Inventory control for web-based articles

[0001] This application claims the benefit of U.S. Provisional Application No. 60/533,595, entitled “METHOD FOR THE OPTIMIZATION OF YIELDS ON WEB BASED ARTICLES,” filed Dec. 31, 2003, and U.S. Provisional Application No. 60/533,596, entitled “METHOD FOR CONTROLLING INVENTORY OF WEB BASED ARTICLES,” filed Dec. 31, 2003, the entire contents of each of which are incorporated herein by reference.

[0002] The present invention relates to automated inspection of systems, and more particularly, to optical inspection of continuously moving webs.

[0003] Inspection systems for the analysis of moving web materials have proven critical to modern manufacturing operations. Industries as varied as metal fabrication, paper, non-wovens, and films rely on these inspection systems for both product certification and online process monitoring. One major difficulty in the industry is related to the extremely high data processing rates required to keep up with current manufacturing processes. With webs of commercially viable width and web speeds that are typically used and pixel sizes that are typically needed, data acquisition speeds of tens or even hundreds of megabytes per second are required of the inspection systems. It is a continual challenge to process images and perform accurate defect detection at these data rates.

[0004] The art has responded to this dilemma by limiting the image processing to very simple algorithms, by limiting the scope and complexity of the detection algorithms, and by using custom inspection system architectures incorporating custom electronic hardware or dedicated preprocessors, each working on part of the data stream. While such systems are capable of achieving the data rates required for the inspection of moving webs, it is very difficult to adapt the system for a new production process and web materials. Also, processing algorithms are limited to the capabilities of dedicated processing modules. Finally, as the image processing algorithms become more complex, the hardware required to implement the required processing quickly becomes unmanageable.

[0005] The manufacturing industry has recognized the importance of being able to produce product “just-in-time” with obvious advantages in reduced inventory. However, achieving this goal often has manufacturers working to develop systems and devices that allow a rapid changeover between various products. The rapid changeover between products is inconsistent with the specialized signal processing hardware now required by the art of optical inspection of moving webs.

[0006] Another dilemma occurs in situations when a given product can be later used for multiple applications, with each of the multiple applications requiring different quality levels. The difficulty is that during the time of manufacture, it is not known which quality level will be required. Therefore, the current art attempts to grade quality level after defect detection by using various defect classification techniques based on spatial features of the extracted defects. While this is sometimes adequate when gross differences exist between defect levels for different quality requirements, it is not adequate for more demanding situations in which subtle differences between defects require different image processing and defect extraction algorithms. Thus, if one waits until after defect extraction for classification, information is lost and the classification is impossible.

[0007] The invention is directed to techniques for the automated inspection of moving webs. An inspection system, for example, acquires anomaly information for a web using an optical acquisition device and performs a preliminary examination with a first, typically less sophisticated algorithm. Image information about the regions of the web containing anomalies is stored for subsequent processing, accepting the likelihood that although some of the anomalies will be defective, many could be “false positives,” i.e., anomalies that are not defective. In fact, some anomaly areas may be ultimately classified as defective if the web is used in a particular product application, but not defective if the web is used in another.

[0008] The original anomaly information can be reconsidered and fully analyzed at a convenient time, even after the inspected web has been wound onto a roll and is unavailable. As a result, the speed of the moving web during the inspection can be much greater than is possible when the entire surface of the web is subjected to a sophisticated analysis.

[0009] Moreover, conversion decisions can be made offline after capture and storage of the original anomaly information. For example, a conversion control system subsequently selects a converting site for converting the web into one or more products. The conversion control system may select the converting site from a plurality of available geographically distributed converting sites based on one or more “site selection parameters,” such as current product inventory levels at the various converting sites.

[0010] Other examples of site selection parameters that may be used to influence the site selection process include order information associated with each of the products at the various converting sites, current product demand levels experienced within the geographic regions of the converting sites, shipping costs and transportation options associated with each of the converting sites, and any time-critical orders pending at the converting sites.

[0011] Other examples include information describing customers associated with each converting site, such as which converting site services preferred or new customers. Other examples include information describing current machine capacity for process lines at the different converting sites, and process times for converting the web at the different converting sites. Conversion control system may use any of these or other site selection parameters individually or in combination to select a converting site for converting the web roll.

[0012] The conversion control system subsequently reconsiders the original image information, and subjects the image information to at least one of a variety of more sophisticated image processing and defect extraction algorithms to effectively separate actual defects from anomalies. The conversion control system then utilizes the defect information to control the manner in which a web is ultimately converted to the products at the selected converting site.

[0013] Specifically, the conversion control system applies the image processing and defect extraction algorithms to generate defect information for the designated products, i.e., products into which the web could be converted. The conversion control system then communicates the defect information to the selected converting site for use in converting the web roll to the designated products.

