link between an eventually retailed cut of meat and the source farm or the source animal; and (b) to provide weight and quality data that is linked to the particular animal from which the parts have been obtained in the boning room. Quality factors other than weight may also be recorded; such as appearance, marbling and colour, and after appropriate procedures, taste, flavour and texture. The animal identifier would usually be the unique ear tag or similar that was used on the farm or feedlot from which the animal came. That data provides information that can be used in the course of breeding programs in which animals that produce better quality meat are selected. By analogy with the widely used artificial-insemination dairy bull selection programmes based on milk tests, the breeding values of beef sires can be determined and the best beef bulls can be used.
Nowadays traceability is also a requirement. For instance the customer expects much more information on a retail label than simply "Prime New Zealand Lamb". The provision of such information accurately yet at low cost is a challenge to be met by the industry and by distributors and retailers. The advent of individual ear tags, bar codes, bar code readers, and automated printers has made the link possible, yet problems remain. For example, Melville in US 6443828 describes an apparatus and process for meat packing with a transferred identity, but the apparatus requires that every step in the process of disassembly along the boning line be undertaken in sequence. Since there is no provision for an identification means that allo ws items to be processed out of order, more would be possible for one item to be held up and put out of sequence while an operator sharpens a knife, for example.
PROBLEMS TO BE SOLVED To provide a production system; either for assembly or for disassembly, wherein sequential processing is not required. To provide means to easily record and report attributes, such as weights of the different parts of each uniquely identified animal while they are being separated from the original carcass or other original object in a boning room. To provide information, otherwise unavailable, detailing the food-related attributes of breeding stock from which the carcasses were bred, for use in selection during breeding programs.
Underlying the above problems there is a need to identify the parts of the object being assembled or disassembled in both space and time during an assembly or a disassembly procedure.
OBJECT
An object of the present application is to provide a re-usable spatial location and unique identification means for parts during an assembly or disassembly process; more specifically to provide means for correlating a carcass with cuts made from the carcass and for recording other parameters; alternatively to provide a more flexibly operated disassembly or boning line by using remotely identifiable workstations, or at least to provide the public with a useful choice.
STATEMENT OF INVENTION
In a first broad aspect the invention provides a set of inter-related equipment for a process of assembly or disassembly of items on a production system, characterised in that the set of equipment includes more than one portable workstation on which either assembly from components or disassembly into components is carried out when the workstation is at a working position; each workstation including a transponder carrying workstation identity data; each transponder being capable of being interrogated by a nearest one of a plurality of interrogators located at specified positions, namely (a) one or more workstation loading positions, at each of which the workstation identity data is obtained from the transponder, forwarded to a computer system, and coupled within the computer system with an identifier for the item to be assembled or disassembled, and at (b) one or more working positions at each of which the workstation identity data is obtained from the transponder and forwarded to the computer system, and at (c) one or more workstation unloading positions at each of which the workstation identity data is obtained from the transponder and forwarded to the computer system thereby identifying the item or items carried on the workstation; the computer system being adapted to maintain and report on a record of progress of each identified portable workstation and the contents of each workstation within the production 95 system and hence to maintain a record of the identified components carried on and
transferred to or from the workstation at any site within the production system.
In a first related aspect, the computer system is further adapted to maintain a record of acquired data describing the or each identified component carried on or transferred to or from the workstation at one or more of the working positions within the production system; 100 said data being selected from a range including: weight, type, colour, shape, texture,
consistency, taste and flavour.
In a second related aspect, the production system is particularly adapted for the disassembly of a carcass of a meat animal into components and the computer system is particularly adapted for the collation and reporting of data describing the disassembly process and 105 describing the components thereby obtained.
In a second aspect, each workstation comprises a receptacle within which the carcass or parts thereof may be disassembled; each workstation being equipped with a transponder capable when interrogated of emitting an unique identification code.
In a first related aspect, the workstation is a re-usable boning tray having an upper or 110 working side, edges, and an under side, and including a transponder.
