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| United States Patent | 4827423 |
| Link to this page | http://www.wikipatents.com/4827423.html |
| Inventor(s) | Beasley; Thomas B. (Pilot Mountain, NC);
Cearley; Thomas W. (Clemmons, NC);
Chandler; David A. (Winston-Salem, NC);
Gondring; Kim A. (Winston-Salem, NC);
Guarino; Richard A. (Pfafftown, NC);
Hutchins; William G. (Pfafftown, NC);
Martin; Marvin R. (Winston-Salem, NC);
Norris; Eugene E. (Winston-Salem, NC);
Prout; Lloyd T. (Winston-Salem, NC);
Schlottman; Jeffrey R. (Winston-Salem, NC);
Smith; Charlotte M. (Winston-Salem, NC);
Summers; William F. (Mocksville, NC);
Twine; David C. (Winston-Salem, NC);
Walsh; R. Victor (Winston-Salem, NC) |
| Abstract | The Computer Integrated Manufacturing System includes a plurality of levels
of computer control which organize and disseminate the information for
controlling shop floor level systems. Both scheduling data and data
relating to process, product, and material specifications as well as bills
of material are generated in an upper level computer system and refined
and down loaded as needed to lower level computers controlling the shop
floor processes. The computers on the upper levels are capable of
communication with the computers on the lower levels and computers on the
same level are capable of communication with each other as needed to pass
information back and forth. |
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Title Information  |
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| Inventor |
Beasley; Thomas B. (Pilot Mountain, NC);
Cearley; Thomas W. (Clemmons, NC);
Chandler; David A. (Winston-Salem, NC);
Gondring; Kim A. (Winston-Salem, NC);
Guarino; Richard A. (Pfafftown, NC);
Hutchins; William G. (Pfafftown, NC);
Martin; Marvin R. (Winston-Salem, NC);
Norris; Eugene E. (Winston-Salem, NC);
Prout; Lloyd T. (Winston-Salem, NC);
Schlottman; Jeffrey R. (Winston-Salem, NC);
Smith; Charlotte M. (Winston-Salem, NC);
Summers; William F. (Mocksville, NC);
Twine; David C. (Winston-Salem, NC);
Walsh; R. Victor (Winston-Salem, NC) |
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| Publication Date |
May 2, 1989 |
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| Parent Case |
BACKGROUND OF THE INVENTION
Cross Reference To Related Application
This is a continuation-in-part of application Ser. No. 005,172, filed Jan.
20, 1987. |
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Title Information  |
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| Market Size |
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Market Review  |
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Technical Review  |
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Claims  |
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What is claimed is:
1. A multilevel computerized process control system, comprising:
a first level computer system comprising at least one first computer for
controlling a plurality of individual processes for producing a plurality
of different products, said first level computer system comprising:
a plurality of sensor inputs for receiving process monitoring sensor
signals from sensors at respective process stations,
a plurality of control outputs for providing control signals for processes
to be controlled, p1 storage for storing process control parameters for
processes to being carried out,
storage for storing bill of materials records containing indications of
materials necessary for products being produced;
storage for storing values of said sensor signals, and
programs for producing said control signals to control said processes as a
function of said sensor signal values and said process control parameters
for processes being carried out;
a second level computer system comprising at least one second computer
connected to said first level computer system and storing a database
having a plurality of files containing process control parameters
associated with different processes which may be required to be performed
by said first level computer system to produce different products, said
files including a process specification file containing records indicating
process control parameters necessary for producing said different products
and a bill of materials file containing records indicating materials
necessary for producing said different products, said second level
computer system:
being connected to receive scheduling information indicative of scheduled
process controls to be carried out by said first level computer system to
produce scheduled products,
being programmed to provide selected ones of said control parameters
necessary to carry out said scheduled process controls to said first level
computer system as said control parameters for processes being carried out
and to provide selected records from said bill of materials file
indicating materials necessary for producing said scheduled products as
said materials for products being produced, and
being programmed to receive indications of said values of said sensor
signals; and
a third level computer system connected to said second level computer
system, said third level computer system being programmed to generate said
database and transmit said database to said second level computer system
and being connected to receive modification instructions for modifying
records of said database, said modification instructions being contained
in a modification instruction file containing information for modifying
said records and information as to times at which modifications to said
records are to be implemented.