[0014] In one embodiment, a system comprises an imaging device, an analysis computer and a conversion control system. The imaging device images a sequential portion of a web to provide digital information. The analysis computer processes the digital information with an initial algorithm to identify regions on the web containing anomalies. The conversion control system selects one of a plurality of converting sites to convert the web into a product, and analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

[0015] In another embodiment, a method comprises imaging a sequential portion of a web to provide digital information, processing the digital information with at least one initial algorithm to identify regions on the web containing anomalies. The method further comprises selecting one of a plurality of converting sites to convert the web into a product, analyzing at least a portion of the digital information with one or more subsequent algorithms to determine which anomalies represent actual defects in the web for the product, and converting the web into the product at the selected converting site based on the determined actual defects.

[0016] In another embodiment, a conversion control system comprises a database storing data defining a set of rules, and an interface to receive anomaly information from an analysis machine. The anomaly information identifies regions of a web containing anomalies. The conversion control system includes a conversion control engine that selects one of a plurality of converting sites to convert the web into a product. The conversion control engine analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

[0017] In another embodiment, a computer-readable medium comprises instructions that cause a processor to store data defining a set of rules, receive anomaly information from an analysis machine located within a manufacturing plant, wherein the anomaly information identifies regions of a web containing anomalies, and apply the rules to select one of a plurality of converting sites to convert the web into a product.

[0018] The invention may offer one or more advantages. For example, the capture and storage of anomaly information for subsequent analysis allows application-specific defect detection methods to be applied, which may provide enhanced defect detection capability. Further, the techniques allow conversion decisions for a given roll or web to be based on one or more parameters, such as inventory levels at possible converting sites, product demand at the converting sites, shipping costs, shipping options, pending orders, site and process line utilization, conversion times, customer information or other parameters.

[0019] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

[0020] For purposes of the present invention, the following terms used in this application are defined as follows:

• • [0021] “web” means a sheet of material having a fixed dimension in one direction and either a predetermined or indeterminate length in the orthogonal direction;
  • [0022] “sequential” means that an image is formed by a succession of single lines, or areas of the web that optically map to a single row of sensor elements (pixels);
  • [0023] “pixel” means a picture element represented by one or more digital values;
  • [0024] “blob” means a connected set of pixels in a binary image;
  • [0025] “defect” means an undesirable occurrence in a product;
  • [0026] “anomaly” or “anomalies” mean a deviation from normal product that may or may not be a defect, depending on its characteristics and severity.
  • [0027] “gray scale” means pixels having a multitude of possible values, e.g. 256 digital values;
  • [0028] “binarization” is an operation for transforming a pixel into a binary value;
  • [0029] “filter” is a mathematical transformation of an input image to a desired output image, filters are typically used to enhance contrast of a desired property within an image;
  • [0030] “application-specific” means defining requirements, e.g., grade levels, based on the intended use for the web;
  • [0031] “yield” represents a utilization of a web expressed in percentage of material, unit number of products or some other manner;
  • [0032] “fiducial marks” means reference points or notations used to define specific, physical locations on the web;
  • [0033] “products” are the individual sheets (also referred to as component) produced from a web, e.g., a rectangular sheet of film for a cell phone display or a television screen; and
  • [0034] “conversion” the process of physically cutting a web into products.

[0035] FIG. 1 is a block diagram illustrating a global network environment in which a conversion control system controls conversion of web material in accordance with the invention.

[0036] FIG. 2 is a block diagram illustrating an exemplary embodiment of a web manufacturing plant.

[0037] FIG. 3 is a flowchart illustrating exemplary operation of the web manufacturing plant.

[0038] FIG. 4 is a block diagram illustrating an example embodiment of a conversion control system.

[0039] FIG. 5 is an example user interface presented by a user interface module with which a user interacts to configure the conversion control system.

[0040] FIG. 6 provides another exemplary user interface presented by the user interface module.

[0041] FIG. 7 is a flow diagram that illustrates exemplary processing of anomaly information by the conversion control system.

[0042] FIG. 8 is a flowchart illustrating one exemplary method in which a conversion control engine uses a single site selection parameter to select a converting site for converting a given web roll.

[0043] FIG. 9 is a flowchart illustrating an exemplary method in which the conversion control engine selects a converting site for a given web roll based on a weighted average of a plurality of configurable site selection parameters.

[0044] FIG. 10 is a block diagram illustrating one embodiment of a converting site.

[0045] FIG. 11 is a flowchart illustrating exemplary operation of the converting site in processing a web in accordance with a conversion plan.

