(19) United States
`(2) Patent Application Publication (10) Pub. No.: US 2003/0149608 A1
`(43) Pub. Date:
`Aug. 7, 2003
`Kall et al.
`
`US 200301.49608A1
`
`(52) U.S. Cl. …......…... 705/8; 700/99
`
`(57)
`
`ABSTRACT
`
`(54) SUITE OF CONFIGURABLE SUPPLY CHAIN
`INFRASTRUCTURE MODULES FOR
`DEPLOYING COLLABORATIVE
`E-MANUFACTURING SOLUTIONS
`(76) Inventors: Jonathan J. Kall, Glenmoore, PA (US);
`Thomas A. Troy, Lansdale, PA (US);
`Robert J. McCarthy, Downingtown,
`PA (US)
`Correspondence Address:
`NEIFELD IP LAW, PC
`2001 JEFFERSON DAVIS HIGHWAY
`ARLINGTON, VA 2.2202 (US)
`(21) Appl. No.:
`10/358,305
`(22) Filed:
`Feb. 5, 2003
`Related U.S. Application Data
`(60) Provisional application No. 60/354,151, filed on Feb.
`6, 2002.
`
`A suite of configurable supply chain infrastructure modules
`provides the “collective manufacturing management infra
`structure” necessary to support a high velocity e-business
`initiative. At the core of the collaboration scheme is the
`Business Process Modeling Module. The Business Model
`ing Module consists of two components: Business Process
`Event Coordinator, and Business Process Modeler. To fur
`ther support the collaborative scheme, a suite of highly
`configurable application templates and pre-configured
`industry applications provide an interface or wrapper around
`the business rules. The application templates are designed to
`be used as stand-alone components, or can be assembled/
`configured into a cohesive solution to provide a basic
`foundation layer for a Collaborative Manufacturing Execu
`tion System (CMES). To address the connectivity of the
`CMES layer to the business layer and the shop floor auto
`mation layer, an Extensible Markup Language (XML) Busi
`ness Connector and Optical Photo Conductor (OPC) Shop
`Floor Connector fulfill the interface needs required to sup
`(51) Int. Cl." … G06F 17/60
`port a collaborative infrastructure.
`
`Publication Classification
`
`Business
`Systems
`
`Product
`Managemant
`Systems
`(CMES)
`
`
`
`
`
`
`
`Master BOM
`
`Master Schedule
`Raw Material
`Inventory, etc.
`
`Intermediate
`Inventory
`
`Finished
`Goods
`
`"Horizontal" Business System Database
`• Raw Material Consumptions
`• Work Order and BOM
`• Formulations
`• Finished Goods
`• Invento
`• Production Statistics
`
`
`
`Connector
`
`
`
`Resourse Tracking
`
`BOM Implementation
`
`Order Processing
`Production Scheduling
`& Tracking
`& Resource Allocatio
`Production Quality
`Product Tracking
`Management
`& Genealogy
`"Horizontal" Production Management (CMES) Database
`• Machine Setup Parameters
`• Process Data
`• Peripheral Device Setup
`• MES Events
`
`
`
`
`
`Manufacturing Information System Architecture
`
`
`
`Connector
`
`CiM Ex. 1049 Page 1
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`

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`Patent Application Publication
`
`Aug. 7, 2003 Sheet 1 of 61
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`US 2003/0149608 A1
`
`
`
`
`
`
`
`Connector
`
`Plant Floor Execution
`(Interwave Coordinator)
`
`
`
`
`
`Connector
`
`Automation
`
`Legend:
`ERP - Enterprise Resource Planning
`PLM - Product Life Cycle Management
`PDM - Product Data Management
`SCM - Supply Chain Management
`CRM - Customer Relations Management
`Automation - PLC, DCS, etc.
