WO2023150690A2

WO2023150690A2 - Method and system for dynamic mapping of production line asset conditions

Info

Publication number: WO2023150690A2
Application number: PCT/US2023/061954
Authority: WO
Inventors: Brock Matthew COFFEE; Girish S. RAO; Po-Chao Lee
Original assignee: Beet, Inc.
Priority date: 2022-02-03
Filing date: 2023-02-03
Publication date: 2023-08-10
Also published as: WO2023150690A3

Abstract

A system and method for generating a map of a plurality of production assets for display on a user interface includes a plurality of production assets, each respective production asset of the plurality of production assets repeatedly performing at least one operation, and generating asset data defined by performance of the at least one operation; receiving, via a controller, the asset data from the plurality of production assets; collecting, via a data collector, the asset data from the controller; a server, in communication with a database, receiving the asset data from the data collector, generating, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, a respective asset bubble corresponding to the respective production asset; mapping the plurality of asset bubbles to a moving bubble chart; and outputting, for display on a user interface, the moving bubble chart.

Description

METHOD AND SYSTEM FOR DYNAMIC MAPPING OF PRODUCTION LINE ASSET CONDITIONS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of United States Provisional Application No. 63/306,453 filed February 3, 2022, the contents of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

[0002] The present disclosure relates generally to collecting and capturing process data from process equipment using a process controller in communication with a computing device and displaying the process data in a dynamic representation.

BACKGROUND

[0003] Manufacturing is a complex operation. There are many events happening simultaneously on a production line. To successfully achieve performance objectives for the production line, the production team needs to track multiple performance indicators on multiple production assets. To accomplish this, a large board at the production line displaying multiple charts of the performance indicators can be seen at most manufacturing facilities. Often, the charts are paper charts, displaying historical data, e.g., performance indicators at the time the chart was printed and/or posted, such that these boards and charts mostly capture what happened in the past. Though these types of charts are usually standardized and helpful to manage the production, the charts mostly serve as review material used at start-up or shift end meetings to review previous day or shift result and to identify next shift actions. These types of charts can also serve the management and visitors to the production facility, providing a visual mean to understand the performance of the line, if the charts are properly maintained to reflect current operating conditions, which in the case of paper charts, requires an ongoing manual effort.

SUMMARY

[0004] In order to manage a production line including multiple production assets, production personnel need to track multiple indicators at the same time on a production line. A method and system to dynamically track and map multiple indicators of multiple assets on one single chart in a production facility is described herein. In an illustrative example, multiple indicators for multiple assets are displayed using a moving bubble chart, which not only provides a means for the production team to track the performance and progression of the key indicators, but also provides a means for the team to predict trending of the production asset performance, analogous to predicting a weather forecast using a moving radar map, by visualizing the motion of the assets displayed on the bubble chart and by analyzing the data. As further described herein, data is collected from one or more production lines in a production facility, each production line including at least one production asset, via a data collector in communication with a facility server and database. The collected data is associated in the database with the production asset and a collection time, e.g., a time at which the data was collected from the production asset, then processed by the server to determine one or more asset indicators for the production asset. An asset indicator can be a production indicator, a condition state indicator, a performance indicator, and/or identifying indicator, as further described herein. The production asset is displayed as a bubble icon (an “asset bubble”) on the moving bubble chart, to visualize the production asset relative to the asset indicators and relative to other production assets displayed by other asset bubbles on the moving bubble chart, as further described herein and shown in the accompanying figures. For example, the position, shape, and/or color of an asset bubble as it appears on the moving bubble chart is determined by the indicator values of multiple asset indicators collected from and/or determined for the production asset by a server receiving the asset data and generating the moving bubble chart, such that as an indicator value of an asset indicator associated with a production asset changes over time, the position and/or appearance of the asset bubble associated with the production asset changes to reflect the change in the indicator value. The system can be configmed to compare the collected data and/or the production indicator determined from the collected data to a predetermined criteria, such as a specification, threshold value, acceptable range, etc., to determine an operating condition of the production asset, and to modify the position and/or appearance of the asset bubble associated with the production asset in the moving bubble chart based on the production asset’s operating condition.

[0005] The system and method described herein includes collecting data from the production asset over time, either continuously or on a sampling basis, determining indicator values for a plurality of asset indicators associated with the production asset, and updating the position of the asset bubble on the moving bubble chart associated with the production asset and/or an appearance feature (shape, size, color, shade, fill) of the asset bubble on the moving bubble chart periodically such that comparison of position and appearance of the asset bubble on the bubble chart at a cunent time to the position and appearance of that asset bubble at a prior time can be used to determine changes in the asset performance and operating condition over time of the production asset illustrated by the asset bubble, and to predict trends in performance and operating condition of the production asset, such that, as required, corrective and/or improvement actions can be taken. In an illustrative example, the moving bubble chart display can be enabled for video playback capabilities, to visualize asset performance changes over time by viewing the dynamic movement of each asset bubble over time in the video playback.

[0006] “Over-cycle” (machine runs over standard cycle time), “Faulted” (machine breakdown or in error stop), and “Quality Rejects” are three major performance indicators contributing to OEE (Overall Equipment Effectiveness) of a production line. In a non-limiting example described herein and illustrated by the accompanying figures, these three production indicators are used to demonstrate how the method and system works to visualize production assets of one or more production lines of a facility by displaying each of the production assets as an asset bubble in a moving bubble chart, each asset bubble being updated over time in position and appearance (by changing an appearance feature such as the bubble size, etc.) on the moving bubble chart based on then current asset data collected from the production assets and/or production line and the indicator values determined therefrom. Using a moving bubble chart to visualize performance indicators and operating conditions of multiple assets of one or more production lines in a production facility in a single display updated over time, provides advantages and benefits including efficient information display for production management, the ability to visually assess historical performance and performance trends, the ability to visually extrapolate future performance and trends, and to provide for visual monitoring of ongoing production, including visual monitoring for results of corrective and improvement actions implemented in the production line.

[0007] An exemplary system and method for generating a map of a plurality of production assets within a moving bubble chart, for display on a user interface, is described herein. The system and method includes a plurality of production assets, each respective production asset of the plurality of production assets repeatedly performing at least one operation, and generating asset data defined by performance of the at least one operation; receiving, via a controller, the asset data from the plurality of production assets; collecting, via a data collector, the asset data from the controller; a server, in communication with a database, receiving the asset data from the data collector, generating, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, a respective asset bubble corresponding to the respective production asset; mapping the plurality of asset bubbles to a moving bubble chart; and outputting, for display on a user interface, the moving bubble chart. In an illustrative example, generating the respective asset bubble corresponding to the respective production asset further includes the server associating, in the database, the asset data generated by the respective production asset with the respective production asset; associating, in the database, a plurality of asset indicators with the respective production asset; and determining, using the asset data, a plurality of indicator values, where determining the plurality of indicator values includes determining a respective indicator value for each respective asset indicator of the plurality of asset indicators. The server generates, using the plurality of indicator values, a respective asset bubble corresponding to the respective production asset; and maps the respective asset bubble to the bubble chart. The above features and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0009] FIG. 1 is a schematic illustration of a system for dynamically mapping asset performance and conditions of a plurality of production assets using asset bubbles displayed in a moving bubble chart;

[0010] FIG. 2 is a schematic illustration of the system of FIG. 1, including a plurality of production lines, each production line including a plurality of production assets;

[0011] FIG. 3 is a schematic illustration of an exemplary moving bubble chart for dynamically mapping asset performance indicators and conditions of the plurality of production assets shown in FIG. 2, wherein the indicator value of the asset indicators of each production asset is indicated by the position and/or appearance (size, color, shading, and/or fill) of the associated asset bubble;

[0012] FIG. 4 is a schematic illustration of the exemplary moving bubble chart of FIG. 3, displaying asset bubbles dynamically mapping asset performance indicators of the plurality of production assets shown in FIG. 2;

[0013] FIG. 5 is a schematic illustration of an exemplary moving bubble chart for dynamically mapping asset performance indicators Over-Cycle %, Faulted %, and Quality Reject % of the plurality of production assets shown in FIG. 1 ;

[0014] FIG. 6 is a schematic illustration of the exemplary moving bubble chart of FIG. 5, dynamically mapping asset performance indicators of the plurality of production assets shown in FIG. 1 ; wherein the condition of each production asset is indicated by a color and/or fdl of the chart sector in which the asset bubble is located;

[0015] FIGS. 7-26 are schematic illustrations of a sequence of video frames excerpted from an example video of the moving bubble chart of FIG. 5 dynamically displaying the asset bubbles associated with the plurality of production assets shown in FIG. 1 over an elapsed time, each video frame capturing the image of the moving bubble chart at a one hour interval, e.g., FIG. 7 shows the video frame captured at Hour 1, FIG. 8 shows the video frame captured at Hour 2, and so on, illustrating the dynamic movement and mapping of each production asset displayed as a corresponding asset bubble over the elapsed time represented by the video.