[0046] FIG. 1 is a block diagram illustrating a global network environment 2 in which conversion control system 4 controls conversion of web material. More specifically, web manufacturing plants 6A-6N represent manufacturing sites that produce and ship web material in the form of web rolls 10. Web manufacturing plants 6A-6N may be geographically distributed.

[0047] The manufactured web material may include any sheet-like material having a fixed dimension in one direction and either a predetermined or indeterminate length in the orthogonal direction. Examples of web materials include, but are not limited to, metals, paper, wovens, non-wovens, glass, polymeric films, flexible circuits or combinations thereof. Metals may include such materials as steel or aluminum. Wovens generally include various fabrics. Non-wovens include materials, such as paper, filter media, or insulating material. Films include, for example, clear and opaque polymeric films including laminates and coated films.

[0048] For many applications, the web materials of web rolls 10 may have an applied coating, which generally are applied to an exposed surface of the base web material. Examples of coatings include adhesives, optical density coatings, low adhesion backside coatings, metalized coatings, optically active coatings, electrically conductive or nonconductive coatings, or combinations thereof. The coating may be applied to at least a portion of the web material or may fully cover a surface of the base web material. Further, the web materials may be patterned or unpatterned.

[0049] Web rolls 10 are shipped to converting sites 8A-8N, which may be geographically distributed within different countries. Converting sites 8A-8N (“converting sites 8”) convert each web roll 10 into one or more products. Specifically, each of converting sites 8 includes one or more process lines that physically cut the web for a given web roll 10 into numerous individual sheets, individual parts, or numerous web rolls, referred to as products 12A-12N. As one example, converting site 8A may convert web rolls 10 of film into individual sheets for use in mobile phone displays or computer monitors. Similarly, other forms of web materials may be converted into products 12 of different shapes and sizes depending upon the intended application by customers 14A-14N. Each of converting sites 8 may be capable of receiving different types of web rolls 10, and each converting site may produce different products 12 depending on the location of the converting site and the particular needs of customers 14.

[0050] Conversion control system 4 selects, in an automated or semi-automated manner, converting sites 8 for converting web rolls 10 based on one or more site selection parameters, such as current product inventory levels at the various converting sites. Conversion control system 4 may utilize other site selection parameters, such as order information associated with each of products 12 at the various converting sites 8, current product demand experienced within the geographic regions serviced by the converting sites, shipping costs and transportation options associated with each of the converting sites, and any time-critical orders pending at the converting sites.

[0051] Other examples of site selection parameters that conversion control system 4 may use include parameters describing customers 14 associated with each of converting sites 8, such as which converting site services preferred or new customers. Other examples include current machine capacity for process lines at converting sites 8, and process times for converting web rolls 10 at the different converting sites. Conversion control system 14 may use any of these or other site selection parameters individually of in combination to select particular converting sites 8 for converting web rolls 10.

[0052] As described in detail herein, each of web manufacturing plants 6 includes one or more inspection systems (not shown in FIG. 1) that acquire anomaly information for the produced webs. The inspection systems of web manufacturing plants 6 perform preliminary examination of the webs using a first, typically less sophisticated algorithm to identify manufacturing anomalies, accepting the likelihood that although some of the anomalies may prove defective, many could be “false positives,” i.e., anomalies that are not defective. In fact, products 12 have different grade levels, also referred to as quality levels, and have different tolerances for manufacturing anomalies. As a result, some of the anomaly areas may be ultimately classified as defective if the corresponding web roll 10 is converted to a particular product 12, but not defective if the web roll is converted to a different product.

[0053] Web manufacturing plants 6 communicate image information about the regions of the web containing anomalies to conversion control system 4 via network 9 for subsequent processing. Conversion control system 4 applies one or more defect detection algorithms that may be application-specific, i.e., specific to products 12, to generate a conversion plan for each web roll 10, i.e., defined instructions for processing the web roll. Conversion control system 4 communicates the conversion plans for web rolls 10 via network 9 to the appropriate converting sites 8 for use in converting the web rolls into products 12.

[0054] In this manner, conversion control system 4 selects converting sites 8 based on one or more parameters, and ultimately directs the conversion of web rolls 10 into products 12. As illustrated below, these site selection parameters may be user selectable, and may be applied independently or collectively using a weighting function or other technique.

[0055] FIG. 2 is a block diagram illustrating an exemplary embodiment of web manufacturing plant 6A of FIG. 1. In the exemplary embodiment, a segment of a web 20 is positioned between two support rolls 22, 24.

[0056] Image acquisition devices 26A-26N are positioned in close proximity to the continuously moving web 20. Image acquisition devices 26 scan sequential portions of the continuously moving web 20 to obtain image data. Acquisition computers 27 collect image data from image acquisition devices 26, and transmit the image data to analysis computer 28 for preliminary analysis.