2. A system as set forth in claim 1 wherein said second level computer
system includes monitor drivers for displaying said values of said sensor
signals on operator console monitors.
3. A system as set forth in claim 1 wherein said database includes a
product specification file having records with data related to
specifications of a product to be produced.
4. A system as set forth in claim 3 wherein said third level computer
system stores an item master file containing records having purchasing
data, and accounting data related to products produced and materials
purchased.
5. A system as set forth in claim 4 wherein said third level computer
system stores a revision control file containing information on revisions
to any other file.
6. A system as set forth in claim 1 including an automated material
delivery system for providing material to said process stations, and a
further second level computer system for controlling operation of said
automated material delivery system in response to commands for material
received from said processing stations.
7. A system as set forth in claim 1 wherein said first level computer
system comprises a lower level of computers having a plurality of
identical computers programmed to carry out specific process functions,
and a higher level computer connected to other first level computer
systems in a communication network, said higher level computer being
connected to said plurality of lower level computers and being programmed
to receive process control parameters required for said lower level
computers to carry out their specific process functions from said second
level computer system, transmit said received process control parameters
to said respective lower level computers as required for said lower level
computers to carry out their programmed specific process functions,
receive sensor signal values from said respective lower level computers
and transmit said received sensor signal values to said second level
computer system.
8. A system as set forth in claim 7 wherein said second level computer
system comprises a superior level computer and an inferior level of
computers, said inferior level of computers comprising a plurality of
identical computers connected together in a communication network and
being connected to a respective plurality of higher level computers of
said first level computer network, said inferior level of computers being
programmed to display said received sensor signal values on display
consoles, and receive from said superior level computer and store
respective portions of said database required for said lower level
computers to carry out their specific process function.
9. A system as set forth in claim 1 wherein said scheduling information
comprises a production schedule for a first predetermined period of time,
and said second level computer system provides to said first level
computer system a second production schedule which covers a second period
of time shorter than said first period of time.
10. A system as set forth in claim 8 wherein said scheduling information
comprises a production schedule covering a first period of time received
by said superior level computer and wherein said superior level computer
provides scheduling information to said inferior level computers which
covers a shorter period of time and said superior level computer provides
said respective portions of said database to said inferior level computers
which contain process parameters required over said shorter period of time
to meet said production schedule.
11. A system as set forth in claim 1 wherein said second level computer
system stores a product definition file having a record for each product
to be scheduled, each record of said product definition file containing
information indicating all bill of material records for a particular
product to be scheduled and all process control parameters for the
particular product to be scheduled.
12. A system as set forth in claim 11 wherein said second level computer
system accesses one of said product definition file records in response to
said scheduling information indicating a product to be produced and passes
the accessed product definition file record to said third level computer
system.
13. A system as set forth in claim 12 wherein said third level computer
system receives said accessed product definition file record and produces
said control signals by determining process variable set points from said
process control records.
14. A system as set forth in claim 7 wherein said third level computer
comprises a plurality of individual higher level computers interconnected
by a networking system.
15. A system as set forth in claim 14 wherein said networking system
comprises a collision system.
16. A systemas set forth in claim 14 wherein said lower level computers are
connected to said higher level computers by a second networking system.
17. A system as set forth in claim 16 wherein said second networking system
comprises a polling system.
18. A systemas set forth in claim 1 wherein said second level computer
system comprises a plurality of individual second level computers
interconnected by a second level networking system.
19. A system as set forth in claim 18 wherein said second level networking
system comprises a collision system.
20. A system as set forth in claim 1 including a common disc storage area
and wherein said second and third level computer systems are connected to
said common disc storage area.
21. A system as set forth in claim 1 wherein said third level computer
system stores a modification file containing records, each modification
order record containing a modification order number, approval data
corresponding to said modification order number and change reason data
indicating a reason for the modification corresponding to said
modification order number.