[0016] In the accompanying drawings, shading has been used to distinguish between various color values of the asset bubbles, such that it would be understood that the use of color as a visual indication of an asset indicator value is a feature and advantage of the system and method described herein. Illustrative examples of the use of color as a differentiating feature of an asset bubble are provided in the drawing Appendix included in related U.S. Provisional Application No. 63/306,453 filed February 3, 2022, to which the present disclosure claims priority, and the contents of which are hereby incorporated by reference in their entirety.

DETAILED DESCRIPTION

[0017] In the following description, numerous details of the embodiments of the present disclosure, which should be deemed merely as exemplary, are set forth with reference to accompanying drawings to provide thorough understanding of the embodiments of the present disclosure. Therefore, those skilled in the art will appreciate that various modifications and replacements may be made in the described embodiments without departing from the protection scope and the spirit of the present disclosure. Further, for clarity and conciseness, descriptions of known functions and structures are omitted hereinafter.

[0018] Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, there is shown in FIG. 1 a system for dynamically mapping asset performance and conditions of a plurality of production assets 20 using a moving bubble chart 70, the system generally indicated at 100 and including a data collector 45 for capturing data from a production facility generally indicated at 10. The system 100 is configured for data collection, data processing, and data visualization of a plurality of production assets of the production facility 10, where a production asset, as that term is used herein, can refer to, for example, a process, a station 20, a production line 15, an asset element 25, a sensor 30, etc., a manufacturing, assembly or other production process which can include one or more machines, sub-processes, production lines, etc., configured to perform coordinated operations, which can include automated, partially automated, and/or non-automated operations. The system 10 visualizes the production process through a display 95 including a moving bubble chart 70, the moving bubble chart 70 including a mapping of a plurality of production assets 20 each displayed, e.g., visualized on the moving bubble chart 70 by a respective bubble icon 80, also referred to herein as an asset bubble 80. The displayed position and appearance (size, shape, color, shading, fill, etc.) of a respective asset bubble 80 is defined by the asset identifying features and the performance and condition of the associated production asset 20 determined from asset data collected from the associated production asset 20.

[0019] Referring to FIGS. 1 and 2, in a non-limiting example, the system 100 includes a facility 10 having one or more production lines 15 (15A, 15B, 15C, 15D, 15E in the illustrative examples) including one or more production assets 20 (STA1... STA6, TRI ... TR4, CR1 ... CR4, SQ1 ... SQ5, AS1... AS4 in the illustrative examples) controlled by one or more controllers 35 (Controller 1 . . . Controller 4) in the illustrative examples) in communication with a data collector 45. The data collector 45 is configured for receiving data from the controllers 35 and transmitting data to a system server 50 for processing and/or storage to a database 55. The database 55 and/or server 50, in a nonlimiting example, can be configured as cloud computing resources. The system 100 further includes at least one user device 60 in communication with the server 50. The user device 60 includes a user interface 65 for displaying data and other process information collected and generated by the system 100 including moving bubble charts 70, and for receiving inputs, including instructions, from a user of the user device 60.

[0020] Each of the stations 20, controllers 35, data collector 45, server 50, and user devices 60 are in communication via a network 40. Examples of the network 40 include but are not limited to the internet, intranet, local area network, mobile communication network, and combmations thereof. Each of the controllers 35, data collector 45, server 50 and user devices 60 can include a memory for receiving, storing, generating, and/or providing data from the production assets 20 and data derived therefrom within the system 100, and further include a central processing unit (CPU) for executing applications and/or algorithms as required to perform the methods described herein. The memory, at least some of which is tangible and non-transitory, may include, by way of example, ROM, RAM, EEPROM, etc., of a size and speed sufficient, for example, for executing the applications and algorithms required to perform dynamic mapping of asset performance and conditions, including generating moving bubble charts 70, receiving, storing, generating, and/or collecting the data from the production assets 20 and controllers 35, storing the data to the database 55, and/or communicating with other devices via the network 40.

[0021] Referring again to FIG. 1, each controller 35 is configmed to control one or more production assets 20 to perform coordinated operations, which can include one or more processing steps and/or a sequence of operations performed by a production asset 20 and/or a combination of production assets 20. A production asset 20 is configmed to repeatedly perform one or more processing steps, one or more operations, and/or a sequence of operations as defined (instructed) by the controller 35. It would be understood that the production asset 20 would, in operation, repeatedly perform the sequence of operations comprising ordered steps as an operating cycle, under control of the controller 35, such that the asset data generated by the production asset 20 would include asset data from each of the repeated operating cycles performed by the production asset 20. A production asset 20 can include one or more asset elements, such as devices, tools, fixtures, etc. for performing the various steps and/or operations as instructed and/or controlled by the controller 35. A production asset 20 can include one or more sensing devices (not shown), also referred to herein as sensors, for sensing one or more parameters or characteristics of the production asset 20, asset elements, objects, and/or product being processed by the production asset 20, the production asset environment, etc., and generating a sensor signal corresponding to the sensed parameter and/or characteristic. In an illustrative example, the sensors are in communication with the controller 35, via the production asset 20 and/or the network 40, such that during performance of each processing step, production cycle, and/or sequence of operations, the sensor is outputting sensor signals which are received by the controller 35 for processing, to generate an asset bubble 80 corresponding to the production asset 20 for display on a moving bubble chart 70 as described further herein. In one example, the production asset 20 and/or production line 15 can be configured as a machine, and/or can include a plurality of machines, such that each production line 15 includes one or more machines. Accordingly, the terminology production asset, production line, assembly line, etc. is not intended to limit the implementation as described and/or claimed herein.

[0022] The asset data collected and/or generated by the controller 35 and/or data collector 45 can include condition state data for a production asset 20, where a state, which may be referred to as a condition state or as a condition, as used herein, refers to a state of the production asset 20 or an asset element, an object (such as a product or a workpiece) being operated on by the production asset 20, a condition, a status, a parameter, a position, or other property being monitored, measured and/or sensed. Non-limiting examples of condition states including cycle start time, cycle stop time, element start time, element travel, element stop time, position of an element or object, a dimensional measurement or parameter of an object which can include a dimensional measurement of a feature of the object, or an asset element, a feature of a production asset 20, a feature of a workpiece to which an operation is being performed by a production asset 20 and/or asset element, a condition of one or more of an asset element, a production asset 20, a production line 15 or workpiece, or a condition of the environment within the facility 10. A condition state could further include for example, an operating condition of a production asset 20 or asset element, such as on, off, open, closed, auto, manual, stalled, blocked, starved, traveling, stopped, faulted, OK, good, bad, in tolerance, out of tolerance, present, not present, extended, retracted, high, low, etc., and can include for example, a measure of a physical property such as chemistry, temperature, pressure, color, shape, position, dimensional conditions such as size, surface finish, thread form, a functional parameter such as voltage, current, torque, pressure, force, etc. of a production asset 20, such as a feature of a workpiece to which an operation is being performed by the production asset 20, such that it would be understood that the terms state, condition, condition state and/or parameter as describing asset data are intended to be defined broadly.

[0023] The controller 35, data collector 45, and/or server 50 can be configured to timestamp the asset data collected from the production asset 20, and to associate the timestamp with the asset data and the production asset 20 in the database 55, for use in generating the asset bubbles 80 and the moving bubble chart 70.

