Systems and Methods for Adjusting Target Manufacturing Parameters on an Absorbent Product Converting Line

Abstract

Systems and processes herein may be configured to correlate manufacturing parameters and performance feedback parameters with individual absorbent articles manufactured by a converting apparatus. Embodiments of the systems herein may include inspection sensors configured to inspect substrates and/or component parts advancing along the converting line and communicate inspection parameters to a controller and historian. The systems may also include process sensors configured to monitor equipment on the converting line and communicate process parameters to the controller and historian. The systems herein may also be adapted to receive performance feedback parameters based on the packaged absorbent articles. The systems may correlate inspection parameters, process parameters, and/or performance feedback parameters with individual absorbent articles produced on the converting line. The controller may also be configured to perform various functions based on the performance feedback parameters.

What is claimed is: 
     
         1 . A method for manufacture of absorbent products, the method comprising:
 providing a communication network;   connecting a first sensor with the communication network;   connecting a second sensor with the communication network;   connecting a controller with the communication network;   advancing a substrate through a converting apparatus;   adding a component part to the substrate;   inspecting at least one of the substrate and the component part with the first sensor;   communicating an inspection parameter from the first sensor to the controller;   comparing the inspection parameter with a target inspection parameter;   inspecting a process with the second sensor;   communicating a process parameter from the second sensor to the controller;   comparing the process parameter with a target process parameter;   cutting the substrate with the component part added thereto into discrete absorbent articles;   packaging the discrete absorbent articles;   receiving a performance feedback parameter based on the packaged absorbent articles;   correlating at least one inspection parameter with a selected packaged absorbent article;   correlating at least one process parameter with the selected packaged absorbent article;   correlating at least one performance feedback parameter with the selected packaged absorbent article; and   adjusting the target inspection parameter or the target process parameter based on the performance feedback parameter.   
     
     
         2 . The method of  claim 1 , wherein the absorbent articles are diapers. 
     
     
         3 . The method of  claim 2 , wherein the components are back ears. 
     
     
         4 . The method of  claim 3 , further comprising bonding the back ear to the substrate with a mechanical bonding unit, and wherein the process parameter corresponds with an applied pressure of the mechanical bonding unit. 
     
     
         5 . The method of  claim 4 , wherein the target process parameter corresponds with a target applied pressure of the mechanical bonding unit. 
     
     
         6 . The method of  claim 3 , wherein the target inspection parameter corresponds with a target placement of the back ears on the substrate. 
     
     
         7 . The method of  claim 3 , wherein the performance feedback parameter corresponds with separation of back ears from diapers while under tension. 
     
     
         8 . The method of  claim 1 , further comprising compiling correlated feedback parameters, correlated inspection parameters, and correlated process parameters to create, modify, or validate manufacturing process models. 
     
     
         9 . The method of  claim 1 , further comprising compiling correlated feedback parameters, correlated inspection parameters, and correlated process parameters to create, modify, or validate product models. 
     
     
         10 . The method of  claim 1 , wherein the step of receiving performance feedback parameters based on the packaged absorbent articles further comprises soliciting and recording consumer feedback relating to in use performance of the packaged absorbent articles. 
     
     
         11 . The method of  claim 10 , further comprising the step of compiling correlated feedback parameters, correlated inspection parameters, and correlated process parameters to harmonize quality specification limits with consumer feedback. 
     
     
         12 . The method of  claim 1 , wherein one inspection parameter corresponds to a detected missing component on the substrate. 
     
     
         13 . The method of  claim 1 , wherein one inspection parameter corresponds to measured placement of a component on the substrate. 
     
     
         14 . The method of  claim 1 , wherein the performance feedback parameter is selected from the group consisting of: leakage; component alignment; and absorbent article fit. 
     
     
         15 . The method of  claim 1 , further comprising testing the selected packaged absorbent article. 
     
     
         16 . A method for manufacture of absorbent products, the method comprising:
 providing a communication network;   connecting a first sensor with the communication network;   connecting a second sensor with the communication network;   connecting a controller with the communication network;   advancing a substrate through a converting apparatus at a first speed;   virtually dividing the substrate into a plurality of virtual segments;   adding a component part to the substrate;   inspecting at least one of the substrate and the component part with the first sensor;   communicating inspection parameters from the first sensor to the controller;   comparing the inspection parameters with a target inspection parameter;   inspecting a process with the second sensor;   communicating a process parameter from the second sensor to the controller;   comparing the process parameter with a target process parameter;   cutting the substrate with the component part added thereto into discrete absorbent articles;   packaging the discrete absorbent articles;   receiving performance feedback parameters based on the packaged absorbent articles;   correlating at least one inspection parameter with a selected packaged absorbent article;   correlating at least one process parameter with the selected packaged absorbent article;   correlating at least one performance feedback parameter with the selected packaged absorbent article; and   adjusting at least one target inspection parameter or at least one the target process parameter based on the performance feedback parameter.   
     
     
         17 . The method of  claim 16 , wherein the first and second sensors each include a sensor clock, wherein the controller includes a controller clock; and further comprising:
 synchronizing the sensor clocks with the controller clock such that reported times of the controller clock and the sensor clocks can be correlated;   assigning a time-stamp to the inspection parameter, the time-stamp based on the sensor clock;   receiving the inspection parameter and corresponding time-stamp from the communication network into the controller; and   correlating the inspection parameter with one virtual segment based on the time-stamp of the inspection parameter and the first speed of the substrate.   
     
     
         18 . The method of  claim 16 , further comprising compiling correlated feedback parameters, correlated inspection parameters, and correlated process parameters to create, modify, or validate prognostic systems. 
     
     
         19 . The method of  claim 16 , further comprising compiling correlated feedback parameters, correlated inspection parameters, and correlated process parameters to facilitate autonomous data mining. 
     
     
         20 . A method for manufacture of absorbent products, the method comprising:
 providing a communication network;   connecting a first sensor with the communication network;   connecting a second sensor with the communication network;   connecting a controller with the communication network;   advancing a substrate through a converting apparatus;   adding a component part to the substrate;   inspecting at least one of the substrate and the component part with the first sensor;   communicating an inspection parameter and a time-stamp from the first sensor to the controller;   inspecting a process with the second sensor;   communicating a process parameter and a time-stamp from the second sensor to the controller;   normalizing the time-stamp for the inspection parameter to a reference location or product;   normalizing the time-stamp for the process parameter to a reference location or product;   cutting the substrate with the component part added thereto into discrete absorbent articles;   packaging the discrete absorbent articles;   receiving performance feedback parameters based on the packaged absorbent articles;   determining and normalizing time-stamps for performance feedback parameters to a reference location or product;   correlating the inspection parameter with a selected packaged absorbent article;   correlating the process parameter with the selected packaged absorbent article;   correlating at least one performance feedback parameter with the selected packaged absorbent article; and   storing the inspection parameter, the process parameter, and product performance parameters in a historian.