22. A multilevel computerized process control system, comprising:
a first level computer system comprising at least one first computer for
controlling a plurality of individual processes for producing a plurality
of different products, said first level computer system comprising:
a plurality of sensor inputs for receiving process monitoring sensor
signals from sensors at respective process stations as well as sensors for
receiving indications of material levels of products in process,
a plurality of control outputs for providing control signals for processes
to be controlled,
storage for storing process control parameters for processes to being
carried out,
storage for storing bill of materials records containing indications of
materials necessary for products being produced;
storage for storing values of said sensor signals, and
programs for producing said control signals to control said processes as a
function of said sensor signal values and said process control parameters
for processes being carried out;
a second level computer system comprising at least one second computer
connected to said first level computer system and storing a first database
having a plurality of files containing process control parameters
associated with different processes which may be required to be performed
by said first level computer system to produce different products, said
files including a process specification file containing records indicating
process control prameters necessary for producing said different products,
and a bill of materials file containing records indicating materials
necessary for producing said different products, and a second database
storing plant production and inventory records containing inventory levels
and plant production data, said second level coputer system: p1 being
connected to receive scheduling information indicative of scheduled
process controls to be carried out by said first level computer system to
produce scheduled products,
being programmed to provide selected ones of said control parameters
necessary to carry out said scheduled process controls to said first level
computer system as said control parameters for processes being carried out
and to provide selected records from said bill of materials file
indicating materials necessary for producing said scheduled products as
said materials for products being produced,
being programmed to receive indications of said values of said sensor
signals and update said plant production and inventory records; and
a third level computer system connected to said second level computer
system, said third level computer system being programmed to generate said
first database and transmit said first database to said second level
computer system and being connected to receive modification instructions
for modifying records of said first database, said modification
instructions being contained in a modification instruction file containing
information for modifying said records of said first database and
information as to times at which modifications to said records of said
first database are to be implemented.
23. A system as set forth in claim 22 wherein said second level computer
system also stores an operating instruction file containing information
from certain records of said first database relating to operating
instructions for producing said different products, and a recipe file
containing information from certain records of said first database
relating to components for producing said different products, and said
operating instruction file and said recipe file comprise said selected
ones of said control parameters provide to said first level computer
system.
24. A system as set forth in claim 22 wherein said second level computer
system provides material on hand displays based on information relating to
material being processed provided from said first level computer system.
25. A system as set forth in claim 24 wherein said second level computer
system further comprises means to permit manual adjustment of inventory
levels in said second database.
26. A system as set forth in claim 24 wherein said second level computer
system provides a transaction log for indicating chronological inventory
events.
27. A system as set forth in claim 22 wherein said second level computer
system includes means for accumulating information relating to raw
material inventories and for producing a raw material inventory report
indicating the inventory level of said raw materials.
28. A system as set forth in claim 22 wherein said second level computer
system includes means for accumulating information relating to products
produced and producing a position report indicating the inventory level of
said products produced.
29. A system as set forth in claim 23 wherein said second level computer
system down loads into active memory of said first level computer system
recipes and operating instructions from said recipe and operating
instruction file for a current run and a next subsequent run, and said
first level computer system also stores a copy of said recipe file and
said operating instruction file.
30. A system as set forth in claim 22 wherein said first level computer
system receives and stores data relating to production based on operating
day, operating shift, and operating run.
31. A multilevel computerized process control system according to claim 1,
wherein said first level computer system comprises a plurality of first
computers disposed in a plurality of manufacturing plants and said second
level computer system comprises at least one second computer in each said
manufacturing plant, and wherein said third level computer system is
connected to all of said second level computers to provide centralized
multi-plant control.
32. A multilevel computerized process control system according to claim 1
wherein said third level computer system is programmed to generate a
master schedule and transmit said master schedule to said second level
computer system as said scheduling information.
33. A multilevel computerized process control system according to claim 32
including in said first level computer system inputs for receiving signals
indicative of inventory levels of materials required to produce scheduled
products and wherein data indicative of material levels of products in
process and inventory levels of materials required to produce scheduled
products are transmitted by said first level computer system to said
second level computer system, and said second level computer system
generates individual schedules for the individual processes based thereon
and based on said master schedule.
34. A multilevel computerized process control system according to claim 33
wherein said second level computer system is programmed to provide call
outs to vendors for ordering materials required by said individual
schedules.
35. A multilevel computerized process control system according to claim 32
wherein said third level computer system is programmed to receive and
generate said master schedule based on data indicating a long range
forecast of demand for products to be produced and data indicating long
range capacity production capacity.