[0024] Referring to the non-limiting example illustrated by FIG. 1, shown is a facility 10 including a production line 15 consisting of a main line 15B including production asset 20 identified in FIG. 1 as Station 1, Station 2, Station 3, Station 4, Station 5, Station 6. Referring to FIGS. 3-26, each of these production assets 20 is depicted in a moving bubble chart 70 by an asset bubble 80, such that Station 1 is depicted as asset bubble STA1, Station 2 is depicted as asset bubble STA2, etc. Each production asset 20 is either fully automated, manual, or mixed manual and automated, and can contain one or more asset elements. The production assets 20 are connected to one or a plurality of controllers 35 via the facility network 40. The controllers 35 are responsible for controlling the automation, e.g., controlling operation of the production assets 20, and receiving/collecting asset data, including, for example, signals from sensors, signals of manual operation feedback, production parameters (process inputs) and production outcome measurement (process outputs).

[0025] The controllers 35 are connected, through the factory network 40, to a data collector 45 that collects the asset data from the controllers 35. In an illustrative example, the data can be collected by the controller 35 and/or the data collector 45 in real time, continuously or on a sampling frequency. The data collector 45 and/or the factory server 50 conducts processing of the asset data, which can include, for example, determining an indicator value of an asset indicator 75, such as a condition state of the production asset 20, using one or more algorithms provided therefor, and/or comparing the asset data to a criteria defined for the asset indicator 75, where the indicator criteria can be a standard, a threshold, a specification, an acceptance range, a boundary 90, etc., to determine a condition state of the production asset 20, and/or whether the indicator value is compliant or non-compliant to the criteria. The factory server 50, which may be a cloud resource, is configured to process the asset data, which can include associating the asset data with a timestamp indicating the time at which the asset data was collected, and/or associating the asset data with the production asset 20 from which the asset data was collected, determining an indicator value for each of one or more asset indicators 75 associated with the production asset 20, storing the asset data, timestamp, indicator values, associated with the production asset 20 to a database 55, generating an asset bubble 80 depicting the production asset 20, generating a moving bubble chart 70 including the asset bubble 80, using the asset data, and/or displaying in a bubble chart display 95, for example, via a user interface 65 of a user device 60, the moving bubble chart 70 as described further herein.

[0026] Referring to FIGS. 3 and 4 of the accompanying drawings, shown is a moving bubble chart 70 generated by system 100, using asset data collected from the production assets 20 shown in FIG. 2. As shown in FIGS. 3 and 4, up to four performance indicators 75 can be tracked and visually displayed in the moving bubble chart 70, where in the present example, Indicator A is shown on the X-axis, Indicator B is shown on the Y-axis, Indicator C corresponds to the size of the asset bubble 80, and Indicator D corresponds to the color of the asset bubble 80 (shown as a shading differential in FIG. 3, and as a color differential in Appendix Fig. 3). In the present example, a selected color is used to indicate the production assets 20 of a particular production line 15, where the production assets 20 in that group are colored a lighter to darker gradient (shade) corresponding to the identification number of the production asset 20 in that group, where the lowest identification number corresponds to the lightest gradient or shade of the color and the highest identification number corresponds to the darkest gradient or shade of the color, for easy visual identification of each production asset 20 of a particular production line 15. In the example shown, Indicator E, the shape of the asset bubble 80, is varied to distinguish production assets 20 of different production lines 15. In the example shown, the various shapes of asset bubbles 80 used as indicator values for Indicator E include circle, square, triangle, upside down triangle, star, donut... etc., which are to be considered non-limiting, and it would be understood that other shapes, such as oval, pentagon, hexagonal, other polygonal shapes both regular and irregular, could be displayed as an asset bubble 80 to distinguish one or a group of asset bubbles 80 (and their associated production assets 20) from another one or group of asset bubbles 80 (and their associated production assets 20). By way of illustration, as shown in FIGS. 2-4 and corresponding color Figures 2-4 of the Appendix of related US Provisional Application No.

63/306,453, the contents of which are hereby incorporated by reference in their entirety , each of the production assets STA1... STA7 of production line 15A are displayed in the moving bubble chart 70 shown in FIGS. 3-4 as circle-shaped asset bubbles 80 A labeled STA1... STA7, colored in lighter (STA1) to darker (STA7) gradients of a first color. In the same example, each of the production assets AS1 ... AS4 of production line 15E (see FIG. 2) are displayed in the moving bubble chart 70 in FIG. 3 as star-shaped asset bubbles 80E labeled AS 1... AS4, colored in lighter (AS 1) to darker (AS4) gradients of a second color. Production assets CR1... CR4 of production line 15C shown in FIG. 2 are displayed in the bubble chart 70 of FIG. 3 as cross-shaped asset bubbles 80C labeled CR1... CR4, colored in lighter (CR1) to darker gradients (CR4) of a third color. Advantageously, the moving bubble chart 70, as illustrated in FIG. 3, can be used to display asset bubbles 80 dynamically visualizing multiple production assets 20 from multiple production lines 15 where the real time condition and/or performance of each of the production assets 20, in terms of multiple Indicators A, B, C, etc. is visually and readily apparent based on the position and/or appearance of the asset bubble 80 associated with each respective production asset 20, and the performance of each production line 15, based on the shape of the asset bubble 80, is visually readily apparent to a viewer of the moving bubble chart 70. Because the moving bubble chart 70 is dynamic, e.g., the respective asset bubbles 80 change position on the chart 70 as their performance condition changes and the moving bubble chart 70 over an elapsed period of time is updated by the server 50 using current asset data, ongoing viewing and/or monitoring of the moving bubble chart 70 also provides a visualization of past performance and trending performance of the production assets 20 visualized on the bubble chart 70. In one example, the trending performance can be extrapolated to predict future performance of the production assets, such that containment and/or preventive actions can be implemented in advance of a non-compliant condition predicted by the extrapolation.

[0027] In the example shown in FIGS. 3 and 4, the bubble chart 70 is generated by the server 50 and outputted for display via a user device 60, using asset data collected from a plurality of different production assets (STA1 ... STA6, TRI ... TR4, CR1... CR4, SQ1... SQ5, AS1... AS4 in the present example) of a plurality of different production lines (15A . . . 15E in the present example), where the asset bubbles 80 are displayed such that as plurality of asset indicators (Indicators A, B, C, D, E in the present example) of each of the plurality of production assets 20 can be dynamically and simultaneously displayed by corresponding asset bubbles 80 on a bubble chart 70. As shown in the figures, the moving bubble chart 70 displays a chart date and time. In one example, the chart date and time indicates the date and time corresponding to the condition state of the production assets 20 depicted by the displayed asset bubbles 80. In one example, the chart date and time corresponds to the date and time the server 50 generated the asset bubbles 80 displayed in the bubble chart 70 according to a sampling plan, which can include continuous sampling of the asset data. In one example, the chart date and time is correlated to the date and time at which the data collector 45 collected and/or received the asset data used to generate the asset bubbles 80 displayed in the bubble chart 70, such that the displayed asset bubbles 80 illustrate the indicator values and/or condition state of the production assets 20 at the displayed data and time.

[0028] In the present example, the assets 20 in each of the five different production lines 15A... 15E are displayed by an asset bubble 80 having a shape determined by the respective production line 15 of the production asset 20 depicted by the asset bubble 80. For example, each of the production assets 20 from production line 15 A are displayed in the bubble chart 70 shown in FIGS. 3 and 4 as circle-shaped asset bubbles 80A corresponding to assets STA in line 15A shown in FIG. 2, each of the production assets 20 from production line 15B are displayed as triangle-shaped asset bubbles 80B (assets TR in line 15B shown in FIG. 2), each of the production assets 20 from production line 15C are displayed as cross-shaped asset bubbles 80C (assets CR in line 15C shown in FIG. 2), each of the production assets 20 from production line 15D are displayed as square-shaped asset bubbles 80D (assets SQ in line 15D shown in FIG. 2), and each of the production assets 20 from production line 15E are displayed as star-shaped asset bubbles 80E (assets AS in line 15E). By setting standards, e.g., criteria of each indicator 75, a user of the system 100, for example, the production team responsible for the facility 10, can view a single bubble chart 70 in a display 95 outputted to a user interface 65 to determine which production asset 20 is non-compliant and/or not performing to the criteria set for that production asset 20, and prioritize actions focused on that production asset 20 to prevent, contain, and/or correct non-compliance with the criteria. The visualization can be easily achieved by looking at the position, the size, and the color gradient of the asset bubbles 80 representing the production assets 20 as shown in the bubble chart 70.