[0057] Image acquisition devices 26 may be conventional imaging devices that are capable of reading a sequential portion of the moving web 20 and providing output in the form of a digital data stream. As shown in FIG. 2, imaging devices 26 may be cameras that directly provide a digital data stream or an analog camera with an additional analog to digital converter. Other sensors, such as, for example, laser scanners may be utilized as the imaging acquisition device. A sequential portion of the web indicates that the data is acquired by a succession of single lines. Single lines comprise an area of the continuously moving web that optically maps to a single row of sensor elements or pixels. Examples of devices suitable for acquiring the image include linescan cameras such as Model#LD21 from Perkin Elmer (Sunnyvale, Calif.), Piranha Models from Dalsa (Waterloo, Ontario, Canada), or Model#TH78H15 from Thompson-CSF (Totawa, N.J.). Additional examples include laser scanners from Surface Inspection Systems GmbH (Munich, Germany) in conjunction with an analog to digital converter.

[0058] The image may be optionally acquired through the utilization of optic assemblies that assist in the procurement of the image. The assemblies may be either part of a camera, or may be separate from the camera. Optic assemblies utilize reflected light, transmitted light, or transflected light during the imaging process. Reflected light, for example, is often suitable for the detection of defects caused by web surface deformations, such as surface scratches.

[0059] Barcode controller 30 controls barcode reader 29 to input roll and position information from web 20. Barcode controller 30 communicates the roll and position information to analysis computer 28.

[0060] Analysis computer 28 processes image streams from acquisition computers 27. Analysis computer 28 processes the digital information with one or more initial algorithms to generate anomaly information that identifies any regions of web 20 containing anomalies that may ultimately qualify as defects. For each identified anomaly, analysis computer 28 extracts from the image data an anomaly image that contains pixel data encompassing the anomaly and possibly a surrounding portion of web 20.

[0061] Analysis computer 28 stores roll information, position information and anomaly information within database 32. Database 32 may be implemented in any of a number of different forms including a data storage file or one or more database management systems (DBMS) executing on one or more database servers. The database management systems may be, for example, a relational (RDBMS), hierarchical (HDBMS), multidimensional (MDBMS), object oriented (ODBMS or OODBMS) or object relational (ORDBMS) database management system. As one example, database 32 is implemented as a relational database provided by SQL Server™ from Microsoft Corporation.

[0062] Analysis computer 28 communicates the roll information as well as anomaly information and respective sub-images to conversion control system 4 for subsequent, offline, detailed analysis. For example, the information may be communicated by way of a database synchronization between database 32 and conversion control system 4.

[0063] FIG. 3 is a flowchart illustrating exemplary operation of web manufacturing plant 6A. Initially, image acquisition devices 26 and acquisition computers 27 acquire image data from moving web 20 (40). The image data may be formed digitally, e.g., by way of a digital video camera, or may be converted to digital information (42). In either case, acquisition computers 27 output streams of digital image information to analysis computer 28 (44).

[0064] Analysis computer 28 applies an initial anomaly detection algorithm to identify regions of the web containing anomalies (46). In some convenient embodiments, the initial anomaly detection algorithm is very fast so as to be capable of being performed in real time by general purpose computing equipment even if a line speed of moving web 20 is great. As a result, some of the identified regions containing anomalies may include “false positives.” Even though there may be many false positives, the initial algorithm is preferably designed such that “escapes,” i.e., true defects not detected as anomalies, rarely, if ever occur.

[0065] Upon applying the initial anomaly detection algorithm, analysis computer 28 assembles anomaly data about the identified regions and stores the anomaly data within database 32 (48). The data typically includes a start position of the anomaly within the web and an encompassing pixel area of each identified region. During this process, analysis computer 28 extracts a portion of the image data for each identified region containing an anomaly (50). Specifically, only a fraction of the original digital image information needs to be extracted for further, more sophisticated analysis by conversion control system 4. The identified regions typically contain information, for example, at least an order of magnitude less than the digital information, as indicated by size in any convenient measure such as file size in bytes. In some applications, the present invention has demonstrated actual data reduction in an order of magnitude of between 3 and 8.

[0066] The extracted anomaly images may be stored in a database 32 or a file server (not shown) (52) and subsequently communicated to conversion control system 4 along with the anomaly and roll information (54). Alternatively, the roll information, anomaly information and anomaly images may be transferred directly for processing by conversion control system 4.

[0067] FIG. 4. is a block diagram illustrating an example embodiment of conversion control system 4 in further detail. In the example embodiment, application server 58 provides an operating environment for software modules 61. Software modules include a plurality of defect processing modules 60A-60M, a user interface module 62 and a conversion control engine 64.