36. A multilevel computerized process control system according to claim 34
wherein said call outs are generated by said second level computer system
by subtracting daily material requirements as determined from said
individual schedules from inventory in the plant.
37. A multilevel computerized process control system according to claim 1
wherein said first level computer system comprises a plurality of
computers connected to control a plurality of said individual processes in
a sequential processing line.
38. A multilevel computerized process control system according to claim 37
wherein said sequential processing line is a cigarette manufacturing line.
39. A multilevel computerized process control system according to claim 38
wherein said cigarette manufacturing line includes means for conditioning
tobacco to carry out a tobacco condition process as one of said sequential
processes.
40. A multilevel computerized process control system according to claim 39
wherein said cigarette manufacturing line includes means for cutting
tobacco to carry out a tobacco cutting process after said tobacco
conditioning process.
41. A multilevel computerized process control system according to claim 40
wherein said cigarette manufacturing line includes means for making
cigarette rods from cut tobacco after said tobacco cutting process to
carry out a cigarette rod making process.
42. A multilevel computerized process control system according to claim 41
wherein said cigarette manufacturing line includes means for packing
cigarette rods into a cigarette pack after said cigarette rod making
process to carry out a cigarette packing process.
43. A multilevel computerized process control system according to claim 42
wherein said cigarette manufacturing line includes means for cartoning
cigarette packs after said cigarette packing process to carry out a carton
packing process.
44. A multilevel computerized process control system according to claim 43
wherein said cigarette manufacturing line includes means for palletizing
cigarette cartons after said carton packing process. |
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Claims  |
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Description  |
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FIELD OF THE INVENTION
This invention relates to computerized control of manufacturing facilities
and especially to control systems known as computer integrated
manufacturing facilities in which an integrated computerized control is
established from the management level through the shop floor level.
DISCUSSION OF RELATED ART
Computerized control systems have been known and widely used for a long
time. In the manufacturing environment, these systems have generally been
used in isolated areas to control a single machine or a single group of
machines for producing a product, or used to control a line of machines in
a process control. In addition, computer systems are commonly used to
assist company accounting departments, sales departments, research and
development departments and the like. Recently, it has been suggested that
a hierarchy of control be established to integrate the various individual
computer systems found in a plant. Such integration, however, has proved
to be difficult and, while much has been written about the desirability of
such a fully automated system, little has actually been accomplished to
bring about an actual fully computerized integrated manufacturing
facility.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a computer integrated
manufacturing facility.
Another object of the present invention is to provide a computer integrated
manufacturing facility in which a novel manufacturing specifications
system is used to define and disseminate bill of materials information as
well as process control specifications.
A further object of the present invention is to provide a computer
integrated manufacturing system in which scheduling information is
combined with the bill of material and process control data to provide
precise control data for manufacturing stations on the shop floor.
Another object of the present invention is to provide a computer integrated
manufacturing system in which individual management centers are
established to control various functions in the plant and the individual
management centers are interconnected so that they can communicate with
each other.
An additional object of the present invention is to provide a computer
integrated manufacturing system in which changes in specifications and
process control data can be made easily, can be verified and can be
disseminated to the shop floor in a timely manner according to a
predetermined implementation schedule.
Yet another object of the present invention is to provide a computer
integrated manufacturing system in which a plurality of levels of
computers are established with communication between computers on each
level as well as communication between computers on adjacent levels.
An additional object of the present invention is to provide a computer
integrated manufacturing system which implements just-in-time concepts for
both machine scheduling and material ordering.