[0029] As previously described, asset data is collected continuously and/or periodically from the plurality of production assets 20 by the controllers 35, data collector 45, and server 50, and is used by the server 50 to periodically and/or continuously update the production performance indicator data (values) associated with each of the production assets 20, which is then used to update the bubble chart 70, by moving the asset bubble 80 associated with each production asset 20 to a position on the bubble chart 70 corresponding to the current values for performance indicators A and B (relative to the y-axis and x-axis), by changing the size of the asset bubble 80 shown on the bubble chart 70 to correspond to the cunent value of performance indicator C, etc.. As the asset bubbles 80 of each production asset 20 are updated periodically based on updated production performance indicator values, an animation showing the time-lapse motions of the asset bubbles 80 will reveal the trending of indicator values of each of the indicators 75 of each of the assets 20. The position of the asset bubble 80 relative to the x-axis and y-axis, the trace showing trending of the movement and/or size of the asset bubble 80, and the change of color gradient, can provide an indication and/or prediction of whether the respective indicators 75 associated with each of the asset bubbles 80 are getting better, remaining constant (stable), or getting worse. In a non-limiting example, the system 100 can be configured to enhance visualization of each asset condition, for example, by further distinguishing an asset bubble 80 in its appearance, for example, causing the asset bubble 80 to blink or vibrate on the display, and/or by adding an exclamation mark or other distinguishing icon beside an asset bubble 80, to indicate, for example, deviation from expected performance, acceleration of a trend, a non- compliance with the criteria set for that asset bubble 80, a trend toward the a non-compliant condition, etc., to alert a user monitoring the display 95 including the bubble chart 70 of a production asset condition which may warrant further action or attention.

[0030] By extrapolating the historical trend of an indicator value of an asset bubble 80, not only can the movement of the asset bubble 80 within the bubble chart 70 be used to visualize past performance, but the extrapolated trend can also be used to visualize and/or predict where and when the indicator values is moving or trending to, if no intervention to modify the trend is taken. This feature provides a significant value in managing production line, by providing trend information which can be used to prioritize improvement activities and resource deployment.

[0031] An asset indicator 75 can be, for example, a performance indicator 75 indicating the performance condition or condition state of the associated production asset 20. Non-limiting examples of performance indicators include a condition or condition state of the production asset 20, a cycle start time, a cycle stop time, a position of an asset element of the production asset 20, a dimension or other measured or sensed parameter or characteristic (pressure, temperature, surface finish, torque, etc.) of the production asset 20 or a workpiece or object being processed by the production asset 20, etc. The indicator value of the performance indicator is determined for the performance indicator using asset data generated and/or collected by the production asset 20, the data collector 45 and/or the server 50. For example, a performance indicator of “condition state” can have an indicator value which is one of “blocked”, “starved”, “faulted”, or “running” indicating a current condition state of the production asset 20, or a cumulative indicator value for cumulative cy cles performed by the production asset 20 such as “Blocked %” of the cumulative cycles, “Faulted %” of the cumulative cycles, and/or a “Reject %” of the cumulative cycles. In another example, a performance indicator of “product length” can have an indicator value expressed as an actual dimensional length, or expressed relative to a specification, such as “long”, “short”, or “acceptable.” The asset indicator 75 can be, for example, an identifying indicator 75 for indicating an identifying parameter of the associated production asset 20, such as the production line 15 that the production asset 20 is associated with, the type of machine(s) (drilling, cutting, stamping, assembly, etc.) comprising the production asset 20, etc. Asset indicators, which can also be referred to herein as production indicators, include performance indicators and identifying indicators.

[0032] Referring to FIGS. 1, 5, and 6, and an illustrative video of the moving bubble chart 70 depicted by the sequential video frames shown in FIGS. 7-26, shown is an illustrative example of the system 100 and method for dynamic mapping the asset performance and conditions of assets 20 operating in a production line 15 of a facility 10 via a display 95 including a bubble chart 70, for outputting to and viewing via a user interface 65 of a user device 60. Referring to FIG. 1, the facility 10 includes at least one production line 15A having a plurality of operating assets 20 configured as work stations STA1... STA7, which are displayed on the moving bubble charts 70 shown in FIGS. 5- 26 by corresponding asset bubbles 80 labeled STA1 ... STA7. In the non-limiting example, the asset performance indicators 75 associated with the production line 15 A include a first indicator “Over- Cycle%” denoted by the X-axis, a second indicator “Faulted%” denoted by the Y-axis, and a third indicator “Reject%” which is denoted by the size of the asset bubble 80. As previously described herein, additional asset indicators 75 can be associated with the production line 15A, which may be displayed on the bubble chart 70, for example, as a color, fill pattern, gradient, or other characteristic of the asset bubble 80. In the present example, the “Over-Cycle%” performance indicator 75 represents the percentage of cycles performed by the production asset 20 which have an actual cycle time exceeding a criteria (standard, acceptance range, threshold, and/or specification) established for that production asset 20. The criteria for each of the performance indicators 75 is saved to the database 55 for use by the server 50 to periodically determine the value of each performance indicator 75, where periodically, as used herein, can indicate the server 50 is calculating and/or determining the value of each performance indicator 75 at a set frequency, for example, each hour, every x minutes, every y parts produced by the asset, at a sampling frequency established for the production asset 20 based on the asset type, cunent performance, a sampling plan, or other process control guidelines, which may be a variable sampling frequency, or on a continuous basis as data is collected, at a frequency set by a user/production manager, or otherwise, such that it would be understood that “periodically” is intended to be defined broadly to encompass all frequencies from continuously determining the performance indicator 75 in real time as data is received by the server 50, to determining the performance indicator 75 at a predetermined interval or sampling frequency.

[0033] In the present example, the actual cycle time used to generate the Over-Cycle% performance indicator 75 can be determined using data collected from the production asset 20 via the controllers 35 and/or data collector 45, which can include sensor data, asset data, and timestamp data associated with the sensor and/or asset data, the data processed by at least one of the controllers 35, data collector 45, or server 50 to determine the actual cycle of each process cycle performed by the production asset 20, where the actual cycle data can be stored to the database 55. The actual cycle time data is processed by the server 50, including, for example, comparing the actual cycle time data to the cycle time criteria for that production asset 20, to determine the “Over-Cycle%”, that is, the percentage of process cycles performed by the production asset 20 which have a cycle time exceeding the cycle time criteria. The value of the Over-Cycle% determined by the server 50 is associated in the database 55 with that production asset 20 and, for example, also associated with one or more of the asset data, cycle time data, time stamp data, etc. The server 50 updates the bubble chart 70 with the current indicator value of the Over-Cycle% by moving the position of the asset bubble 80 associated with that production asset 20 to a position on the bubble chart 70 corresponding with the current indicator value of the Over-Cycle% as depicted by the x-axis. Referring to FIGS. 5 and 6, for example, production asset STA6 is shown having a cunent Over-Cycle% of 60%, production assets STA1 and STA4 are each shown having a current Over-Cycle% of 10%, and so on. [0034] Using a similar method, the other asset performance indicators 75, Faulted%, and Reject% are calculated periodically, using asset and/or sensor data received by the server from one or more of the controllers 35 and data collector 45, which is used to periodically determine the value of each of these performance indicators 75 for each of the production assets 20 and their corresponding asset bubbles 70 displayed on the moving bubble chart 70. In the present example, Faulted% is determined by the percentage of time the production asset 20 is in a machine breakdown or error stop condition, and Quality Reject% is determined by the percentage of products which are rejected for noncompliance to a quality standard. As described for Over-Cycle%, the server 50 receives data from the production asset 20, controller 35, data collector 45, etc., and uses the received data, which may be timestamped and/or stored to the database 55, to periodically determine the current value of each of the performance indicators Faulted% and Quality Reject%. The server 50 updates the bubble chart 70 with the current value of the Faulted% indicator by moving the position of the asset bubble 80 associated with that production asset 20 to a position on the bubble chart 70 corresponding with the current value of the Faulted% as depicted by the y-axis. Referring to FIGS. 5 and 6, for example, production asset STA6 is shown having a current Faulted% of 18%, production asset STA1 is shown having a current Faulted% of 1%, STA4 is shown having a current Faulted% of 3%, and so on. The server 50 updates the bubble chart 70 with the current value of the Quality Reject% indicator by modify ing the size of the asset bubble 80 associated with that production asset 20 to a size corresponding with the cunent indicator value of the Quality Reject%, to visually indicate the relative Quality Reject% of that production asset 20 as compared with other production assets 20 displayed as asset bubbles 80 on the bubble chart 70. In one example, the moving bubble chart 70 can include a scale relating the Quality Reject% to the size of the asset bubble 80. Referring to the present example shown in FIGS. 5 and 6, production asset STA6 displayed as asset bubble STA6 is shown having a Quality Reject% which is relatively higher than production assets STA4 and STA1, displayed respectively as smaller asset bubbles STA4 and STA1, where STA1 is displayed as having a relatively smaller Quality Reject% than STA4.