[0068] Software modules 61 interact with database 70 to access data 72, which may include anomaly data 72A, roll data 72B, image data 72C, product data 72D, converting site data 72E, defect maps 72F, composite defect maps 72G, conversion control rules 72H, and conversion plans 72I.

[0069] Database 70 may be implemented in any of a number of different forms including a data storage file or one or more database management systems (DBMS) executing on one or more database servers. As one example, database 32 is implemented as a relational database provided by SQL Server™ from Microsoft Corporation.

[0070] Anomaly data 72A, roll data 72B, and image data 72C represent the roll information, anomaly information and respective anomaly images received from web manufacturing plants 6 (FIG. 1). Product data 72D represents data associated with products 12 (FIG. 1). More specifically, product data 72D defines each type of product 12 producible by each converting site 8. For each product 12, product data 72D specifies one or more defect processing modules 60 that are required to determine whether a given web roll 10 satisfies the quality requirements for the particular product. In other words, product data 72D specifies one or more defect processing modules 60 that are to be used to analyze anomaly data 72A and image data 72C for each product 12.

[0071] In addition, product data 72D stores other information related to products 12 that may be utilized by conversion control system 4 when selecting converting sites 8 and generating conversions plans for web rolls 10. For example, product data 72D may further include data specifying an estimated revenue per unit for each of products 12. Product data 72D may also include data specifying an estimated income per unit for each of products 12, an estimated conversion time to convert a web roll to each product, a current level of industry demand for each of product or other data that may be useful in selecting conversion plans.

[0072] Converting site data 72E represents data associated with converting sites 8. For example, converting site data 72E may store site location, number of process lines and a current available capacity of each process line for each of converting sites 8. Converting site data 72E may store other data, including but not limited to, data specifying a current level of inventory for each product 12 at each converting site 8, shipments costs associated with shipping a web roll to each converting site, shipment options available for each converting site, current order information from customers 14 received by each converting site, data specifying new or preferred customers for each converting site, and other data that may be useful in selecting conversion plans.

[0073] Conversion control engine 64 utilizes converting site data 72E to select the respective converting site 8 used to convert each of the web rolls 10 in accordance with conversion control rules 72H. For example, based on conversion control rules 72H, conversion control engine 64 may select converting sites 8 based on current inventory levels or other site selection parameters. Conversion control rules 72H specify one or more site selection parameters for consideration by conversion control engine 64 when selecting converting sites 8. Based on the specified site selection parameters, conversion control engine 64 retrieves the appropriate data from converting site data 72E and selects converting sites 8.

[0074] Defect processing modules 60 output defect maps 72F that specify which anomalies are considered actual defects for the different products 12. In other words, each defect map 72F corresponds to a particular web roll 10 and a specific product 12. Each defect map 72F specifies the particular defect locations of a particular web roll 10 based on the product-specific requirements of the corresponding product 12.

[0075] Conversion control engine 64 analyzes defect maps 72F to select the ultimate product or products into which each of the web rolls 10 is to be converted. Upon selecting a particular converting site 8 and a product or set of products for a given web roll 10, conversion control engine 64 generates a respective conversion plan 72I. Each conversion plan 72I provides precise instructions for shipment and processing the respective web roll. More specifically, each conversion plan 72I identifies the particular converting site 8 and defines configurations for processing lanes to physically slice the web into individual product sheets. Conversion control system 4 outputs shipment instructions directing the shipment of each web roll 10 to a respective destination converting site 8 based on the converting plan. Further, conversion control system 4 communicates conversion plans 72I via network 9 to the appropriate converting sites 8 for use in converting the web rolls into the selected products.

[0076] User interface module 62 provides an interface by which a user can configure the site selection parameters used by conversion control engine 64. For example, as illustrated below, user interface module 62 allows the user to direct conversion control engine 64 to consider one or more of a variety of site selection parameters. Examples include current inventory levels, order information, product demand, shipping costs and transportation options associated with each of converting sites 8, data specifying any time-critical orders pending at the converting sites, data describing preferred or new customers, current machine and site capacity and process times.

[0077] FIG. 5 is an example user interface 80 presented by user interface module 62 with which a user interacts to configure conversion control engine 64. Exemplary interface 80 includes input mechanism 82 by which the user enters a unique identifier for a web roll. Other mechanisms for selecting a roll may be used, such as a drop-down menu, search function, selectable list of recently manufactured rolls or the like.

[0078] In addition, user interface 80 provides a plurality of input mechanisms 86-92 by which the user can select one or more site selection parameters for consideration by conversion control engine 64 when selecting a converting site 8 and generating a recommended conversion plan. In this example, user interface 80 includes a first input selection mechanism 86 to direct conversion control engine 64 to select a converting site 8 based on the current inventor levels at the converting sites.

