GB2567214A

GB2567214A - Process performance measurement

Info

Publication number: GB2567214A
Application number: GB1716399.9A
Authority: GB
Inventors: Senogullari Oguz; Taraktas Firat; Ceylan Osman
Original assignee: Ozbros Enginering Ltd
Current assignee: Ozbros Enginering Ltd
Priority date: 2017-10-06
Filing date: 2017-10-06
Publication date: 2019-04-10
Also published as: GB201716399D0; TR201814812A2

Abstract

The wearable process performance monitoring apparatus comprises a wearable control unit 10, a wearable sensor unit 12 with motion sensors 20, and a management system configured in a learning mode to: receive motion sensor data of a complete process performance cycle; identify process and non-process related motion sensor data within the data; identify a start and end point of the process from the data; and calculate a process cycle time associated with the process. The management system preferably comprises an operational mode where real time sensor data of each performance of a process is received. Preferably, the management system in the operational mode can generate alerts when the real-time motion sensor data: varies by a pre-determined amount from the stored motion sensor data; is interrupted for a predetermined period of time; or changes abruptly, indicative of a user emergency. The motion sensors are preferably mounted on a user’s finger. The control unit is preferably mounted around a user’s limb or torso.

Description

PROCESS PERFORMANCE MEASUREMENT

Field of the Invention

This invention relates generally to process performance measurement and, more particularly, to a process monitoring apparatus for monitoring, tracking and/or analysing a process, and to a method of monitoring, tracking and/or analysing a process using such apparatus.

Background of the Invention

A process, as referred to herein, is a sequence of manual activities (“process steps”) carried out successively as in the case, for example, of product assembly. Time compression and speed are vitally important elements in any supply chain success, especially for organisations operating in more competitive markets. However, quality and accuracy are equally important factors, especially in a production process. In processes where one or more human operatives are required to manually perform steps, there is an increased need to ensure that consistent process cycle times and quality are maintained, and it is known for organisations to implement performance measurement systems that facilitate ongoing monitoring of a process.

In conventional performance measurement systems, the cycle time of a process is typically simulated using an external program before and after the process is designed, and then process times are recorded by a nearby camera (or even manually by a respective operative), and these recorded process times are then analysed against the simulated process cycle time by a software program to generate an associated performance measurement by transferring data from a camera to a spread sheet or an external program with manual analysis of engineers or the process. Data can also be collected manually in a form. This type of data acquisition process is prone to error and, without any additional performance measurement facility, there is no real time monitoring of quality or accuracy of the process being performed. Furthermore, due to the human element within the process, process performance events and cycle times are not uniform.

Quality, or at least accuracy, can be supported using an additional control system. Conventionally, the control system stores each process step (defined by a component to be installed) and a hand-held reader is utilised by the operative to scan each component before installation so that the control system can verify that it is correct. The additional process steps required to scan each component are, of course, time consuming and increase the process cycle time. Thus, US2016/0161301 describes a wearable workwear unit that is principally intended to replace the above-mentioned hand-held readers, thereby reducing the additional time needed for data acquisition. However, whilst so-called process steps are defined, these are defined in terms of the end result of a physical activity. No account is taken of the manner in which that physical activity is performed nor the transitions between each physical activity forming a process, i.e. the process flow itself. No account is taken of the flow of the operative’s hand movements, physical movements required to transition between each process step, the operative’s stance and relative position through the whole range of movements, etc. Therefore, no monitoring of the efficiency or ergonomic characteristics of the process performance can be monitored. Whilst the device of US2016/0161301 can monitor process cycle times, there is no facility to continuously analyse the manner in which an operative is performing the process (i.e. the entire range of movements performed). Indeed, each process step is stored separately in terms of the activity to be completed, so there is no facility for the entire set of hand movements forming a complete process to be stored, let alone monitored. Furthermore, there is no facility for monitoring the safety or wellbeing of workers on the factory floor.

It would be desirable to provide an integrated wearable unit that does not just monitor quality and process times, but has the ability to analyse the manner in which an operative is performing a complete process flow, with a view to being able to monitor the efficiency and ergonomic characteristics thereof and, optionally, facilitating a process whereby these aspects could be analysed and improved to optimise process cycle times without compromising quality. At least some aspects of the present invention seek to address at least some of these issues.

Summary of the Invention

In accordance with a first aspect of the present invention, there is provided a process performance monitoring apparatus, comprising:

- a wearable control unit;

- a wearable sensor unit comprising one or more motion sensors; and

- a management system configured, in a learning mode, to:

o receive from said control unit, and store, a data set comprising motion sensor data representative of a complete cycle of the performance of a process;

o identify process an non process-related motion sensor data within said data set;

o identify, from said data set, a start and end point of said process; and o calculate a process cycle time associated with said process.