[0035] In a non-limiting example, the asset data can be collected, processed, and stored through an automated system as previously described in one or more of US Patent Application Nos. 12/954747, 13/354044, 13/486275, 13/693758, 14/705421, 14/833799, 15/306954, 15/306959, 16/951494, 16/957604, 16/957876, and continuation and continuation-in-part applications claiming priority thereto, all of which are co-owned by the applicant.

[0036] Referring again to the example shown in FIGS. 1, 5 and 6, the system 100 is advantaged by generating, in a single display 905 including a moving bubble chart 70 generated as described herein, a dynamic map and visualization of multiple performance indicators 75 of each of a plurality of production assets 20 from one or more production lines 15 (see FIGS. 2 and 3) depicted by asset bubbles 80 corresponding to each of the production assets 20, providing an efficient and comprehensive display of the production status of a complex production facility for monitoring, identifying improvement opportunity, and managing the assets 20 and lines 15 of the production facility 10. For example, from a quick glance at the moving bubble chart 70 shown in FIG. 5 it can be determined that production asset STA6 has the worst Over-Cycle% and Quality Reject%, and the second worst Faulted%, based on the position and size of the corresponding asset bubble STA6 relative to the asset bubbles 80 displayed for the other production assets STA1 ... STA5 and STA7, and such that improvement resources can be directed to production asset STA6 as a first priority in the present example.

[0037] In the present example, the second improvement priority should be addressed to production asset STA2, which as shown by the relative position of asset bubble STA2 on the bubble chart 70, has the highest Faulted% and second worst Over-Cycle%. As a third priority for improvement in the present example, resources should be directed to production asset STA5 which, as shown by the relative position and size of asset bubble STA5 on the bubble chart 70, has the third worst Faulted% and Over-Cycle% and the second worst Quality Reject%.

[0038] In the non-limiting example shown in FIG. 6, the moving bubble chart 70 can be categorized to several different sectors 85 of the bubble chart 70, which in the present example are shown as quadrants or sectors I, II, III, IV, to indicate the relative severity of the operating condition of a production asset 20 corresponding to an asset bubble 80 displayed in a particular sector 85, and as such can be used as criteria to trigger an alert when the asset condition is in a critical sector 85, and/or is trending or moving to a more critical sector, for example, from sector I to sector II, as shown in FIG. 6 of the present example. The sectors 85 can be defined by sector boundaries 90, which may correspond to and/or be determined by criteria established for one or more of the asset indicators, including, for example, specifications, operating limits, thresholds, or other criteria identifying compliant and non-compliant conditions or operating parameters of the production asset 20.

[0039] Referring now to FIGS. 7-26, shown are schematic illustrations of a sequence of video frames of the moving bubble chart 70 of FIG. 5 when displayed as a video, dynamically displaying the asset bubbles 80 associated with the plurality of production assets 20 shown in FIG. 1, each video frame capturing the image of the moving bubble chart 70 at a one hour interval, e.g., FIG. 7 shows the video frame captured at Hour 1 (“bubble chart at Hour 1”), FIG. 8 shows the video frame captured at Hour 2 (“bubble chart at Hom 2”), and so on, illustrating the dynamic movement and mapping of each asset bubble 80, corresponding to the change in indicator value of each asset indicator 75 of each respective production asset 20 associated with a respective asset bubble 80, over the elapsed time of Hour 1 through Hour 20 of the production operation represented by the video, collectively FIGS. 7- 26. In the example illustrated by FIGS. 7-26, asset bubbles 80 corresponding to production assets STA1 ... STA7 of production line 15 A (see FIG. 2) are mapped in a bubble chart 70 generated and outputted to a user interface 65 as a display 95. The appearance and position of each asset bubble 80 is defined by the indicator values of the asset indicators 75 associated with the production asset 20 corresponding to the asset bubble. In the present example, the production asset 20 is associated with three performance indicators, “Faulted %” (x-axis of bubble chart 70), “Over-Cycle %” (y-axis of bubble chart 70), and “Reject %” (size of asset bubble 80). The position on the bubble chart 70 and the size of each asset bubble 80 is determined by the then cunent condition of the production asset 20 corresponding to that asset bubble 80. For example, at Hour 1 of operation shown in FIG. 7, production asset STA6 corresponding to asset bubble 80A is operating with a current Faulted % of about 18%, a current Over-Cycle % of 60% and a Reject % which is the highest (largest bubble) relative to the other stations STA1. . . STA4 and STA7 mapped to the bubble chart 70. By comparison, at Hom 16 of operation shown in FIG. 22, production asset STA6 corresponding to asset bubble 80A is operating with a current Faulted % of about 6%, a current Over-Cycle % of about 23%, and a Reject % which is no longer the highest (largest bubble) relative to the other stations STA1. . . STA4 and STA7 mapped to the bubble chart 70, showing an improving performance trend at Hour 16 as compared with Hour 1.

[0040] The dynamic mapping and process visualization resulting from viewing the displayed video frames shown in FIGS. 7-27 in time sequence from Hour 1 through Hour 20 illustrate the advantages and benefits that the dynamic mapping provide, including insight into performance trends for each of the production assets 20 displayed on the bubble chart 70 as a respective asset bubble 80, an efficient and compact visualization view of the performance of the production assets 20 individually and relative to other production assets in the same or other production lines 15, monitoring for the results of actions taken on the production asset 20, including containment, corrective and/or improvement actions, etc. In the present example illustrated by the sequenced video frames shown in FIGS. 7-27, as the production hours go by, the performance indicators of production assets STA6 and STA2 started to improve, with the corresponding asset bubbles STA6 and STA2 moving to lower left corner of the moving bubble chart 70, which in the present example is the observed result of production improvement resources applied to the production assets STA6 and STA2. In the example, improvement in production asset STA5 also is shown, as the size of the asset bubble STA5 shrinks over time, and moves to lower left corner as well, indicating that over the elapsed time the Faulted %, Over-Cycle %, and Reject % of the production asset STA5 have each improved.

[0041] In the example shown in FIGS. 7-26, at the beginning of the dynamic mapping (Hour 1), asset bubble STA7 was located close to origin of the bubble chart 70 in a baseline position, and sized to indicate a moderate Quality Reject% relative to other production assets such as STA1 (lower Reject%) and STA6 (higher Reject%). As time progresses from Hour 1 through Hour 11 (FIGS. 7- 18), the performance indicators and condition of production asset STA7 gets progressively worse, as visualized by the position of the asset bubble STA7 moving up and to the right on the bubble chart 70, with bubble size increasing rapidly. At Hour 11, improvement actions are implemented on production asset STA7, and as shown in the progression of bubble chart frames at Hours 12-20 (FIGS. 19-26), the performance of production asset STA7 improves over time, as shown by movement of the asset bubble STA7 returning to the prior (baseline) position, and a reduction in size of the asset bubble STA7 to the baseline size, confirming visually the effectiveness of the improvement actions which were implemented.