[0079] Input mechanism 88 directs conversion control engine 64 to select one of converting sites 8 based on order information (e.g., the number of backorders) associated with each of converting sites 8. Similarly, input mechanism 90 directs conversion control engine 64 to select one of converting sites 8 based on current product demand experienced within the geographic region serviced by each of the converting sites. Input mechanism 92 directs conversion control engine 64 to select one of converting sites 8 to minimize the overall time required to covert the web roll, including shipment and process time.

[0080] Upon selection of one or more parameters, the user selects SUBMIT button 98, which directs conversion control system 4 to select one of converting sites 8 based on the selected site selection parameters and process the selected web roll with defect processing modules 60 for output of a corresponding conversion plan.

[0081] In this manner, user interface 80 provides a simplistic illustration of how a user may configure conversion control engine 64 to utilize one or more site selection parameters. User interface 80 may require the user to select one and only one of the input mechanisms 86-92. Alternatively, user interface 80 may allow the user to select one or more of input mechanisms 86-92 to be used in combination.

[0082] FIG. 6 provides another exemplary user interface 100 presented by user interface module 62. In this embodiment, exemplary interface 100 includes input mechanisms 102-108 by which the user enters respective weighting functions for each parameter. Specifically, in this example, input mechanisms 102-108 allow the user to enter a weighting function ranging from 0 to 100 for each parameter, where 0 directs conversion control engine 64 to exclude the parameter and 100 represents the highest possible weighting.

[0083] When selecting a converting site 8 for a given web roll 10, conversion control engine 64 converts site data 72E to determine values for each site selection parameter: inventory levels, current orders, demand levels and conversion time for each potential converting site. As described in further detail below, conversion control engine 64 may then normalize the computed results of each site selection parameter for each converting site 8, and then compute weighted values from the normalized results. Finally, conversion control engine 64 selects a converting site 8 as a function (e.g., a sum) of the weighted values. Other techniques may be utilized in which conversion control system 4 utilizes multiple parameters when selecting a converting site 8 for a web roll 10.

[0084] FIG. 7 is a flow diagram that illustrates the processing of anomaly information by conversion control system 4 in further detail. In particular, FIG. 7 illustrates the processing of anomaly data 72A and image data 72C by defect processing modules 60.

[0085] Conversion control system 4 receives the image and anomaly data, such as images 144, 146, that were extracted initially from a web 20 by an analysis computer 28 located at a web manufacturing plant 6 using a simple first detection algorithm.

[0086] As illustrated in FIG. 7, defect processing modules 60 apply “M” different algorithms (designated A₁-A_m 158 in FIG. 7) as needed for up to N different requirements 150 for products 12. Cross-reference table 152 of FIG. 7 is used to illustrate the mapping between requirements 150 and defect processing modules 60. Specifically, cross-reference table 152 shows which defect processing modules 60 are utilized in determining whether each anomaly is a defect or a false positive for a given requirement 150.

[0087] In some embodiments, a larger number of rather simpler algorithms are conveniently used in parallel. In particular, it is often convenient that at least one of the subsequent defect processing modules 60 apply an algorithm that includes comparing each anomaly against a combination threshold-pixel size criterion. In actual practice with, for example, optical films, an anomaly having only a subtle difference in brightness value from a target is unacceptable if the area is large, and an anomaly having a great difference in brightness from a target value is unacceptable even if the area is very small.

[0088] In addition, the algorithms applied by defect processing modules 60 can incorporate very complex image processing and defect extraction including, but not limited to, neighborhood averaging, neighborhood ranking, contrast expansion, various monadic and dyadic image manipulations, digital filtering such as Laplacian filters, Sobel operators, high-pass filtering and low-pass filtering, texture analysis, fractal analysis, frequency processing such as Fourier transforms and wavelet transforms, convolutions, morphological processing, thresholding, connected component analyses, blob processing, blob classifications, or combinations thereof. Other algorithms may be applied based on the specific web and defect types to achieve a desired accuracy level of defect detection.

[0089] Each of the N product requirements 150 can be accomplished using selected combinations of individual defect processing algorithms 158. The algorithms may use very simple threshold and minimum blob processing or more complex algorithms such as spatial filters, morphological operations, frequency filters, wavelet processing, or any other known image processing algorithms. In this exemplary cross-reference table 152, product requirement R₁ uses a combination of algorithms A₂, A₄, and A_M, each applied to every anomaly image to determine which anomalies are actual defects for R₁. In most convenient embodiments, a simple OR logic is employed, i.e. if any of A₂, A₄, and A_M report the anomaly as an actual defect, that portion of web 20 does not satisfy product requirement R₁. For specialized applications, the logic through which the reports of the subsequent algorithms 158 are combined into a determination of whether a product requirement 150 is satisfied may be more complex than a simple OR logic. Similarly, product requirement R₂ uses A₂, A₃, and A₄, etc. Thus, the anomalies that are identified as defects for R₂ may be similar to or significantly different than defects for R₁.

