Process control method for improving manufacturing operations

Claim 1

A method for controlling a manufacturing process which produces a product comprising the steps of a. establishing at least one specification for the product which specification defines one of a specification nominal value with tolerances and a range, and has a corresponding specification plot line; b. taking samples of the product during...a plurality of time periods; c. measuring the samples relative to the specification to create at least one measurement for each sample; d. recording the measurements and corresponding time period for each sample in a database; e. applying for a plurality of time periods at least one statistical process control algorithm to at least one selected set of sample measurements from that time period to define for that set of sample measurements and time period at least one statistical value with an associated sample plot line reflecting a statistical representation of the set of sample measurements; f. graphically displaying in a bar type graph the specification plot line adjacent sample plot lines from the plurality of time periods for which the statistical process control algorithm has been applied; and g. adjusting the manufacturing process as necessary in response to the bar type graph, wherein steps b thru f are performed during at least one of a setup run and a manufacturing run.

Claim 2

A method for controlling a manufacturing process which produces a product comprising the steps of a. establishing at least one specification for the product which specification defines one of a specification nominal value with tolerances and a range, and has a corresponding specification plot line; b. taking samples of the product during...a plurality of time periods; c. measuring the samples relative to the specification to create at least one measurement for each sample; d. recording the measurements and corresponding time period for each sample in a database; e. applying for a plurality of time periods at least one statistical process control algorithm to at least one selected set of sample measurements from that time period to define for that set of sample measurements and time period at least one statistical value with an associated sample plot line reflecting a statistical representation of the set of sample measurements; f. graphically displaying in a bar type graph the specification plot line adjacent sample plot lines from the plurality of time periods for which the statistical process control algorithm has been applied; and g. adjusting the manufacturing process as necessary in response to the bar type graph, wherein steps b thru f are performed during at least one of a setup run and a manufacturing run.

Claim 13

A system for monitoring a production process which produces a product during a plurality of time intervals that meets predetermined specifications comprising: a. a central processing unit; b. data input means connected to the central processing unit; c. a display means connected to the central processing unit which is capable of displaying tables containing alphanumeric characteristics and a bar type graph containing a set of substantially parallel lines below the tables; and d. a memory connected to the processing unit, the memory capable of storing data for each time period received from the data input means and containing a program for: i) displaying in tabular form selected data received from the data input means, ii) applying at least one statistical process control algorithm to at least a portion of the selected data which is displayed in tabular form to create at least one statistical value with an associated plot line for each time period reflecting a statistical representation of the portion of the selected data for that time period; iii) creating a specification plot line corresponding to at least one specification entered through the data input means; and iv) causing the display means to display in tabular form selected specifications, selected manufacturing data, and selected statistical values and to display near the tabular form a bar-type graph containing plot lines from a plurality of time periods and a specification plot line, the plot lines being displayed substantially parallel to one another.

Claim 14

A system for monitoring a production process which produces a product during a plurality of time intervals that meets predetermined specifications comprising: a. a central processing unit; b. data input means connected to the central processing unit; c. a display means connected to the central processing unit which is capable of displaying tables containing alphanumeric characteristics and a bar type graph containing a set of substantially parallel lines below the tables; and d. a memory connected to the processing unit, the memory capable of storing data for each time period received from the data input means and containing a program for: i) displaying in tabular form selected data received from the data input means, ii) applying at least one statistical process control algorithm to at least a portion of the selected data which is displayed in tabular form to create at least one statistical value with an associated plot line for each time period reflecting a statistical representation of the portion of the selected data for that time period; iii) creating a specification plot line corresponding to at least one specification entered through the data input means; and iv) causing the display means to display in tabular form selected specifications, selected manufacturing data, and selected statistical values and to display near the tabular form a bar-type graph containing plot lines from a plurality of time periods and a specification plot line, the plot lines being displayed substantially parallel to one another.