In accordance with the above and other objects, the present invention is a
multilevel computerized control system, comprising a first level computer
system having at least one first computer for controlling a plurality of
individual processes for producing a plurality of different products. The
first level computer system comprises a plurality of sensor inputs for
receiving process monitoring sensor signals from sensors at respective
process stations, a plurality of control outputs for providing control
signals for processes to be controlled, storage for storing process
control parameters for processes to being carried out, storage for storing
bill of materials records containing indications of materials necessary
for products being produced, storage for storing values of the sensor
signals, and programs for producing the control signals to control the
processes as a function of the sensor signal values and the process
control parameters for processes being carried out. A second level
computer system is also included. The second level computer system
comprises at least one second computer connected to the first level
computer system for storing a database having a plurality of files
containing process control parameters associated with different processes
which may be required to be performed by the first level computer system
to produce different products. The files include a process specification
file containing records indicating process control parameters necessary
for producing the different products and a bill of materials file
containing records indicating materials necessary for producing the
different products. The second level computer system is connected to
receive scheduling information indicative of scheduled process controls to
be carried out by the first level computer system to produce scheduled
products, is programmed to provide selected ones of the control parameters
necessary to carry out the scheduled process controls to the first level
computer system as the contrl parameters for processes being carried out
and to provide selected records from the bill of materials file indicating
materials necessary for producing the scheduled products as the materials
for products being produced, and is programmed to receive indications of
the values of the sensor signals. Finally, a third level computer system
is included. The third level computer system is connected to the second
level computer system and is programmed to generate the database and
transmit the database to the second level computer system. The third level
computer system is also connected to receive modification instructions for
modifying records of the database. The modification instructions are
contained in a modification instruction file containing information for
modifying the records and information as to times at which modifications
to the records are to be implemented.
In accordance with other aspects of the invention, the second level
computer system includes monitor drivers for displaying the values of the
sensor signals on operator console monitors.
Furthermore, the database may include a product specification file having
records with data related to specifications of a product to be produced, a
bill of materials file continuing a list of materials needed to produce a
product, an item master file containing records having purchasing data,
and accounting data related to products produced and materials purchased,
and a revision control file containing information on revisions to any
other file.
An automated material delivery system may be included for providing
material to the process stations, and a further second level computer
system may be provided for controlling operation of the automated material
delivery system in response to commands for materials received from the
processing stations.
Each first level computer system may comprise a lower level of computers
having a plurality of identical computers programmed to carry out specific
process functions, and a higher level computer connected to other first
level computer systems in a communication network. The higher level
computer is connected to the lower level computers and is programmed to
receive process control parameters from the second level computer system
required for the lower level computers to carry out their specific process
functions, transmit the received process control parameters to the
respective lower lever computers as required for the lower level computers
to carry out their programmed specific process functions, receive sensor
signal values from the respective lower level computers and transmit the
received sensor signal values to the second level computer system.
The second level computer system may comprise a superior level computer and
an inferior level of computers. The inferior level of computers comprises
a plurality of identical computers connected together in a communication
network and is connected to a respective plurality of higher level
computers of the first level computer network. The inferior level of
computers is programmed to display the received sensor signal values on
display consoles, and receive from the superior level computer and store
respective portions of the database required for the lower level computers
to carry out their specific process functions.
The scheduling information may comprise a production schedule covering a
first production period which comprises a first time period. The first
production schedule is received by the superior level computer and the
superior level computer provides scheduling information to the inferior
level computers which covers a shorter period of time and the superior
level computer provides the respective portions of the database to the
inferior level computers which contain process parameters required over
the shorter period of time to meet the production schedule.
The invention also includes a manufacturing control system comprising a
computer database system for storing information relating to products to
be manufactured and processes for manufacturing the products as well as
information relating to changes in the products and processes. The
database system includes a product file containing detail specification
records for finished and intermediate products, a process file containing
records with process parameters and instructions for machines or groups of
machines used for producing the products in the product file, a material
file containing records with detail specification data for purchased
materials, and a change order file containing information relating to
proposed changes in records of the other files. The change order file
contains records indicating the type of change, change approval
information and the effective date of the change.
The invention also includes the method of controlling the computer
integrated manufacturing system and the method of manipulating the
database.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects of the present invention will become more
readily apparent when the invention becomes more fully understood from the
detailed description set forth below, reference being had to the
accompanying drawings in which like reference numerals represent like
parts throughout and in which:
FIG. 1. shows an overview of a plant to be controlled by the computer
integrated manufacturing system of the present invention.
FIGS. 2a, 2b, 2c and 2d show an overview of the computer architecture used
in the computer integrated manufacturing system of the present invention.
FIG. 3. shows an overview of the organization of the software systems of
the computer integrated manufacturing system of the present invention.
FIG. 4. is a table showing the relationship of the access keys for the
manufacturing standards system as they relate to the files of the
manufacturing standards system.