Preferably the transponder is concealed within the under side of the tray.
Preferably the workstation is a tray made of a durable plastics material capable of being washed and sterilised for re-use.
Optionally the workstation includes at least one optically readable label mounted upon a 115 surface of the tray.
In a second broad aspect the invention provides a method for operating a boning room, characterised in that a computer or system of computers is provided with information from data input means identifying a single carcass on arrival at the boning room, and then is provided with information from data input means identifying one or more boning trays each
120 including a uniquely numbered transponder as having received parts of said identified
single carcass; and then is provided with information, including position and descriptive information from a plurality of transponder interrogation means at known positions within the boning room; said computer or system of computers thereby also acquiring information describing the parts of the identified carcass during and after disassembly into parts upon
125 said boning trays. In a first related aspect the computer or system of computers is capable of exporting information describing the parts of the identified carcass as exposed during disassembly to an external user.
In a second related aspect the computer or system of computers is capable of monitoring 130 and reporting on the disassembly process.
In a third related aspect, the computer or system of computers is capable of placing carcass- related information describing one or a group of disassembled parts upon a data carrier at the completion of the boning process such as a label for a package.
PREFERRED EMBODIMENT
135 The description of the invention to be provided herein is given purely by way of example and is not to be taken in any way as limiting the scope or extent of the invention.
Throughout this specification unless the text requires otherwise, the word "comprise" and variations such as "comprising" or "comprises" will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other 140 integer or step or group of integers or steps. Each document, reference, patent application or patent cited in this text is expressly incorporated herein in their entirety by reference. Reference to cited material or information cited in the text should not be understood as a concession that the material or information was part of the common general knowledge or was known in New Zealand or any other country.
145 DRAWINGS
Fig la: A perspective view of a boning tray including a transponder according to the invention.
Fig lb: An elevation view of a boning tray including a transponder according to the invention.
150 Fig lc: A plan view of a boning tray including a transponder according to the invention.
Fig 2: is a diagram showing one possible layout of a boning "line" or production system according to the invention, where sequential processing is not a requirement.
INTRODUCTION The underlying concept of this invention is to create a uniquely identified, portable 155 workstation including a transponder. The workstation can be moved around and worked on at a variety of places within the premises. Thanks to the transponder, it is possible for a suitably connected data management processor to maintain in its memory real-time record of where each workstation is at any time. Further, a workstation can be weighed or otherwise assessed from time to time, while being identified by means of the transponder at 160 each assessment. For instance the incremental loss of weight of each identified workstation from action to action can be related to the weights of parts removed. Even further, the origin of the object placed on the workstation at the beginning of a disassembly process can be correlated with the identity of workstation itself. It will be evident that the use of many such workstations at a site allows disassembly processes to proceed independently of each 165 other. The invention allows any combination of sequential steps to be performed by
different people upon the same workstation, or disassembly steps to be taken by the same person over the entire process. There is a supervising computer system.
EXAMPLE 1 - Meat processing; boning room.
In this Example, the uniquely identified portable workstation is an approximately
170 rectangular receptacle or boning tray having a top surface surrounded by low sides, one or more optional handles for moving purposes, and an underneath surface. This "identifiable, moveable boning tray" is the core component of this invention. It may be moved about a boning room and weighed from time to time, or left in one place. Rather than referring to a "boning line" wherein every tray moves in a strict sequential order, this Example describes 175 a "boning system" where trays, which comprise "portable workstations" may at least to some extent be processed out of order. The supervising computer system keeps track.
