A computer system utilizing duplexed central processors and three types of satellite computer terminals has been developed for the control of manufacturing processes and product tests. The system was designed for use in a plant producing data processing equipment. The prime objectives of the project were (1) to reduce the time required for the plant to accept new products or product changes, (2) to reduce control and test equipment costs by using standard control and test equipment, and (3) to improve product quality through more uniform processes and tests. The objectives were met by using small, stored-program computer terminals to control individual tests and processes. These terminals are connected to a central computer system which assists with data processing and serves as an input/output device for the terminals.The design and implementation of the system occurred in two phases. During the first phase the stored-program test terminal, a high-speed data transmission system, and a multiplexer were designed and installed on an IBM 1460Data Processing System. A programming system was developed concurrently with the hardware. This system included a real-time monitor and application and utility programs which were written for operation in a time-shared environment. During the second phase of development a process control terminal, a data acquisition terminal, and a new multiplexer for duplexingtwo 1460Data ProcessingSystems were designedand implemented. Also developedwereshared filecontrol units, an improved transmission system,and programming designedto effectively utilize the power of two computer systems on a real-time basis.
Historically, control functions for "make "and "test"operations in discrete manufacturing processes have been satisfied with special purpose hardware. In recent years, computers have replaced much of this special purpose hardware. The initial reasons for employing computers were to decrease capital and development costs while providing greater flexibility in responding to process changes. It now appears that the greatest benefits of applying computers in discrete manufacturing processes are the increased process yields and decreased rework through the use of Process Introduction A discrete manufacturing process consists of the following operations: 1. Receiving inspection where parts or raw materials enter a process; 2. Process, fabrication and assembly operations such as plating, etching, casting, joining or machining; 3. "In process" measurement and test where process and product characteristics and parameters are monitored; and 4. Final test or inspection which is the last step in a discrete process where the product is measured against specifications and design criteria.Traditionally, the complex test and process control operations in such discrete processes have been performed by sophisticated custom hardware. Such equipment lacks versatility since it must be modified to react to process changes and scrapped in cases of product evolution. The impact of process or product changes can be minimized with the use of computer control systems. In the application of such systems, control functions are executed by software which is relatively easy to modify in order to react to process and product changes. Functions performed by hardware can be limited to that necessary to interface a computer to the product or process (e.g., channel interfaces and signal conditioning). In addition to controlling testers and process equipment, the computer can be programmed to perform application data analysis. Product measurement data and process parameters can be obtained and translated for communication to operators. Such information can be compared to constants in order to make accept/reject decisions, eStablish process set points and qualify measurements for later engineering analysis. In addition to handling control information, the computer control system can report tester and process equipment behavior in order to determine maintenance and calibration requirements. Quality and Production Control data such as defects per units, in process inventory, and yields can also be extracted from information collected by the computer. Figure 1 is an illustration of a discrete process where dedicated data processing systems interface to process operations. As shown, the receiving inspection, inprocess and final testers are independently controlled
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