[0090] After determining which anomalies are considered actual defects by using cross-reference table 152, conversion control engine 64 formulates defect maps 72F of actual 5 defect locations corresponding to the various product requirements for the roll. In some situations, conversion control engine 64 may generate one or more composite defect maps 72G by splicing one or more portions of defect maps 72F. In this illustrated example, conversion control engine 64 generates a composite map 72G having a first portion 160 spliced from a defect map for a first product requirement (MAP-R1) and a second portion 162 from a defect map for a second product requirement (MAP-R2). In this manner, conversion control engine 64 may determine that a web may be best utilized if certain portions of the web are converted into different products. Once this has been done, it is often possible to discard the subimage information to minimize the needed storage media.

[0091] Further details of image processing and subsequent application of the anomaly detection algorithms applied by defect processing modules 60 are described by commonly assigned and co-pending U.S. patent application Ser. No. 10/669,197, entitled “APPARATUS AND METHOD FOR AUTOMATED WEB INSPECTION,” having Attorney Docket No. 58695US002, filed Apr. 24, 2003, the entire contents of which are incorporated herein by reference.

[0092] FIG. 8 is a flowchart illustrating one exemplary method in which conversion control engine 64 uses a single site selection parameter to select a converting site 8 for a given web roll 10. In this example, conversion control engine 64 utilizes inventory levels as a site selection parameter, although other site selection parameters could be used in a similar manner.

[0093] Initially, conversion control engine 64 identifies a set of potential products 12 into which the web roll 10 may be converted (200). Some web rolls 10, for example, may be suitable for conversion into only a subset of products 12. Next, conversion control engine 64 determines a set of converting sites 8 that support any one or more of the identified products 12 (201).

[0094] Conversion control engine 64 then selects a converting site 8 and a product from the identified set of converting sites 8 based on inventory levels (202). For example, conversion control engine 64 may access converting site data 72E and retrieve inventory data for each potential product for the identified converting sites 8. Conversion control engine 64 may then rank the set of potential converting sites 8 based on inventory levels for the potential products. Conversion control engine 64 selects the potential converting site and product having the level of lowest inventory.

[0095] Conversion control engine 64 next accesses product data 72D of database 70 to identify the product requirements for the selected product, and selects one or more of the defect processing modules 60 based on the-identified requirements (203).

[0096] Next, conversion control engine 64 invokes the selected defect processing modules 60, which apply respective defect detection algorithms to anomaly data 72A and image data 72C received from a web manufacturing plant 6 to formulate defect information for the selected product. Conversion control engine 64 generates defect maps 72F for the web roll based on the defects identified by defect processing modules 60 (204). Conversion control engine 64 generates a conversion plan 72I in accordance with the defect map (216).

[0097] Conversion control engine 64 may further communicate the conversion plan to the selected converting site 8, and output (e.g., display or print) shipment instructions for shipping the particular web roll 10 to the selected converting site (218). In this manner, conversion control engine 64 applies inventory levels as a site selection parameter to select a converting site 8, and then applies defect processing modules 60 based on the selected converting site and product.

[0098] FIG. 9 is a flowchart illustrating an exemplary method in which conversion control engine 64 selects a converting site 8 for a given web roll 10 based on a weighted average of a plurality of configurable site selection parameters.

[0099] Initially, conversion control engine 64 identifies a set of potential products 12 into which the web roll 10 may be converted (300). Next, conversion control engine 64 determines a set of converting sites 8 that support any one or more of the identified products 12 (302).

[0100] Next, conversion control engine 64 calculates values for all of the specified site selection parameters, e.g., inventory level, order levels, product demand and conversion time for each of converting site 8 (304). Conversion control engine 64 then normalizes each of the parameters to a common range, such as 0 to 100 (308).

[0101] Conversion control engine 64 then adjusts each of the parameters in accordance with a user-configurable weighting, as shown in FIG. 6 (310), and computes a total weighted average for each converting site (312). Conversion control engine 64 selects the converting site and product corresponding to the maximum weighted average of the site selection parameters (314).

[0102] Conversion control engine 64 then identifies at least one defect module for the selected product 12 into which the web roll 10 is to be converted (316), and invokes the defect processing modules 60 to apply defect detection algorithms and generates a defect map 72F for the web roll (318).

[0103] Conversion control engine 64 produces a conversion plan based on the generated defect map (320). Conversion control engine 64 then communicates the conversion plan to the appropriate converting site 8 and outputs (e.g., display or print) shipment instructions for shipping the particular web roll 10 to the converting site (322). In this manner, conversion control engine 64 may consider multiple site selection parameters when selecting a converting site 8 for converting a web roll 10 into products based on stored image anomaly information.