Thus, the present invention provides a process performance monitoring, tracking and/or analysing apparatus that “learns” a process in terms (at least) of its optimum process cycle time such that it is subsequently able to monitor/track each performance of the process (by various workers) to ensure that it is being performed correctly/optimally, and also to enable alerts to be generated in the event of an error, for example. Quality issues can thus be identified.

In an exemplary embodiment, the management system may be further configured, in said learning mode, to receive and store component data representative of one or more components used in said process, and where in said process cycle said one or more components are used. As a result, the apparatus provides a means of storing, not just every movement required to complete the process, but also the components used at each stage therein. It is therefore, in effect, a data set exactly representative of the entire process. This then enables the apparatus to subsequently monitor each performance of the process, both in terms of the motion sensor data generated and also the components used, to a) provide a complete record of each performance of the process (for future analysis), and b) enable each process cycle to be tracked in real time and errors/anomalies to be detected and alerts generated.

Thus, in an exemplary embodiment, the control unit and/or management system may be configured, in an operational mode, to receive real-time motion sensor data representative of each performance of a process, and, optionally, store said motion sensor data in the form of a respective data set representative of each performance of said process. The control unit and/or management system may, in said operational mode, be further configured to compare said real-time motion sensor data with stored motion sensor data, and generate an alert in the event that said real-time motion sensor data varies by a predetermined amount from said stored motion sensor data. The alert may, for example, comprise a local alert, provided on said wearable control unit, in the form a visual indicator, an audible indicator and/or a tactile (e.g. vibrational) indicator provided to the user. However, in addition or alternatively, the indicator may be provided at a remote location to a supervisor or other manager.

The apparatus may further comprise a scanning device for scanning an identifier of a component used in the performance of a process and provide to said control unit and/or management system real-time component data representative of said identifier, said control unit and/or management system being configured to, in said operational mode, compare said real-time component data with said stored component data and generate an alert if said real-time component data does not match said stored component data. Once again, such an alert may be provided locally, to the user, and/or remotely to a supervisor or manager.

The scanning device may be provided in or on the wearable control unit and/or the wearable sensor unit. The control unit and/or management system may be configured to monitor the real-time motion sensor data and, in the event that the motion sensor data is interrupted for a predetermined period of time and/or changes abruptly, indicative of a user emergency, generate an alert.

The apparatus may be configured to collect real-time motion sensor data and/or realtime component data for storage in the form of real-time process cycle records.

The wearable sensor unit may comprise at least one motion sensor adapted to be mounted on a respective at least one user finger. Indeed, a plurality of motion sensors may be provided, with each motion sensor being mounted on a respective one of the user’s fingers. The wearable control unit may comprise attachment means for mounting the control unit around a user’s limb or torso.

The wearable control unit and the wearable sensor unit may be adapted for wireless data communications therebetween. However, in an alternative exemplary embodiment, a hard wired data connection may be provided between the or each motion sensor and the control unit. The control unit may be adapted for wireless data communications with a remote management system.

Brief Description of the Drawings

These and other aspects of the present invention will be apparent form the following specific description, in which embodiments of the present invention are described, by way of examples only, and with reference to the accompanying drawings, in which:

Figure 1 is a schematic block diagram of a process monitoring apparatus according to an exemplary embodiment of the present invention;

Figure 1a is a schematic block diagram of a control unit of process monitoring apparatus according to an exemplary embodiment of the present invention;

Figure 1b is a schematic block diagram of a control unit of process monitoring apparatus according to an exemplary embodiment of the present invention;

Figures 2a and 2b are front and rear illustrations respectively of a wearable unit of process monitoring apparatus according to an exemplary embodiment of the present invention;

Figure 3 is a schematic rear view of a wearable unit of process monitoring apparatus according to an exemplary embodiment of the present invention;

Figure 4 is a schematic rear view of a wearable unit of process monitoring apparatus according to another exemplary embodiment of the present invention;

Figure 5 is a schematic rear view of a wearable unit of process monitoring apparatus according to another exemplary embodiment of the present invention;

Figure 6 is a schematic view of a wearable unit of process monitoring apparatus according to yet another exemplary embodiment of the present invention;

Figures 7a and 7b are schematic rear views of wearable units of process monitoring apparatus according to another exemplary embodiment of the present invention;

Figure 8 is a schematic rear view of a wearable unit of process monitoring apparatus according to another exemplary embodiment of the present invention;

Figure 9 is a schematic rear view of a wearable unit of process monitoring apparatus according to another exemplary embodiment of the present invention;