A boning tray 100 according to the invention is shown in Figs la, lb and lc. Fig la is a perspective view of the tray from above and to one side; Fig lb is an elevation view with the transponder projected on to the surface, and Fig lc is a plan view of the working
180 surface. While size is not fixed, a typical tray might conveniently be 800 mm in width, 400 mm in depth, and the sides 107 of the tray might be 15-75 mm high- not necessarily all the same height - as at 102. Preferably the trays are stackable, and the sides are sloped so as to form part of a stack. The transponder shown as dashed lines in Fig la is not normally visible from above, and need not be placed in the exact centre of the tray although
185 symmetry is an advantage. In Fig lb, the thickness of the working surface where the
transponder 105 is embedded is exaggerated. In practice the underside of preferred trays is provided with a pattern of ridges (not shown) so as to provide strength without excessive mass and to assist in sliding over a wet surface. One ridge that holds the transponder may be made wider. Preferably the internal transition from floor to walls is smoothly rounded
190 for cleaning purposes since repeated cleaning and sterilization of the working surface 101 will be required. Preferably the boning tray is constructed of a tough material capable of withstanding impacts from knives while boning is carried out, yet capable of being cleaned and sterilised for re-use. Suitable materials include (without limitation) high-density polyethylene and various types of Nylon™. Metal such as stainless steel is a possibility for
195 some applications, although the transponder environment must be made transparent to rado- frequency fields. Tray materials could be coloured if that is useful, such as for operator relief or to relate groups of trays with each other. Dimensions of the boning tray should take note of convenience for the operators as well as the containment function. Optionally one or more internal ridges (not shown) may be included in the top of the tray for the purpose of
200 segregation of cuts and waste during a procedure of boning and trimming at one or more sites along a boning line.
Each moveable boning tray includes a unique tray identification means 105 capable of being read remotely. In one example, a central cavity 103 underneath the tray may be filled with a non-conductive material 104 and a conventional or possibly a heat-resistant
205 transponder is embedded within the material. The skilled reader will appreciate that the embedding material should not affect transmission of electromagnetic energy (radio- frequency fields) at the operating frequencies. Preferably each unique number is repeated in a human-readable marking or an optically readable marking 106, for convenience.
Each preferred transponder holds for example a permanent 64-bit substantially unique 210 digital code, which may include error- sensing bits. This code is capable of distinguishing any one boning tray from any other. Although Fig 1 shows a rectangular transponder, any convenient shape is acceptable. A compatible nearby reading means or interrogator (Fig 2: 123), concealed within a top surface of any working position, emits short range radio signals capable of interrogating the transponder 105 at a certain frequency and power in the 215 conventional manner, as well known to those skilled in the relevant arts, and subsequently reads and reports the information carried within returned signals which specifically identify the individual boning tray and which are sent by cables or wireless means (shown as dotted lines 122 A in Fig 2) to the computer system 122. The short-range transponder reading means or interrogator 123 is placed near the base of the tray at the loading point 110 (see 220 Fig 2), at each work station 111 , at each weigh station, optionally at each work station, and optionally at packing stations 114— 117; wherever the tray needs to be identified. Use of wireless signals has the advantage over optical identification that it does not require an unobscured, well-lit and properly oriented target and a clean lens to actually see the target. The transponder in each tray is well protected although it should be made of a type that is 225 resistant to sterilisation temperatures. Then, as long as the computer system 122 has been initially provided with information from 110 as to which tray is filled with which carcass or part thereof, the identity of cuts either in or taken from that tray is available.
An optical label, name, target 106 or targets may also be mounted upon one or more external or internal surfaces. Some kinds of optical target include redundancy in the
230 markings so that the target may be read reliably even if substantially obscured. Some
preferred targets resemble two-dimensional bar-codes and may use Hamming or other error correction methods to overcome the "noise" inherent in partially obscured labels, as is known to those skilled in the arts. A plain bar code could be used. After all, each tray and its label(s) will be cleaned after each use. Both optical labels and wireless transponders may
235 be used on the same tray, because it may be convenient to have a human-readable or an optically readable label on each tray.
This invention makes much use of quality indicators such as weights because one objective is to return meat quality information, coupled to each animal passing through the meat processing plant, back to the farmer or feed lot operator that supplied the stock, so that 240 breeding selection and performance data including feeding data can be returned. Typically, the system would weigh the boning tray loaded with a carcass to be dismembered, and then would weigh each cut separately, and perhaps also weigh the trimmings, so that the business can be monitored more accurately.