FIG. 5. shows the file organization of the manufacturing standards system
of the computer integrated manufacturing system of the present invention.
FIG. 6. shows the relationship of the various files of the manufacturing
standards system.
FIG. 7. shows the relationship of the change order file and the revision
file to the other files of the manufacturing standards system.
FIG. 8 shows a flow chart depicting the change order implementation
sequence of the manufacturing standards system.
FIG. 9. shows the structure of the product definition file of the factory
manufacturing standards system of the present invention.
FIG. 10. shows the structure of the configuration matrix of the factory
manufacturing standards system of the present invention.
FIG. 11. shows an overall view of the scheduling functions performed in
accordance with the present invention.
FIG. 12 is a block diagram showing the overall flow of information in the
scheduling system of the present invention.
FIG. 13. shows a detailed view of one making and packing complex.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in relation to a cigarette
manufacturing facility, it being understood that the principles and
concepts described herein are also application to other types of
manufacturing plants.
In order to understand the concepts of the present invention, it is helpful
to understand the major functions to be performed in the manufacture of a
cigarette. FIG. 1 shows a block diagram flow chart of the operations to be
performed in the manufacture of a cigarette.
First, tobacco is received at the grade entry area 100. Here, grded tobacco
in bales is pulled according to a pull list which is displayed on a
monitor according to a stored recipe. The tobacco has been previously
marked with a bar code indicating the grade of the bale. As is well known,
tobacco is graded according to grade, belt, and crop year. The actual
grading of the tobacco is not the subject of the present invention and
will not be discussed in detail here. In general there are two types of
tobacco processed. These are Turkish tobacco and domestic tobacco. These
two types may require different subsequent processing and therefore may be
received at different grade entry areas 100.
The bar code on the bale is read and automatically compared with a grade
code stored in the recipe file indicating the grade of tobacco required.
If the received bale is acceptable, it is sliced into smaller sections
which are weighed so as to in feed the appropriate amount required by the
recipe, preconditioned to provide an appropriate amount of moisture for
subsequent delamination, and then passed to the strip condition area 102.
In strip condition area 102, the slices are delaminated in a delaminating
feeder which passes the tobacco to a conditioning drum. The conditioning
drum increases the temperature and the moisture level of the tobacco to be
within a predetermined range. After leaving the conditioning drum, the
tobacco flow is divided into two equal parallel lines. Each of these lines
has a separator in which the lighter, loosened lamina is separated from
the heavier, unloosened leaf by an ascending air stream. Moreover, dirt
particles are separated from the lighter lamina. The heavier lamina is
exposed to another conditioning process in a steam flotation chamber. This
results in an additional loosening up of the tobacco.
Grade entry area 100 together with strip condition area form the receiving
and blending (R&B) zone. There may be a plurality of R&B lines depending
on the total amount of tobacco to be processed.
From the R&B zone the conditioned tobacco is fed to the group blended
strips area 104 (GBS zone). The GBS zone comprises three infeed lines
which feed 20 bins arranged in two groups of five bin pairs. The bins of
the GBS zone provide intermediate storage for various tobacco blends,
which are not yet final blends according to the stored recipe. The various
R&B zones communicate by conveyors to the three infeed lines of the GBS
zone in order to fill the GBS bins. The various bin pairs are assigned to
different types of blends. For example, four of the bin pairs may contain
a Burley tobacco blend, three of the bin pairs may contain a Flue Cured
tobacco blend, one bin pair may contain a Maryland tobacco blend, one bin
pair may contain a Turkish tobacco blend, etc.
Each bin pair of the GBS zone is connected by conveyor to feed either one
of two infeed lines to the final blended strips area 106 (FBS zone). The
FBS zone comprises four bin pairs which are fed with tobacco from the bin
pairs of the GBS zone according to a recipe. That is, the tobacco being
stored in the intermediate storage of the FBS zone is moved upon demand to
the FBS zone in controlled quantities so that a final blend is obtained in
each of the FBS zone bin pairs.