[0042] Still referring to the example of FIGS. 7-26, while the performance of production asset STA3 remains stable throughout the period shown, e.g., from Hour 1 through Hour 20, the condition of production assets STA1 and STA4 get progressively worse. As shown through the sequence of bubble charts, beginning at Hour 2, production asset STA1 shows an increasing Over-Cycle% by movement of the position of the asset bubble STA1 relative to the x-axis, with the Quality Reject% also increasing, as shown by an increase in the size of the asset bubble STA1 over time. The rapid and worsening condition of STA1 as displayed on the bubble chart 80 over time provides a visual indicator to the production team to prioritize improvement resources to production asset STA1. As shown through the sequence of bubble charts, beginning at Hour 8, production asset STA4 shows an increasing Faulted% by movement of the asset bubble STA4 relative to the y-axis, with the Quality Reject% also increasing, as shown by an increase in the size of the asset bubble STA4 over time, visualizing a creeping deterioration in the performance of production asset STA4. As described for FIG. 6, when an asset bubble 80 moves into a specified zone of the moving bubble chart 80 and/or across a predetermined boundary or criteria defined for the production asset 20 associated with the asset bubble 80, an alert can be activated by the server 50, for example, sending an alert notification to a production team member, such as a SMS or email message, and/or a visual alert can be activated in the moving bubble chart 80, such as activating the asset bubble 80 to blink, displaying an alert icon near or on the asset bubble 80, activating an audio alert, etc., via the user device 60.

[0043] The embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims. [0044] The following Clauses provide example configurations of a system and method for generating a moving bubble chart configured to dynamically map a plurality of production assets disclosed herein.

[0045] Clause 1. A system for generating a map of a plurality of production assets for display on a user interface, the system comprising: a plurality of production assets, wherein each respective production asset of the plurality of production assets is configured to: repeatedly perform at least one operation; and generate asset data defined by performance of the at least one operation; a controller configured to receive the asset data from the plurality of production assets; a data collector configured to collect the asset data from the controller; a server in communication with a database; the server configured to: receive the asset data from the data collector; generate, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, wherein a respective asset bubble corresponds to the respective production asset; map the plurality of asset bubbles to a bubble chart; and output, for display on a user interface, the bubble chart.

[0046] Clause 2. The system of clause 1, wherein the server is configured to generate the respective asset bubble corresponding to the respective production asset by: associating, in the database, the asset data generated by the respective production asset with the respective production asset; associating, in the database, a plurality of asset indicators with the respective production asset; determining, using the asset data, a plurality of indicator values; wherein determining the plurality of indicator values includes determining a respective indicator value for each respective asset indicator of the plurality of asset indicators; generating, using the plurality of indicator values, a respective asset bubble corresponding to the respective production asset; and mapping the respective asset bubble to the bubble chart.

[0047] Clause 3. The system of clause 2, further comprising: the plurality of asset indicators including a first asset indicator and a second asset indicator; the bubble chart including: a first axis defined by the first asset indicator; a second axis defined by the second asset indicator; the plurality of indicator values determined for the respective production asset including: a first indicator value determined for the first asset indicator; a second indicator value determined for the second asset indicator; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble at a position on the bubble chart determined by: the first indicator value mapped to the first axis; and the second indicator value mapped to the second axis.

[0048] Clause 4. The system of clause 3, wherein: the first asset indicator is defined by a first condition state of the respective production asset; and the second asset indicator is defined by a second condition state of the respective production asset.

[0049] Clause 5. The system of clause 4, wherein: the first condition state is a faulted state of the respective production asset; and the second condition state is an over-cycle state of the respective production asset.

[0050] Clause 6. The system of clause 3, wherein asset data defined by performance of the at least one operation includes: a cycle start time of the at least one operation; and a cycle stop time of the at least one operation.

[0051] Clause 7. The system of clause 2, wherein: the asset data defined by performance of the at least one operation includes an operating parameter of the at least one operation; and at least one asset indicator of the plurality of asset indicators is defined by the operating parameter.

[0052] Clause 8. The system of clause 3, further comprising: the plurality of asset indicators including a third asset indicator; the plurality of indicator values determined for the respective production asset including a third indicator value determined for the third asset indicator; the respective asset bubble including a first appearance feature defined by the third indicator value; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble including the first appearance feature. [0053] Clause 9. The system of clause 8, wherein the first appearance feature is defined by at least one of a shape, a size, a color, a shade, or a fill pattern of the respective asset bubble.

[0054] Clause 10. The system of clause 8, wherein: the third asset indicator is defined by a third condition state of the respective production asset.

[0055] Clause 11. The system of clause 10, wherein: the third condition state is a rejected state of the respective production asset.

[0056] Clause 12. The system of clause 8, wherein: the third asset indicator is defined by an identifying feature of the respective production asset.

[0057] Clause 13. The system of clause 12, wherein the identifying feature is defined by a production line including the respective production asset.

[0058] Clause 14. The system of clause 12, wherein: the respective production asset includes at least one of a machine or a sensor; and the identifying feature is defined by the at least one of the machine or the sensor.

[0059] Clause 15. The system of clause 1, further comprising: the controller configured to time stamp the asset data with a timestamp; the server configured to associate, in the database, the asset data with the timestamp.

[0060] Clause 16. The system of clause 1, wherein the bubble chart is configured as a moving bubble chart, the system further comprising: the data collector configured to continuously collect real time asset data from the controller; the server configured to: continuously receive the real time asset data from the data collector; continuously generate, using the real time asset data, the plurality of asset bubbles; continuously map in real time, the plurality of asset bubbles to the bubble chart; continuously output in real time, for display on the user interface, the bubble chart.

[0061] Clause 17. The system of clause 1, further comprising: the data collector configured to collect cunent asset data from the controller; the server configured to periodically: receive the current asset data from the data collector; generate, using the current asset data, the plurality of asset bubbles defined by the current asset data; update the bubble chart by: mapping the plurality of asset bubbles defined by the current asset data to a current bubble chart; and outputting, for display on the user interface, the current bubble chart including the plurality of asset bubbles defined by the current asset data.

[0062] Clause 18. The system of clause 17, further comprising: a sampling plan; wherein the server is configured to periodically update the bubble chart as defined by the sampling plan.

[0063] Clause 19. The system of clause 17, further including: a chart date and a chart time displayed by the bubble chart; wherein the chart date and the chart time is correlated to a date and a time associated in the database with the asset data used to generate the asset bubbles displayed in the bubble chart.

[0064] Clause 20. The system of clause 19, further including: the server configured to output a video displaying the bubble chart as generated by the server over a period of time. [0065] Clause 21. The system of clause 2, further including the server configured to: associate, in the database, indicator criteria with the respective asset indicator; compare the respective indicator value to the indicator criteria; and determine whether the respective indicator value is non-compliant to the indicator criteria.

[0066] Clause 22. The system of clause 21, further including: the server configured to use the asset data collected periodically from the data collector to extrapolate a trend of the respective indicator value for the respective production asset.

[0067] Clause 23. The system of clause 22, further including: the server configured to generate, using the trend, a predicted time when the respective indicator value will become non-compliant to the indicator criteria.

[0068] Clause 24. The system of clause 21, further including: the server configured to generate an alert when the respective indicator value is determined to be non-compliant to the indicator criteria. [0069] Clause 25. The system of clause 24, wherein the alert is a visual alert displayed in the bubble chart.

[0070] Clause 26. The system of clause 25, wherein the visual alert includes changing an appearance of the respective asset bubble.

[0071] Clause 27. The system of clause 24, wherein: the alert is a user alert; and the server is configured to output the user alert to the user interface.

[0072] Clause 28. A method for generating a map of a plurality of production assets for display on a user interface, the method comprising: providing a plurality of production assets; each respective production asset of the plurality of production assets: repeatedly performing at least one operation; and generating asset data defined by performance of the at least one operation; receiving, via a controller, the asset data from the plurality of production assets; collecting, via a data collector, the asset data from the controller; providing a server in communication with a database; the method further comprising the server: receiving the asset data from the data collector; generating, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, wherein a respective asset bubble corresponds to the respective production asset; mapping the plurality of asset bubbles to a bubble chart; and outputting, for display on a user interface, the bubble chart.

[0073] Clause 29. Anon-transitory computer-readable storage medium comprising computer instructions stored thereon; wherein the computer instructions are configured to enable a computer to perform the method according to clause 28.

[0074] Clause 30. The method of clause 28, wherein generating the respective asset bubble corresponding to the respective production asset further comprises the server: associating, in the database, the asset data generated by the respective production asset with the respective production asset; associating, in the database, a plurality of asset indicators with the respective production asset; determining, using the asset data, a plurality of indicator values; wherein determining the plurality of indicator values includes determining a respective indicator value for each respective asset indicator of the plurality of asset indicators; generating, using the plurality of indicator values, a respective asset bubble corresponding to the respective production asset; and mapping the respective asset bubble to the bubble chart.