Some examples of the available quality-describing information that may be tied to one 245 animal, and later used for farm quality control or for breeding value purposes by application of the transponder-equipped tray workstations of the invention are:
1) Weight of each individual retained (for eventual sale) part.
2) Weight of trimmings or discards such as fat and bones.
3) Appearance of some or all retained parts - such as marbling, colour, and shape, and 250 texture or consistency.
4) Samples may be cooked and tasted under a suitably controlled environment, or
chemically assessed. Some examples of the process or performance information that may be tied to one workstation by application of the transponder-equipped tray workstations of the invention 255 are:
1) Operator positioning, within a working area or boning room.
2) Operator speed.
3) Operator precision.
4) Location of any one work station at any time.
260 The invention also provides a method for maintaining identity of a disassembled carcass using a plurality of separately identified boning trays. This method may involve several steps, such as first receiving identification of a single carcass, being carried to the area of the boning line or lines on a conveyor hook by means of a unique identifier on the hook, and read out to a remote information processor. That identifier may be another transponder.
265 The invention includes the step of identifying one or more boning trays 100 as previously described in this section as becoming (at 110 in Fig 2) loaded with parts of the identified single carcass to the remote computer system here shown as 122, via data cables 122 A. The hook identifier (not shown) for the whole or partial carcass is coupled to or linked to the tray identifiers within a database or comparable means within a digital computer or network
270 of computers (not shown) which supervises the boning room and collects quality-related information. Coupling or linking may make use of a relational database or other forms of software well known to those skilled in the relevant arts.
During the process of converting the contents of each boning tray into salable cuts and waste, there is no particular reason to continuously read each tray transponder, although any
275 option is available for any preferred management system. There is no requirement to keep the trays moving through the disassembly process in a strictly sequential order. Hence, if one boning operator is faster than another for any reason, the faster operator's tray can bypass the slower operator's tray at any point. Faster operators are not held up by slower operators. Speed differences might be caused by worker experience, carcass quality,
280 different quarters, and interruptions to work. Not all boning stations need be manned.
In the diagrammatic example of Fig 2, boxes 111 represent separate working positions, herein called boning stations, with a worker likely to be at each one. Each working position is provided with an interrogator 123, typically within the top surface. Each boning station 111 may receive loaded boning trays (the "workstations" of the invention) directly from the 285 loading point 110, and may also receive trays from other stations as suggested by arc 119. There is no required specific order of tray movements, since the tray contents will be positively identified at the end stage, when packing occurs. In Fig 2, a loop 113 represents an optional sequencer intended to present any one boning tray 100 at any one packing station (114, 115, 116 or 117), or present each tray to every packing station in sequence. It
290 is assumed that a worker is at some or all of the packing stations and can visually pick and identify a specific cut, weigh it, and pack it. Automation may be used. Of course, there is considerable freedom to vary this example plan of boning room operations. The nonsequential arrangement of the boning "line" in Fig 2 is an option made possible by the use of uniquely labelled boning trays; it is not a necessary aspect. The same invention will be
295 useful with sequential boning lines, while it is fault-tolerant in that type of arrangement.
Each weighing station (such as the one at position "111 A" in Fig 2) is provided with an interrogator 123, typically within the surface. The computer system, having already registered the boning tray and its initial weight at 110, will be able to calculate the weight of the contents at the weighing station such as 111 A, which serves as one indication of the
300 quality of the animal from which the carcass and the cuts were derived. Apart from weight (a measuring device for which is represented symbolically by 120 at working position 111 A), which is a clear candidate for objective quality assessment, means may be provided at one or more stations 111 to assess colour, shape, and marbling. For example, a colour image may be recorded in a standardized way using well-known digital camera (121)
305 technology (at 11 IB). The stored image would be associated in the computer system with the uniquely numbered boning tray and in turn the originating animal. Means to assess texture and consistency may require a mechanical device that reports the amount of force needed to indent the cut, or may accept an operator comment. Taste and flavour may be assessed by a person or persons after processing (cooking) a sub-sample, or may be
310 assessed by chemical analysis methods such as gas or liquid chromatography of volatile compounds. The quality data would be reported (such as by report 124 upon a data carrier such as paper or as an electronic file) to the organization that raised the animals, such as a farmer or a feedlot manager. That data, which comprises phenotypic information, may be used to establish the relative genetic quality of the sire and dam of the animal that was
315 processed, for breeding selection purposes. It may also be used to show whether the animals were properly fed.