Figure 10 is a schematic flow diagram illustrating a method performed by a computation unit of apparatus according to an exemplary embodiment of the present invention;

Figure 10A is a schematic flow diagram illustrating a process flow performed by the control unit to enter the “Learning” mode;

Figure 10B is a schematic flow diagram illustrating a process flow performed by the control unit in the “Learning” mode;

Figure 10C is a schematic flow diagram illustrating a process flow performed by the control unit to enter the “Operational” mode;

Figure 11 is a schematic flow diagram illustrating a method performed by a data management system of apparatus according to an exemplary embodiment of the present invention;

Figure 11A is a schematic flow diagram illustrating a process flow performed by the control unit in the Operational” mode; and

Figure 12 is a schematic block diagram of a Wearable Control Unit and Wearable Sensor unit of a process monitoring apparatus according to an exemplary embodiment of the present invention

Detailed Description

Referring to Figure 1 of the drawings, a process monitoring apparatus according to an exemplary embodiment of the present invention comprises a wearable unit 1, comprising a wearable control unit 10, in this case embodied in the form of a wrist band, and a wearable sensor unit 12, in this case embodied in the form of a glovelike garment.

Referring to Figure 1a of the drawings, the control unit 10 comprises (at least) a sensor module 14, a microcontroller(and/or microprocessor, and/or FPGA, and/or custom designed processor(s)) 16 and a memory module 18 (and/or a peripheral device). In an exemplary embodiment, the control unit may be mounted in or on a plastic/rubber-based wrist wrap or a textile wrist wrap, for example. However, the present invention is not necessarily intended to be limited in this regard and, in other exemplary embodiments, the control unit 10 may be embodied in a different type of wearable structure, such as, for example, a belt-like unit configured to be worn around a user’s waist, elbow, knee, etc. Referring to Figure 1 b of the drawings, a control unit 10 may comprise a processing unit, a power management module, a memory, display, hard drive, communications devices, etc., a battery and a wireless charging means. However, the present invention is not intended to be specifically limited in this regard.

Optional Elements for Figure 1b (the Control Unit):

Processing Unit: Processor, microcontroller, FPGA, DSP, custom designed device. It may include RAM, ROM, and RTC internally or externally. It may include an operating system.

Display: CRT, LCD, OLED, LED, liquid crystal, touch screen, AMOLED, EPD, QDLED, IMOD

Communication Device: Wireless radios using EM waves (such as Wi-Fi, Bluetooth), visible or invisible light, ultrasound, wired communication devices (LAN, RS232, RS485, and etc.)

Battery Management: AC-DC converters, DC-DC converters, chargers, battery backup devices, regulators, battery monitors, switches, current sensing, voltage and current references, limiters

Others: Satellite navigation devices (such as GPS, GLONASS, GALILEO, BEIDOU and etc.), electrical and mechanical switches and buttons, external sockets for additional memory or devices, active or passive antennas, indication LEDs, buzzer, vibration devices, communication adapters (RS232, RS485, LAN, and etc.), database adapters, fiber optic adapters

Referring to Figures 2a and 2b of the drawings, the sensor unit 12 may be embodied in a glove-like garment comprising a flexible panel 12a, configured to cover a user’s palm in use, with an integral edge portion 12b at the top defining a set of individual sheaths 18 to receive a user’s respective fingers. The flexible panel 12a may be formed of any flexible (e.g. textile) material, and the integral edge portion 12b and sheaths 18 may be formed of a resiliently flexible material such as, for example, polyurethane-based synthetic fibre, to provide a comfortable but tight fit around the user’s fingers, without unduly constricting their movement. However, the present invention is not necessarily intended to be limited in this regard. In use, the panel 12a covers a user’s palm, and the edge portion 12b spans their metacarpophalangeal joints, with their fingers protruding through respective sheaths 18, such that the tips of their fingers above the knuckles are uncovered and able to move freely. The user’s thumb is also uncovered, in this exemplary embodiment, and the panel 12a is shaped, adjacent the thumb, to leave the base of the thumb free and unencumbered to flex as required.

Referring to Figure 3 of the drawings, a motion sensor 20 is mounted in or on each sheath 18 and configured to communicate motion data representative of movement of the user’s fingers to the control unit 10, as will be described in more detail later. Each motion sensor 20 may, for example, comprise a magnetometer, accelerometer or gyroscope, or combinations of these, although other suitable types of motion sensors may be apparent to a person skilled in the art and the present invention is not necessarily intended to be limited in this regard.