[0075] Clause 31. The method of clause 30, further comprising: the plurality of asset indicators including a first asset indicator and a second asset indicator; the bubble chart including: a first axis defined by the first asset indicator; a second axis defined by the second asset indicator; the plurality of indicator values determined for the respective production asset including: a first indicator value determined for the first asset indicator; a second indicator value determined for the second asset indicator; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble at a position on the bubble chart determined by: the first indicator value mapped to the first axis; and the second indicator value mapped to the second axis.

[0076] Clause 32. The method of clause 31, wherein: the first asset indicator is defined by a first condition state of the respective production asset; and the second asset indicator is defined by a second condition state of the respective production asset.

[0077] Clause 33. The method of clause 32, wherein: the first condition state is a faulted state of the respective production asset; and the second condition state is an over-cycle state of the respective production asset.

[0078] Clause 34. The method of clause 31, wherein asset data defined by performance of the at least one operation includes: a cycle start time of the at least one operation; and a cycle stop time of the at least one operation.

[0079] Clause 35. The method of clause 30, wherein: the asset data defined by performance of the at least one operation includes an operating parameter of the at least one operation; and at least one asset indicator of the plurality of asset indicators is defined by the operating parameter.

[0080] Clause 36. The method of clause 31, further comprising: the plurality of asset indicators including a third asset indicator; the plurality of indicator values determined for the respective production asset including a third indicator value determined for the third asset indicator; the respective asset bubble including a first appearance feature defined by the third indicator value; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble including the first appearance feature.

[0081] Clause 37. The method of clause 36, wherein the first appearance feature is defined by at least one of a shape, a size, a color, a shade, or a fill pattern of the respective asset bubble.

[0082] Clause 38. The method of clause 36, wherein: the third asset indicator is defined by a third condition state of the respective production asset.

[0083] Clause 39. The method of clause 38, wherein: the third condition state is a rejected state of the respective production asset.

[0084] Clause 40. The method of clause 36, wherein: the third asset indicator is defined by an identifying feature of the respective production asset. [0085] Clause 41. The method of clause 40, wherein the identifying feature is defined by a production line including the respective production asset.

[0086] Clause 42. The method of clause 40, wherein: the respective production asset includes at least one of a machine or a sensor; and the identifying feature is defined by the at least one of the machine or the sensor.

[0087] Clause 43. The method of clause 28, further comprising: time stamping, via the controller, the asset data with a timestamp; associating in the database, via the server, the asset data with the timestamp.

[0088] Clause 44. The method of clause 28, wherein the bubble chart is configured as a moving bubble chart, the method further comprising: continuously collecting, via the data collector, real time asset data from the controller; continuously receiving, via the server, the real time asset data from the data collector; continuously generating, via the server and using the real time asset data, the plurality of asset bubbles; continuously mapping in real time, via the server, the plurality of asset bubbles to the bubble chart; continuously outputting in real time, via the server and for display on the user interface, the bubble chart.

[0089] Clause 45. The method of clause 28, further comprising: collecting, via the data collector, current asset data from the controller; periodically receiving, via the server, the current asset data from the data collector; periodically generating, via the server and using the current asset data, the plurality of asset bubbles defined by the current asset data; periodically updating the bubble chart by: mapping the plurality of asset bubbles defined by the current asset data to a cunent bubble chart; and outputting, for display on the user interface, the current bubble chart including the plurality of asset bubbles defined by the current asset data.

[0090] Clause 46. The method of clause 45, further comprising: providing a sampling plan; periodically updating, via the server, the bubble chart as defined by the sampling plan.

[0091] Clause 47. The method of clause 45, further including: a chart date and a chart time displayed by the bubble chart; wherein the chart date and the chart time is correlated to a date and a time associated in the database with the asset data used to generate the asset bubbles displayed in the bubble chart.

[0092] Clause 48. The method of clause 47, further including: outputting, via the server, a video displaying the bubble chart as generated by the server over a period of time.

[0093] Clause 49. The method of clause 30, further comprising the server: associating, in the database, indicator criteria with the respective asset indicator; comparing the respective indicator value to the indicator criteria; and determining whether the respective indicator value is non- compliant to the indicator criteria.

[0094] Clause 50. The method of clause 49, further comprising: extrapolating a trend of the respective indicator value for the respective production asset, via the server and using the asset data collected periodically from the data collector. [0095] Clause 51. The method of clause 50, further including: the server generating, using the trend, a predicted time when the respective indicator value will become non-compliant to the indicator criteria.

[0096] Clause 52. The method of clause 49, further including: generating, via the server, an alert when the respective indicator value is determined to be non-compliant to the indicator criteria.

[0097] Clause 53. The method of clause 52, wherein the alert is a visual alert displayed in the bubble chart.

[0098] Clause 54. The method of clause 53, wherein the visual alert includes changing an appearance of the respective asset bubble.

[0099] Clause 55. The method of clause 49, wherein the alert is a user alert, the method further comprising: outputting, via the server, the user alert to the user interface.

[00100] The detailed description and the drawings or figures are supportive and descriptive of the invention, but the scope of the invention is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed invention have been described in detail, various alternative designs and embodiments exist for practicing the invention defined in the appended claims.

Claims

CLAIMS What is claimed:

1. A system for generating a map of a plurality of production assets for display on a user interface, the system comprising: a plurality of production assets, wherein each respective production asset of the plurality of production assets is configured to: repeatedly perform at least one operation; and generate asset data defined by performance of the at least one operation; a controller configured to receive the asset data from the plurality of production assets; a data collector configured to collect the asset data from the controller; a server in communication with a database; the server configured to: receive the asset data from the data collector; generate, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, wherein a respective asset bubble corresponds to the respective production asset; map the plurality of asset bubbles to a bubble chart; and output, for display on a user interface, the bubble chart.

2. The system of claim 1, wherein the server is configured to generate the respective asset bubble corresponding to the respective production asset by: associating, in the database, the asset data generated by the respective production asset with the respective production asset; associating, in the database, a plurality of asset indicators with the respective production asset; determining, using the asset data, a plurality of indicator values; wherein determining the plurality of indicator values includes determining a respective indicator value for each respective asset indicator of the plurality of asset indicators; generating, using the plurality of indicator values, a respective asset bubble corresponding to the respective production asset; and mapping the respective asset bubble to the bubble chart.

3. The system of claim 2, further comprising: the plurality of asset indicators including a first asset indicator and a second asset indicator; the bubble chart including: a first axis defined by the first asset indicator; a second axis defined by the second asset indicator; the plurality of indicator values determined for the respective production asset including: a first indicator value determined for the first asset indicator; a second indicator value determined for the second asset indicator; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble at a position on the bubble chart determined by: the first indicator value mapped to the first axis; and the second indicator value mapped to the second axis.

4. The system of claim 3, wherein: the first asset indicator is defined by a first condition state of the respective production asset; and the second asset indicator is defined by a second condition state of the respective production asset.

5. The system of claim 4, wherein: the first condition state is a faulted state of the respective production asset; and the second condition state is an over-cycle state of the respective production asset.

6. The system of claim 3, wherein asset data defined by performance of the at least one operation includes: a cycle start time of the at least one operation; and a cycle stop time of the at least one operation.

7. The system of claim 2, wherein: the asset data defined by performance of the at least one operation includes an operating parameter of the at least one operation; and at least one asset indicator of the plurality of asset indicators is defined by the operating parameter.

8. The system of claim 3, further comprising: the plurality of asset indicators including a third asset indicator; the plurality of indicator values determined for the respective production asset including a third indicator value determined for the third asset indicator; the respective asset bubble including a first appearance feature defined by the third indicator value; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble including the first appearance feature.

9. The system of claim 8, wherein the first appearance feature is defined by at least one of a shape, a size, a color, a shade, or a fill pattern of the respective asset bubble.

10. The system of claim 8, wherein: the third asset indicator is defined by a third condition state of the respective production asset.

11. The system of claim 10, wherein: the third condition state is a rejected state of the respective production asset.

12. The system of claim 8, wherein: the third asset indicator is defined by an identifying feature of the respective production asset.

13. The system of claim 12, wherein the identifying feature is defined by a production line including the respective production asset.

14. The system of claim 12, wherein: the respective production asset includes at least one of a machine or a sensor; and the identifying feature is defined by the at least one of the machine or the sensor.