`APS - Advanced Planning & Scheduling
`
`Fig. 1
`
`CiM Ex. 1049 Page 2
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 2 of 61
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`US 2003/0149608 A1
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`CiM Ex. 1049 Page 3
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 3 of 61
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`US 2003/0149608 A1
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 5 of 61
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`US 2003/0149608 A1
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`Patent Application Publication
`
`Aug. 7, 2003 Sheet 6 of 61
`
`US 2003/0149608 A1
`
`Supply Chain Modules:
`
`XML Business Connector
`
`Business Process
`Event Coordinator
`Industry Applications:
`Support Applications:
`Roll Tracker
`Lab Assistant
`Discrete Assembler
`Shop Scheduler
`Food Processor
`Pharma Manager
`MedL)evice Tracker
`Custom Application(s)
`
`
`
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`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
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`Utility Services:
`Event Messenger
`Work Traveler
`Label Manager
`Data Archiver
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`OPC Shop Floor Connector
`Automation:
`
`
`
`Legend:
`PLC - Programmable Logic Controller
`DCS - Distributed Control System
`SCADA Supervisory Control & Data Acquisition
`Fig. 5
`
`
`
`Application Templates:
`Work Order Management
`WIP Management
`Inventory Management
`Material Management
`Tool Management
`Quality Management
`Quality Data Collection
`Defect Tracker
`Downtime Tracker
`Specification Managemen
`Shipping
`RMA
`ECO
`Work Instructions
`Electronic Notebook
`
`CiM Ex. 1049 Page 7
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`

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`Patent Application Publication
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`Aug. 7, 2003 Sheet 7 of 61
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`US 2003/0149608 A1
`
`Master Plan
`Forecast
`Orders
`
`
`
`
`
`Plan
`300
`
`-
`
`Better Planning:
`True inventory,
`Latest PV,
`Accurate Capability
`-
`
`Plant Schedule:
`Sequence by line + product
`(Manual/LEAN/FCS)
`
`Schedule
`301
`
`Product Code:
`Setup
`Process
`Tear Down
`
`
`
`
`
`Analyze/Report
`
`
`
`Better Sequencing:
`Higher Throughput,
`More Predictable LIFR
`
`Better Process:
`Lower Waste,
`Higher Utilization,
`Process Excellence
`
`Fig.6
`
`CiM Ex. 1049 Page 8
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`

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`Patent Application Publication
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`Aug. 7, 2003 Sheet 8 of 61
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`US 2003/0149608 A1
`
`Fig. 7
`
`Start of Coordinator
`Module Installation
`
`?
`Install RDBMS on the Coordinator Database Server
`
`Install Web Services on the Coordinator Web Server
`
`@ Install Coordinator Business Process Modeler
`on the Coordinator Production Server
`
`|
`
`Install Coordinator Business Process Event Coordinator on the @
`Coordinator Production Server (authoring and runtime components)
`
`|
`
`.
`
`The following Coordinator Application
`Templates are available for Installation:
`+ Work Order Management
`+ WIP Management
`+ Material Management
`+ Tool Management
`Gs)
`+ Quality Management
`|
`+ Quality Data Collection
`Install Desired Coordinator
`Application Templates on the H+ Defect Tracker
`Coordinator Application Server||+ Downtime Tracker
`+ Specification Management
`+ Shipping
`+ Return Merchandise Authorization (RMA)
`+ Engineering Change Order (ECO)
`+Material Review Board (MRB)
`+ Work Instructions
`+ Electronic Notebook
`
`
`
`CiM Ex. 1049 Page 9
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 9 of 61
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`US 2003/0149608 A1
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`Fig. 8
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Install Desired Coordinator
`Industry Applications on the
`Coordinator Application Server
`
`Install Desired Coordinator
`Support Applications on the
`Coordinator Application Server
`
`480
`
`The following Coordinator Industry
`Applications are available for Installation:
`+ Roll Tracker
`+ Discrete Assembler
`+ Food Processor
`+ Pharma Manager
`+ MedIDevice Tracker
`
`The following Coordinator Support
`Applications are available for Installation:
`+ Lab Assistant
`+ Shop Scheduler
`
`.