[0104] FIG. 10 is a block diagram illustrating one embodiment of a converting site 8A. In this exemplary embodiment, converting site 8A includes a web roll 10A that has been loaded and readied for conversion.

[0105] Conversion server 508 receives conversion maps from conversion control system 4, and stores the conversion maps in database 506. A barcode is read from roll 10A, which informs conversion server 508 of the particular web 503, allowing the conversion server to access database 506 and retrieve the corresponding conversion map. The barcode may be read by input device 500 when web 503 is placed in motion or via a hand-held barcode device prior to loading.

[0106] Conversion server 508 displays a conversion plan, thereby allowing workers to configure conversion unit 504. Specifically, conversion unit 504 is configured to physically cut web 503 into numerous individual sheets (i.e., products 12A) in accordance with the conversion plan.

[0107] As web 503 passes through the system during the marking operation, input device 500 reads barcodes and associated fiducial marks are regularly sensed. The combination of barcode and fiducial mark enables one to precisely register the physical position of web 503 to the defects identified in the conversion plan. Regular re-registration ensures ongoing registration accuracy. One skilled in the art is capable of establishing the re-registration through conventional physical coordinate transformation techniques. Once web 503 is registered to the conversion map, the physical position of specific defects is known.

[0108] When defects pass under web marker 502, marks are applied to web 503 to visually identify the defects. Specifically, conversion server 508 outputs a series of commands to a web marker 502, which then applies locating marks to the web 503. In many applications of the present invention, web marker 502 places the locating marks on or adjacent to the defects within web 503 in accordance with the respective conversion plan. However, in some specialized applications the locating marks are spaced in a predetermined way from the anomalies whose position they identify. Web marker 502 may include, for example, a series of ink-jet modules, each having a series of jet nozzles.

[0109] The type of mark and the exact position of the mark on or near the defect may be selected based upon the web material, defect classification, web processing required to address the defect, and the intended end use application of the web. In the case of the arrayed ink marker, markers are fired preferentially depending on their cross-web position as defects pass the unit in the down-web direction. With this method, marking accuracies of less than 1 mm have been regularly achieved on high-speed webs with production rates greater than 150 ft/minute. However, higher speed webs in excess of 1000 meter/minute are within the capability of the invention.

[0110] Conversion server 508 may pause the conversion of web 503 at any point in accordance with the conversion plan to allow reconfiguration of conversion unit 504. For example, in the event web 503 is to be converted to different products, conversion server 508 halts the conversion process after the first product is produced to allow conversion unit 504 to be reconfigured for the subsequent product. Positioning of cutting devices and other mechanisms, for example, may be reconfigured as needed to produce the second product.

[0111] FIG. 11 is a flowchart illustrating exemplary operation of a converting site, such as converting site 8A of FIG. 16, in processing a web in accordance with a conversion plan.

[0112] Initially, conversion server 508 receives and stores roll information and conversion plans from conversion control system 4 (520). This may happen prior to or after receiving web rolls. For example, conversion server 508 may receive roll information and a conversion plan for a particular web roll weeks before the physical web roll arrives at the converting site. Alternatively, conversion server 508 may receive roll information and a conversion plan for a web roll already stored within inventory at the converting site.

[0113] Next, conversion server 508 receives barcode information, for a particular web roll to be converted, causing conversion server 508 to access database 506 and retrieve the corresponding conversion map (522). As noted above, the barcode may be read prior to loading (e.g., by a hand-held barcode device), as illustrated in FIG. 17, or via input device 500 after web 503 is loaded and readied for conversion.

[0114] Conversion server 508 displays a conversion plan, thereby allowing workers to configure conversion unit 504 to physically cut web 503 into numerous individual sheets (i.e., products 12A) in accordance with the conversion plan (526). Alternatively, conversion unit 504 may be configured in an automated or semi-automated manner in accordance with the conversion plan.

[0115] Once conversion unit 504 is configured, web 503 is set in motion and input device 500 reads barcodes and associated fiducial marks (528), and web marker 502 may be utilized to visually mark web 503 in order to assist in the visual recognition of defective products (530). Conversion unit 504 converts the received web 503 to form products 12A (532).

[0116] At any point within the conversion plan, conversion server 508 may determine that a reconfiguration is required by the plan (534). If so, conversion server 508 directs the reconfiguration of conversion unit 504 (536). This process continues until all of web 503 is converted to one or more products 12A in accordance with the conversion plan (538).

[0117] Various embodiments of the invention have been described. These and other embodiments are within the scope of the following claims.