15. The system of claim 1, further comprising: the controller configured to time stamp the asset data with a timestamp; the server configured to associate, in the database, the asset data with the timestamp.

16. The system of claim 1, wherein the bubble chart is configmed as a moving bubble chart, the system further comprising: the data collector configmed to continuously collect real time asset data from the controller; the server configmed to: continuously receive the real time asset data from the data collector; continuously generate, using the real time asset data, the plurality of asset bubbles; continuously map in real time, the plurality of asset bubbles to the bubble chart; continuously output in real time, for display on the user interface, the bubble chart.

17. The system of claim 1, further comprising: the data collector configmed to collect current asset data from the controller; the server configmed to periodically: receive the current asset data from the data collector; generate, using the current asset data, the plurality of asset bubbles defined by the cunent asset data; update the bubble chart by: mapping the plurality of asset bubbles defined by the current asset data to a current bubble chart; and outputting, for display on the user interface, the current bubble chart including the plurality of asset bubbles defined by the cunent asset data.

18. The system of claim 17, further comprising: a sampling plan; wherein the server is configured to periodically update the bubble chart as defined by the sampling plan.

19. The system of claim 17, further including: a chart date and a chart time displayed by the bubble chart; wherein the chart date and the chart time is correlated to a date and a time associated in the database with the asset data used to generate the asset bubbles displayed in the bubble chart.

20. The system of claim 19, further including: the server configured to output a video displaying the bubble chart as generated by the server over a period of time.

21. The system of claim 2, further including the server configured to: associate, in the database, indicator criteria with the respective asset indicator; compare the respective indicator value to the indicator criteria; and determine whether the respective indicator value is non-compliant to the indicator criteria.

22. The system of claim 21, further including: the server configured to use the asset data collected periodically from the data collector to extrapolate a trend of the respective indicator value for the respective production asset.

23. The system of claim 22, further including: the server configured to generate, using the trend, a predicted time when the respective indicator value will become non-compliant to the indicator criteria.

24. The system of claim 21, further including: the server configured to generate an alert when the respective indicator value is determined to be non-compliant to the indicator criteria.

25. The system of claim 24, wherein the alert is a visual alert displayed in the bubble chart.

26. The system of claim 25, wherein the visual alert includes changing an appearance of the respective asset bubble.

27. The system of claim 24, wherein: the alert is a user alert; and the server is configured to output the user alert to the user interface.

28. A method for generating a map of a plurality of production assets for display on a user interface, the method comprising: providing a plurality of production assets; each respective production asset of the plurality of production assets: repeatedly performing at least one operation; and generating asset data defined by performance of the at least one operation; receiving, via a controller, the asset data from the plurality of production assets; collecting, via a data collector, the asset data from the controller; providing a server in communication with a database; the method further comprising the server: receiving the asset data from the data collector; generating, using the asset data, a plurality of asset bubbles for mapping to a bubble chart, wherein a respective asset bubble corresponds to the respective production asset; mapping the plurality of asset bubbles to a bubble chart; and outputting, for display on a user interface, the bubble chart.

29. A non-transitory computer-readable storage medium comprising computer instructions stored thereon; wherein the computer instructions are configured to enable a computer to perform the method according to claim 28.

30. The method of claim 28, wherein generating the respective asset bubble corresponding to the respective production asset further comprises the server: associating, in the database, the asset data generated by the respective production asset with the respective production asset; associating, in the database, a plurality of asset indicators with the respective production asset; determining, using the asset data, a plurality of indicator values; wherein determining the plurality of indicator values includes determining a respective indicator value for each respective asset indicator of the plurality of asset indicators; generating, using the plurality of indicator values, a respective asset bubble corresponding to the respective production asset; and mapping the respective asset bubble to the bubble chart.

31. The method of claim 30, further comprising: the plurality of asset indicators including a first asset indicator and a second asset indicator; the bubble chart including: a first axis defined by the first asset indicator; a second axis defined by the second asset indicator; the plurality of indicator values determined for the respective production asset including: a first indicator value determined for the first asset indicator; a second indicator value determined for the second asset indicator; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble at a position on the bubble chart determined by: the first indicator value mapped to the first axis; and the second indicator value mapped to the second axis.

32. The method of claim 31 , wherein: the first asset indicator is defined by a first condition state of the respective production asset; and the second asset indicator is defined by a second condition state of the respective production asset.

33. The method of claim 32, wherein: the first condition state is a faulted state of the respective production asset; and the second condition state is an over-cycle state of the respective production asset.

34. The method of claim 31, wherein asset data defined by performance of the at least one operation includes: a cycle start time of the at least one operation; and a cycle stop time of the at least one operation.

35. The method of claim 30, wherein: the asset data defined by performance of the at least one operation includes an operating parameter of the at least one operation; and at least one asset indicator of the plurality of asset indicators is defined by the operating parameter.

36. The method of claim 31 , further comprising: the plurality of asset indicators including a third asset indicator; the plurality of indicator values determined for the respective production asset including a third indicator value determined for the third asset indicator; the respective asset bubble including a first appearance feature defined by the third indicator value; wherein mapping the respective asset bubble to the bubble chart includes displaying the respective asset bubble including the first appearance feature.

37. The method of claim 36, wherein the first appearance feature is defined by at least one of a shape, a size, a color, a shade, or a fill pattern of the respective asset bubble.

38. The method of claim 36, wherein: the third asset indicator is defined by a third condition state of the respective production asset.

39. The method of claim 38, wherein: the third condition state is a rejected state of the respective production asset.

40. The method of claim 36, wherein: the third asset indicator is defined by an identifying feature of the respective production asset.

41. The method of claim 40, wherein the identifying feature is defined by a production line including the respective production asset.

42. The method of claim 40, wherein: the respective production asset includes at least one of a machine or a sensor; and the identifying feature is defined by the at least one of the machine or the sensor.

43. The method of claim 28, further comprising: time stamping, via the controller, the asset data with a timestamp; associating in the database, via the server, the asset data with the timestamp.

44. The method of claim 28, wherein the bubble chart is configured as a moving bubble chart, the method further comprising: continuously collecting, via the data collector, real time asset data from the controller; continuously receiving, via the server, the real time asset data from the data collector; continuously generating, via the server and using the real time asset data, the plurality of asset bubbles; continuously mapping in real time, via the server, the plurality of asset bubbles to the bubble chart; continuously outputting in real time, via the server and for display on the user interface, the bubble chart.

45. The method of claim 28, further comprising: collecting, via the data collector, current asset data from the controller; periodically receiving, via the server, the current asset data from the data collector; periodically generating, via the server and using the current asset data, the plurality of asset bubbles defined by the current asset data; periodically updating the bubble chart by: mapping the plurality of asset bubbles defined by the current asset data to a current bubble chart; and outputting, for display on the user interface, the current bubble chart including the plurality of asset bubbles defined by the cunent asset data.

46. The method of claim 45, further comprising: providing a sampling plan; periodically updating, via the server, the bubble chart as defined by the sampling plan.

47. The method of claim 45, further including: a chart date and a chart time displayed by the bubble chart; wherein the chart date and the chart time is correlated to a date and a time associated in the database with the asset data used to generate the asset bubbles displayed in the bubble chart.

48. The method of claim 47, further including: outputting, via the server, a video displaying the bubble chart as generated by the server over a period of time.

49. The method of claim 30, further comprising the server: associating, in the database, indicator criteria with the respective asset indicator; comparing the respective indicator value to the indicator criteria; and determining whether the respective indicator value is non-compliant to the indicator criteria.

50. The method of claim 49, further comprising: extrapolating a trend of the respective indicator value for the respective production asset, via the server and using the asset data collected periodically from the data collector.

51. The method of claim 50, further including: the server generating, using the trend, a predicted time when the respective indicator value will become non-compliant to the indicator criteria.

52. The method of claim 49, further including: generating, via the server, an alert when the respective indicator value is determined to be non- compliant to the indicator criteria.

53. The method of claim 52, wherein the alert is a visual alert displayed in the bubble chart.

54. The method of claim 53, wherein the visual alert includes changing an appearance of the respective asset bubble.

55. The method of claim 49, wherein the alert is a user alert, the method further comprising: outputting, via the server, the user alert to the user interface.