The final blended tobacco is passed from one of the bin pairs of the FBS
zone according to the recipe to the casing area 108. The casing area
comprises a casing drum into which steam, moisture and casing are
provided. After being cased, the tobacco is passed to the cutting area 110
where it is cut to the proper size for the tobacco product being produced,
according to the recipe. The cut tobacco is then dried and cooled in the
drying and cooling area 112 and then passed to the top dressing area 114.
The casing area 108, cutting area 110, drying and cooling area 112 and top
dressing area 114 form the cutting and casing zone (C&C) of the process.
Further details of the C&C zone are set forth in co-pending application
Ser. No. 865,483, filed May 20, 1986, abandoned, and assigned to the
assignee of the present invention, the disclosure of which is incorporated
herein by reference thereto.
The portion of the system made up by the R&B, GBS, FBS and C&C constitutes
the primary processing portion of the cigarette manufacturing process.
From the C&C zone, the tobacco is transported to the cut filler storage
area 116. This area comprises a plurality of bins for storing the cut
filler until it is needed for the final cigarette making step.
When needed, the cut filler is transported via conveyor to the rod making
area 118 where the cigarette rods are formed. After formation of the rods,
the rods are packed together usually 20 to a pack in the packing area 120.
The packs of cigarettes are then packed into a carton in the carton
packing area 122. The cartons of cigarettes are then packed into a case in
the case packing area 124. The cases are then assembled together on
pallets in the pelletizing area 126. One rod making machine, one packer,
one carton packer, one case packer and one palletizer are assembled into a
single making and packing (M&P) complex. A single plant may contain 72 or
more such complexes. The M&P complexes are fed from bins which are
themselves fed from the FBS bins. The M&P bins are connected such that
three bins feed six complexes. This provides sufficient flexibility for
the simultaneous manufacture of a plurality of cigareete brands even if
one or more of the complexes become disabled.
Finally, the palletized product is moved to the finished goods area 128 for
storage or shipment for sale.
As will be discussed in further detail below, a plant also may include an
automatic guided vehicle (AGV) system comprising a plurality of guided
vehicles which operate under computer control to bring materials to the
M&P complexes when needed and to transport finished product to the
finished goods area when the cases have been palletized. The plant also
includes an automated materials storage and retrieval system known as a
factory service system (FSS) which takes the form of a computerized
warehouse for storing and retrieving the materials to be delivered to the
M&P complexes by the AGV system.
The foregoing provides an overview of the cigarette making process
controlled by the present invention. In general this comprises primary
processing, making and packing and finished goods. It should be understood
that the foregoing describes the activities of a single plant. However, a
plurality of plants may be operating at the same time. It is also possible
that some of the activities discussed above may be carried out at a first
plant and some of the activities may be carried out at a second plant with
the product of the first plant being shipped to the second plant for
further processing. All of these possibilities are contemplated by the
present invention.
COMPUTER ARCHITECTURE
FIG. 2 shows the general architecture of the computer system used in the
present invention. The system includes a mainframe computer system 130
located at corporate headquarters. This computer system is referred to as
the level IV system and is used to generate the material specifications,
product specifications, and process specifications which are eventually
used to produce product art the shop floor. The level IV system could be
any mainframe but in this particular instance is shown to be an IBM
computer system.
It should be noted that the term "material" is used hereafter to refer to a
material which is purchased for use in manufacturing a product. A
"product" is something which is manufactured even if the "product" is only
used for the manufacture of another product. Accordingly, as will be
discussed in more detail below, both materials and products are used in
the manufacture of other products.
The level IV computer system 130 may be connected to a plurality of plants.
A single plant is shown in FIG. 2 to comprise a level III computer system
made up of Digital Equipment Corporation (DEC) VAX 11/750 computers 132
and 134 as well as DEC VAX 8600 computers 136, 138 and 140. The level IV
system is shown to communicate to the level III system through one or more
DECnet/SNA gateways at 56 KB. This communication link is served by one or
more DEC PDP 11/24 computers.
The computers of the level III system communicate to each other through an
ETHERNET communication link. This is a conventional collision detection
type communication link provided by DEC. It is not essential that the
computers of the level III system be from the same manufacturer. However,
it is imperative that they be capable of communication with each other.
Accordingly, by having the computers originate from the same vendor, the
communication between computers is easily achieved by using vendor
supplied systems.
The level III systems perform functions to be d | | |