WO2019034839A1

WO2019034839A1 - A manufacturing method and system

Info

Publication number: WO2019034839A1
Application number: PCT/GB2018/052220
Authority: WO
Inventors: Christopher Alan BRUNSDON; Robert Reuven FRANKS
Original assignee: Tommytrinder.Com Limited
Priority date: 2017-08-14
Filing date: 2018-08-02
Publication date: 2019-02-21
Also published as: GB201712986D0

Abstract

The present invention relates to a method of controlling manufacture of building frames. The method includes the steps of: a processing apparatus receiving a set of constraints from each of a plurality of manufacturers for a plurality of frame types; a user apparatus receiving input from a user to define a frame of a user-specified frame type within the set of constraints associated with the specified frame type; the processing apparatus processing the user defined frame in accordance with the associated set of constraints to produce manufacturing instructions; transmitting the instructions to the associated manufacturer; and controlling manufacture of the frame on one or more manufacturing apparatus in accordance with the instructions. A system is also disclosed.

Description

A Manufacturing Method and System Field of Invention The present invention is in the field of manufacturing control systems. More particularly, but not exclusively, the present invention relates to a method and system for controlling manufacturing processes for building frames.

Background

Automated and semi-automated manufacturing processes for customised products are typically orchestrated via a centralised system which is controlled by manufacturing engineers. Engineers at the manufacturer receive orders from a plurality of different customers. Even in the modern era, these orders typically come in via facsimile. Where the orders are received via email, these typically arrive at computing devices not connected to the centralised manufacturing system. Engineers then parse the details of the order and prepare instructions for the centralised manufacturing system. Engineers may need to parse and modify the order based upon their knowledge of the nature of the materials and product.

The centralised manufacturing system may include intelligence to arrange for optimal use of raw materials for manufacture of the customised product and manage orchestration of the manufacture process across multiple manufacturing apparatus considering phasing of manufacturing, utilisation of apparatus, and prioritisation of the order. There is a desire to further automate the customised manufacturing process. Customers of manufacturers (e.g. retailers) often also desire the ability to provide to their customers customised product ranges from multiple manufacturers. This is particularly important for retailers of building frames whose product offerings are, necessarily, highly customisable. This creates complexity for the retailer who must be cognisant of the manufacturing issues of each manufacturer, and for the manufacturer who must accommodate imperfect instructions.

Therefore, there is a need to manage these idiosyncrasies at both sides with a superior manufacturing control system.

It is an object of the present invention to provide a manufacturing control system which overcomes the disadvantages of the prior art, or at least provides a useful alternative.

Summary of Invention

According to a first aspect of the invention there is provided a method of controlling manufacture of building frames, including:

a) a processing apparatus receiving a set of constraints from each of a plurality of manufacturers for a plurality of frame types;

b) a user apparatus receiving input from a user to define a frame of a user-specified frame type within the set of constraints associated with the specified frame type;

c) the processing apparatus processing the user defined frame in accordance with the associated set of constraints to produce manufacturing instructions;

d) transmitting the instructions to the associated manufacturer; and e) controlling manufacture of the frame on one or more manufacturing apparatus in accordance with the instructions. Each of the frame types may include a plurality of components. The set of constraints may include one or more selected from the set of dimension ranges for components and dependencies between components. Each of the components may be associated with pricing information. Each pricing information may be selected from the set of price by length, price by mass, price based upon a percentage of a base price for the frame type, or a zero price. One or more of the plurality of components may include one or more of a plurality of sub-components. The method may further include the processing apparatus receiving a set of pricing information from each of the plurality of manufacturers for the plurality of frame types; and processing the input in accordance with the associated set of constraints and set of price data to generate a total price for the frame. The method may further include the processing apparatus receiving a set of default information from each of the plurality of manufacturers for the plurality of frame types. At least some parameters for the frame may be derived from the associated default information. The user may be associated with one of a plurality of retailers.