Each packing station may include transponder-reading or interrogator means 123 appropriate for the tray recognition system in use. Typically, the interrogator is located within a tabletop surface. The tabletop surface may also include weighing means 120. 320 When each boning tray is presented at a specific packing station (one of 114, 115, 116 or 117), identification of the boning tray to the remote information processor is established by the embedded transponder through an interrogator at that packing station so that a customised label at that packing station can be prepared from the currently stored data for that workstation, using a programmable printer for each packed item. For instance that label
325 may include the identity of the corresponding disassembled carcass. It may be that a single packing station sorts and processes only one kind of cut from a boning tray 100, or that one packing station is capable of discriminating between a variety of cuts and labelling them separately, for later sorting of the packed items.
The label that is actually printed may comprise indicia printed directly onto a container, or 330 it may be printed on to a separate self-adhesive label that is then stuck onto a plastic bag or whatever is used to hold each packed item. Optionally the weight and type of each packed item is also printed onto the label in human-readable form.
The indicia as printed at the packing station on the boning line, or at least some of said indicia, may be read directly by a person, such as a customer in a retail shop. However it is 335 likely that one class of item at the boning line might be packed in bulk and only later be unpacked into a number of individual items on a retailer's shelf so that aspect of maintained identity is beyond the control of those operating the meat packing process. In that case, a standardised marking such as a one or two dimensional bar code may be used, and later translated into a number of individual customer labels.
340 Since the computer system knows where each boning tray supplied from any particular carcass is situated, it would be easily possible for example to call back all trays from one particular carcass, no matter where they are, if for example evidence of disease is found in one tray such that the entire carcass would thereby fail a meat hygiene requirement. (The placement of persons specifically serving as meat inspectors can be accommodated within
345 the invention).
The invention can be applied to other assembly or disassembly chains, such as food preparation, electronics manufacture, and so on, where a "job" is kept together on a remotely identifiable tray.
ADVANTAGES
350 1) An assembly or disassembly chain in which sequential processing is not necessary yet close control is maintained, is provided. 2) Identification of packed items, in relation to the source carcass as received and
hence to the farm of origin, is assured.
3) All feasible quality information can be referred back to the carcass and hence to the 355 breeding animals that gave rise to the carcass.
4) All feasible quality information can be referred back to the farm or feedlot on which the animal was raised and hence provide farm performance or efficiency
information.
5) The preferred identification system is robust and fully compatible with the intended 360 working environment.
6) Flexible boning-line work patterns are allowed for, for instance so that each worker can work at best efficiency, yet identity of cuts is maintained.
7) The operators need not take any action at all to identify their boning trays during the disassembly process.
365 Finally, it will be understood that the scope of this invention as described by way of
example and/or illustrated herein is not limited to the specified embodiments. Where in the foregoing description, reference has been made to specific components or integers of the invention having known equivalents, then such equivalents are included as if individually set forth. Those of skill will appreciate that various modifications, additions, known
370 equivalents, and substitutions are possible without departing from the scope and spirit of the invention as set forth in the accompanying claims.