`
`Install Desired Coordinator
`Connectors on the
`Coordinator Application Server
`
`The following Coordinator Conncctors
`are available for Installation:
`+ XML Business Connector
`+ OPC Shop Floor Connector
`
`Install Desired Coordinator
`Utilities on the
`Coordinator Application Server
`
`The following Coordinator Utilities
`are available for Installation:
`+ Event Messenger
`+ Work Traveler
`+ Label Manager
`+ Data Archiver
`+ Auto Tracker
`+ Auto Collector
`
`Install Desired Coordinator
`Visualization Tools on the
`Coordinator Application Server
`
`
`
`The ?ollowing Coordinator Visualization
`Tools are available for Installation:
`+ Digital Dashboard
`
`|
`End of Coordinator
`Module Installation
`
`CiM Ex. 1049 Page 10
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 12 of 61
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`CiM Ex. 1049 Page 45
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`CiM Ex. 1049 Page 46
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`US 2003/0149608 A1
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`CiM Ex. 1049 Page 60
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`Patent Application Publication
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`US 2003/0149608 A1
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`Patent Application Publication
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`Aug. 7, 2003 Sheet 61 of 61
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`US 2003/0149608 A1
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`Interwave Coordinator - Specification Management
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`Nominal Val
`0IIll?lål Value
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`Specification Details:
`H-Material Class Specifications
`Specification
`HMaterialClass A
`#---MCA 001, Revision 1.1 || Revision Dale|10-0CT-2002 032.43AM.
`#---MCA 002, Revision 16 || Type
`Material Class.
`+---MCCA 003, Revision 24 || Description [Winder process variables
`MaterialClass B
`}--- MC B 001, Revision 1.3
`Specification Parameters:
`tº Mg-
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`£SCTIDI1011
`F---MC B 002, Revision 19
`arameter
`ype
`F---MC B 003, Revision 1.5
`PARAM 01
`ANALOG Run Rate
`H---MC B 004, Revision 0.0
`PARAM_02
`ANALOG Web Tension
`---MC B 005, Revision 30
`MaterialClass B
`|
`H---MC C_001, Revision 10
`|
`----MC_C 002, Revision 10
`-MaterialClass D
`-MaterialClass E
`H-Material Specifications
`-
`HMaterial A
`H---MTL. A 001, Revision 14
`!---MTLA-002, Revision 22
`Material_B
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`---MTL B_001, Revision 1.3
`---MTL_B 002, Revision 1.7
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`Specification
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`Revision
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`Description
`Winder solution setup
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`Material Qucues Production Summary
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`Dispense Rate
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`Dispense Temperature 30
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`kgs/sec
`degC
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`Fig. 56
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`SUITE OF CONFIGURABLE SUPPLY CHAIN
`INFRASTRUCTURE MODULES FOR DEPLOYING
`COLLABORATIVE E-MANUFACTURING
`SOLUTIONS
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`[0001] This application claims priority under 35 USC
`119(e) to U.S. provisional application serial No. 60/354,151,
`filed Feb. 6, 2002.
`
`BACKGROUND OF THE INVENTION FIELD
`OF THE INVENTION
`[0002] The present invention relates to Manufacturing
`Executive Systems (MES). Particularly, the present inven
`tion relates to Collaborative Manufacturing Executive Sys
`tems (CMES), which can be defined as “collaborative manu
`facturing management infrastructure.”
`
`DISCUSSION OF THE BACKGROUND
`[0003] U.S. Pat. No. 6,470,227 (hereinafter 227 patent)
`discloses a method for automating a manufacturing process
`including configuring application objects embodied in a
`computer program. The inventors recognized that the 227
`patent does not provide any solution to synchronize key
`supply chain modules (ERP, PLM, and APS etc.) and
`production support systems (LIMS and FCS etc.) with
`events and activities that occur on the factory floor, and that
`the 227 patent fails to disclose the ability to synchronize
`and coordinate activities across multiple manufacturing
`sites.