Each of the plurality of manufacturers may specify availability of the plurality of frame types offered by the manufacturer for each of the plurality of retailers, such that a user can only specify a frame type from a manufacturer when is made available. Each of the plurality of manufacturers may specify a pricing modifier for one or more of the plurality of frame types for one or more of the retailers, such that the associated pricing modifier modifies the total price for the frame. The instructions may be received by a manufacturing control system which controls manufacture of the frame. The one or more manufacturing apparatus may include one or more selected from the set of notch saw, cut off press, extrusion bender, roll coater, vinyl elder, corner cleaner, and straight line beveller. According to a further aspect of the invention there is provided a system for controlling manufacture of building frames, including:

One or more user apparatus, each configured to receive input from a user to define a frame of a user-specified frame type of a plurality of frame types within a set of constraints associated with the specified frame type and to transmit the user defined frame to a processing apparatus;

A processing apparatus configured to receive a set of constraints from each of a plurality of manufacturers for a plurality of frame types, to receive and process the user-defined frame in accordance with the associated set of constraints to produce manufacturing instructions and to transmit the instructions to the associated manufacturer; and

One or more manufacturing control systems, each configured to control manufacture of the frame on one or more manufacturing apparatus in accordance with the instructions. Other aspects of the invention are described within the claims.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 : shows a block diagram illustrating a system in accordance with an embodiment of the invention; and Figure 2: shows a flow diagram illustrating a method in accordance with an embodiment of the invention. Detailed Description of Preferred Embodiments

The present invention provides a method and system for controlling manufacture of building frames.

The inventors have discovered that an intermediary system can be used which sits between customers and multiple manufacturers. This intermediary system can include constraint data from each manufacturer for different types of building frames. In this way, a user of the intermediary system can define customised building frames for a user and the system can enforce the constraints to ensure viable frames can be manufactured. The instructions for the building frames from the system can then control manufacture of the frames without human engineering intervention. In Figure 1 , a control system 100 for the manufacture of building frames in accordance with an embodiment of the invention is shown.

The control system 100 includes a processing apparatus 101 and a database 102.

The processing apparatus 101 may be configured for receiving a set of constraints from each of a plurality of manufacturers for multiple frames types.

The database 102 may be configured for storing the set of constraints from each manufacturer for multiple frame types.

The control system 100 may further include one or more user apparatus 103a/b/c. Each user apparatus 103a/b/c may be configured to receive input from a user to define a frame of user-specified frame type within the set of constraints associated with the specified frame type. The processing apparatus 101 may be further configured to process the user defined frame in accordance with the associated set of constraints to produce manufacturing instructions and to transmit the instructions to the associated manufacturer.

The control system 100 may further include a plurality of manufacturing control systems 104a/b/c. Each manufacturing control system 104a/b/c may be connected to one or more manufacturing apparatus 105a/b/c, such as a notch saw, cut off press, extrusion bender, roll coater, vinyl elder, corner cleaner, and straight line beveller, and may be configured to receive the manufacturing instructions to control manufacture of the frame on, for example, one or more of the manufacturing apparatus.

Referring to Figure 2, a method 200 for controlling manufacture of building frames will now be described in accordance with an embodiment of the invention.

In step 201 , a processing apparatus (e.g. 101 ) receives a set of constraints from each of a plurality of manufacturers for a plurality of frame types. The set of constraints may be received over a communications network from a server or user device for each manufacturer.

Definitions for frame types may also be received from the manufacturer. The definitions may include a series of attributes for the frame type such as:

Name, description, material type (e.g. PVC, timber, aluminium, etc.), product type (e.g. casement window, sash window, bifold door, etc.), profile suite, glazing method (e.g. internal, external, or both), joint type (e.g. welded mechanical, etc.), and set of possible design styles. A default set of parameters may also be received from the manufacturer for each frame type.

The frame types may include a plurality of components. The set of constraints may include possible dimension ranges for some or all of the components and/or dependencies between the components. The components may be structured within a hierarchical tree such that the top level may be comprised of : profiles, hardware, glass, glazing and finish. "Profiles" may, for example, include sections, reinforcings and ancillaries. The bottom layer of the tree may be component which may comprise: name, part code, and attributes (such as section length, weight, shape, etc.). The constraints for each component may include dimension ranges such as minimum/maximum length and rule-sets to define dependencies between components (for example, if a particular profile frame section is greater than a certain length then a different reinforcing (from the default) must be used (similar rule-sets may define a minimum number of sashes for that length and minimum number of hinges to be used). Pricing information may also be received from the manufacturers for the plurality of frame types and/or each component. These may be, for example, a combination of unit price and price per metre or price per kilogram or price per metre squared.

In step 202, a user apparatus (e.g. 103a, 103b, or 103c) receives input from a user to define a frame of a user-specified frame type within the set of constraints associated with the specified frame type. The user input may be received via the user input mechanism described in relation to UK Patent Application No. GB1602256.8.