Claims

WE CLAIM:
1. A set of inter-related equipment for a process of assembly or disassembly of items on a production system, characterised in that the set of equipment includes more than one
375 portable workstation on which either assembly from components or disassembly into
components is carried out when the workstation is at a working position; each workstation including a transponder carrying workstation identity data; each transponder being capable of being interrogated by a nearest one of a plurality of interrogators located at specified positions, namely
380 a) one or more workstation loading positions, at each of which the workstation identity data is obtained from the transponder, forwarded to a computer system, and coupled within the computer system with an identifier for the item to be assembled or disassembled, and at b) one or more workstation working positions at each of which the workstation 385 identity data is obtained from the transponder and forwarded to the computer system, and at c) one or more workstation unloading positions at each of which the workstation identity data is obtained from the transponder, thereby identifying the item or items carried on the workstation, and forwarded to the computer system;
390 the computer system being adapted to maintain and report on a record of progress of each identified portable workstation and the contents thereof within the production system and hence to maintain a record of the identified components carried on and transferred to or from the workstation at any site within the production system.
2. A set of equipment as claimed in claim 1, characterised in that the computer system is 395 further adapted to hold a record of acquired data describing the or each identified
component carried on or transferred to or from the workstation at one or more of the working positions within the production system; said data being selected from a range including: weight, type, colour, shape, texture, consistency, taste and flavour.
3. A set of equipment as claimed in claim 2, characterised in that the production system is 400 particularly adapted for the disassembly of a carcass of a meat animal into components and the computer system is particularly adapted for the collation and reporting of data describing the disassembly process and describing the components thereby obtained.
4. A set of equipment as claimed in claim 3, characterised in that each workstation comprises a receptacle within which the carcass or parts thereof may be disassembled; each
405 workstation being equipped with a transponder capable when interrogated of emitting an unique identification code.
5. A workstation for a disassembly process as claimed in claim 4, characterised in that the workstation is a re-usable boning tray having an upper or working side, edges, and an under side, and including a transponder.
410 6. A workstation for a disassembly process as claimed in claim 5, characterised in that the transponder is concealed within the under side of the tray.
7. A workstation for a disassembly process as claimed in claim 5, characterised in that the workstation is a tray made of a durable plastics material capable of being washed and sterilised for re-use.
415 8. A workstation for a disassembly process as claimed in claim 5, characterised in that the workstation includes at least one optically readable label mounted upon a surface of the tray.
9. A method for operating a boning room, characterised in that a computer or system of computers is provided with information from data input means identifying a single carcass
420 on arrival at the boning room, and then is provided with information from data input means identifying one or more boning trays each including a uniquely numbered transponder as having received parts of said identified single carcass; and then is provided with
information, including position and descriptive information from a plurality of transponder interrogation means at known positions within the boning room; said computer or system of
425 computers thereby also acquiring information describing the parts of the identified carcass during and after disassembly into parts upon said boning trays.
10. A method for operating a boning room as claimed in claim 9, characterised in that said computer or system of computers is capable of exporting information describing the parts of the identified carcass as exposed during disassembly to an external user.
430 11. A method for operating a boning room as claimed in claim 9, further characterised in that the computer or system of computers is capable of monitoring and reporting on the disassembly process.
12. A method for operating a boning room as claimed in claim 9, further characterised in that the computer or system of computers is capable of placing carcass-related information describing one or a group of disassembled parts upon a data carrier at the completion of the boning process.
PCT/NZ2012/000033 2011-03-08 2012-03-06 Remotely identifiable boning workstations WO2012121616A1 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998054599A2 (en) * 1997-05-28 1998-12-03 Peter Haagensen Primal tracking
US6545604B1 (en) * 1999-07-01 2003-04-08 Micron Technology, Inc. Methods for electronic tracking of units originating from a common source, and assemblies comprising transponders attached to meat spikes

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998054599A2 (en) * 1997-05-28 1998-12-03 Peter Haagensen Primal tracking
US6545604B1 (en) * 1999-07-01 2003-04-08 Micron Technology, Inc. Methods for electronic tracking of units originating from a common source, and assemblies comprising transponders attached to meat spikes

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