`
`SUMMARY OF THE INVENTION
`[0004] A MES system means a software application that
`provides a real-time view of manufacturing operations.
`These systems perform the task of integrating corporate or
`plant business systems information with shop floor data
`systems. The resulting values provided by MES are data that
`can be automatically converted into “actionable informa
`tion” that can then be used for improved decision making at
`all levels of the manufacturing enterprise. For example,
`MES provides values derived from data obtained from
`operations, manufacturing management, engineering, IT,
`planning, materials management, etc.
`[0005] ACMES system is about information, and how to
`get your data from the plant floor, from production control,
`from inventory and quality control, from purchasing, from
`engineering, from marketing and sales, and turn that data
`into information that can be used by managers at all levels
`of the enterprise to make mission-critical decisions. To
`summarize. CMES is about communication, and how to
`optimize the bi-directional flow of information to and from
`the operating units in a manufacturing enterprise.
`[0006] Therefore, it is the object of the present invention
`to provide a collaborative manufacturing execution system
`(CMES) and method. The CMES is designed in the form of
`a collaborative software system infrastructure that interfaces
`with business systems, the supply chain modules, such as
`Enterprise Resource Planning (ERP) and Advanced Plan
`ning & Scheduling (APS), production support systems, such
`as Laboratory Information Management Systems (LIMS),
`Finite Capacity Scheduling (FCS) Systems, and plant floor
`
`systems, such as Supervisory Control and Data Acquisition
`Systems (SCADA), Distributed Control Systems (DCS),
`and Programmable Logic Controllers (PLC).
`[0007] This collaborative infrastructure, which is a col
`laborative manufacturing execution system (CMES), Sup
`ports and enables high velocity e-business initiatives for
`manufactures in many different market segments, e.g., auto
`motive, consumer products, food and beverage, pharmaceu
`tical, electronic. Furthermore, this collaborative infrastruc
`ture is able to coordinate and synchronize business systems,
`production support systems and plant floor systems across
`multiple manufacturing sites through an enterprise intranet
`or the Internet.
`[0008] FIG. 1 illustrates a commercial embodiment of a
`CMES application of this invention, named Interwave Coor
`dinator. Interwave Coordinator is used to reduce time and
`expense spent in understanding process and product flow in
`manufacturing environments and provide real-time integra
`tion among them. Interwave Coordinator is also utilized by
`enterprises to make business objectives decision and deter
`mine the requirements for manufacturing and designing
`products using quantitative information regarding defects,
`downtime, rework requirements, and resulting quality.
`[0009] Furthermore, FIG. 1 illustrates how Interwave
`Coordinator provides all of the coordination and synchro
`nization with the external entities (ERP, PLM, PDM, etc.) at
`a business level that are impacted by the events and activities
`that occur on the plant floor. This coordination and synchro
`nization is provided via business process modeling modules,
`such as the Business Process Event Coordinator, along with
`a supporting communication connector module, such as the
`XML Business Connector. In addition, Interwave Coordi
`nator provides the internal coordination and synchronization
`to support typical plant floor production management func
`tions, such as Work Order Management, WIP Management,
`Inventory Management, etc. This coordination and synchro
`nization is provided via another supporting communication
`connector module, such as the OPC Shop Floor Connector.
`These two types of coordination and synchronization pro
`vide a completely synchronized information system to sup
`port the tremendous information demands of a CMES
`model. As a result, there will be no overlapping and discon
`nected segments in various levels of manufacturing work
`flow and among remote manufacturing sites. The CMES of
`this invention includes a suite of universal application
`templates, utilities and pre-configured solutions that lever
`age Microsoft technology such as Visual Basic, COM+ and
`SQL Server.
`[0010] The universal application templates are config
`urab