The frame may be pre-configured in accordance with the default set of parameters. To define the frame, user input may modify the pre-configured frame. In addition, during definition the frame in accordance with the user input, the default set of parameters may be used for one or more components until modified by further user input. For example, the bottom-level Component type 'frame' may have a default Component whose width attribute is 48mm and the bottom-level Component type 'bead' may have a default Component whose shape is 'curved'. Prior to step 202, the user may be presented on the user apparatus with the set of frame types available to them for each manufacturer. The user may then specify the frame type. After this point, the set of constraints, default set of parameters and/or pricing information for the user-specified frame type may be transmitted from the processing apparatus to the user apparatus. In an alterative embodiment, the processing apparatus may transmit some or all of this information for every frame type, or every available frame type for a user- specified manufacturer.

During step 202, if any default dimension of the product or component is changed then the user apparatus may check that all the constituent components constraints are adhered to. If not, the system may not allow the change and an appropriate message may be shown as to the reason.

During step 202, the frame may be rendered (or drawn) on a display at the user apparatus in accordance with the user input and set of constraints.

User input may be further received during step 202 to configure the frame by selecting one or more user interface modes displayed on the user apparatus such as: Frame, Glass, Glazing, Colour, and switching out Components from the Defaults (e.g. Choose another Glass pattern to use). Each component selected may have its accompanying attributes, pricing information and constraints which are then used to redraw, re-price and check against.

Dependency rulesets between components may also be checked to ensure that certain components cannot be used in combination with another. For example a certain size of opener may be too large for current 'sash reinforcing' component. The user is notified and a stronger reinforcing component may be found automatically or the user may override this and choose another.

In step 203, the processing apparatus processes the user defined frame in accordance with the associated set of constraints to produce manufacturing instructions.

In step 204, the manufacturing instructions are transmitted (e.g. by the processing apparatus 101 ) to the associated manufacturer (e.g. to their manufacturing control system 104a, 104b, or 104c).

In step 205, manufacture of the frame one or more manufacturing apparatus (e.g. 105a, 105b, or 105c) is controlled (e.g. by the associated manufacturing control system 104a, 104b, or 104c).

A potential advantage of some embodiments of the present invention is that customised building frames can be manufactured at multiple manufacturers with minimal/no intervention from a human engineer. While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of applicant's general inventive concept.

Claims

1. A method of controlling manufacture of building frames, including:

d) transmitting the instructions to the associated manufacturer; and e) controlling manufacture of the frame on one or more manufacturing apparatus in accordance with the instructions.

2. A method as claimed in claim 1 , wherein each of the frame types includes a plurality of components.

3. A method as claimed in claim 2, wherein the set of constraints includes one or more selected from the set of dimension ranges for components and dependencies between components.

4. A method as claimed in any one of claims 2 to 3, wherein each of the components is associated with pricing information.

5. A method as claimed in claim 4, wherein each pricing information is selected from the set of price by length, price by mass, price based upon a percentage of a base price for the frame type, or a zero price.

6. A method as claimed in any one of claims 2 to 5, wherein one or more of the plurality of components includes one or more of a plurality of sub-components.

7. A method as claimed in any one of the preceding claims, further including:

the processing apparatus receiving a set of pricing information from each of the plurality of manufacturers for the plurality of frame types; and

processing the input in accordance with the associated set of constraints and set of price data to generate a total price for the frame.

8. A method as claimed in any one of the preceding claims, further including:

the processing apparatus receiving a set of default information from each of the plurality of manufacturers for the plurality of frame types; wherein at least some parameters for the frame are derived from the associated default information.

9. A method as claimed in any one of the preceding claims, wherein the user is associated with one of a plurality of retailers.

10. A method as claimed in any one of preceding claims, wherein each of the plurality of manufacturers specify availability of the plurality of frame types offered by the manufacturer for each of the plurality of retailers, such that a user can only specify a frame type from a manufacturer when is made available.

1 1 . A method as claimed in claim 10, wherein each of the plurality of manufacturers specify a pricing modifier for one or more of the plurality of frame types for one or more of the retailers, such that the associated pricing modifier modifies the total price for the frame.

12. A method as claimed in any one of the preceding claims, wherein the instructions are received by a manufacturing control system which controls manufacture of the frame.

13. A method as claimed in any one of the preceding claims, wherein the one or more manufacturing apparatus include one or more selected from the set of notch saw, cut off press, extrusion bender, roll coater, vinyl elder, corner cleaner, and straight line beveller.

14. A system for controlling manufacture of building frames, including:

One or more manufacturing control systems, each configured to control manufacture of the frame on one or more manufacturing apparatus in accordance with the instructions.