As stated above, the control unit 10 is embodied in a wearable band. The band may incorporate a strip or layer of polyurethane-based synthetic fibre as well as a textile layer, and may include an edge strip of hook or loop type material. A cuff member, formed of cooperating hook or loop type material may be provided on the sensor unit 12 such that the sensor unit 12 and control unit 10 can be detachably connected together at the user’s wrist, in use. The control unit 10 may include a visual display unit 21 for displaying/communicating information to the user. It may, for example, include a touchscreen display, and/or button, and/or vibration unit, and/or rotating bezel, etc. for enabling user interaction.

Referring back to Figure 1 of the drawings, the apparatus further comprises a computation unit 2, a data management system 3 and a user interface 4. These elements are likely to be remote from the wearable device comprising the control unit 10 and sensor unit 12, and the control unit may be configured for two-way communication (wired or wireless) with the computation unit 2, the data management system 3 and/or the user interface 4, as will be described in more detail hereinafter.

It will be understood by a person skilled in the art that the sensor unit may be configured as required, according to the processes required to be monitored. Thus, referring to Figure 4 of the drawings, the sensor unit 12 could include sheaths 18 (incorporating respective sensors 20) for just the thumb, forefinger and middle finger of the user, leaving their ring finger and little finger free. However, other sensor configurations, including one or a combination of user digits, are envisaged and the present invention is not intended to be limited in this regard. In another exemplary embodiment, as illustrated in Figure 5 of the drawings, the sensor unit 12 may include sheaths 18 (incorporating respective sensors 20) for the user’s thumb as well as all four of their fingers. Indeed, in this case, the glove-like structure may incorporate a panel covering the back of the hand, such that the garment resembles a fingerless glove on both sides. In yet another exemplary embodiment, the sensors may be incorporated in a glove-like garment, wherein the fingers (including the tips) are completely covered, and motion sensors embedded or otherwise incorporated at appropriate locations therein/thereon.

Whilst the wearable unit of the present invention has thus far been described with the control unit in the form of a wearable wrist band, the present invention is not necessarily intended to be limited in this regard. Referring to Figure 6 of the drawings, the control unit 10 may be worn elsewhere on the user’s body (in this case on a belt-like garment worn around the user’s waist) and motion sensors 20 may be mounted or worn on other parts of their body, e.g. their arms and/or legs, instead of (or as well as) their fingers.

In all cases, raw sensor data generated by the sensors 20 in response to movement of the user’s hands/fingers/arms/legs etc (depending on where the sensors are located in use) is transmitted to the sensor module 14 of the control unit 10 and is read thereby. The apparatus may incorporate means (integrated or associated with the motion sensors) to continuously generate additional data associated with the motion data, such as location, orientation and speed data. This additional data is also transmitted to the sensor module 14 of the control unit in association with the raw motion data. Thus, for each process step performed by the user, the sensor module 14 receives real time data that is accurately representative of the precise movement performed by the user (and not just the end result, i.e. the performance of the process step). This real time data, thus read and compiled by the sensor module into data sets, is then compressed before transmission thereof to the computation unit 2. Sensor data (including the above-mentioned additional data) may be transmitted to the sensor module 14 of the control unit 10 by any of a number of wired or wireless data transmission methods. For example, in its simplest form, and as illustrated in Figures 7a and 7b of the drawings, a serial (or even parallel) data communications cable may be utilised, whereby a single cable 22 is connected between the sensor module 14 and a respective sensor 20. In another exemplary embodiment, as illustrated in Figures 8a and 8b ofthe drawings, the sensor module 14 of the control unit 10 may be connected to the (or each) sensor 20 by means of a strain gauge and wire arrangement 24. In another exemplary embodiment (such as that of Figure 6 or as illustrated schematically in Figures 9a and 9b ofthe drawings), a wireless data transmission protocol may be used to transmit sensor data from the sensor(s) 20 to the sensor module 14 of the control unit 10. In yet another exemplary embodiment, sensor data may be wirelessly transmitted to the sensor module 14 of the control unit 10 by means of magnetic induction. Other forms of data transmission, wired or wireless, for transmitting sensor data from the sensor(s) 20 to the sensor module 14 will be apparent to a person skilled in the art, and the present invention is not necessarily intended to be limited in this regard.

The apparatus (i.e. the control unit and/or the data management system) has two modes of operation, namely a “learning” mode and an “operational” mode. Referring to Figure 10A ofthe drawings, the data management system (DMS) 3 sends a “Setup” command to the microcontroller 16, also referred to herein as the computational unit (CU). In order to enter the “Learning” mode, the CU must first ensure that the sensors 20 in the sensor module 14 (also referred to herein as the Wearable Sensor Unit (WSU)) and the control unit 10 (also referred to herein as the Wearable Control Unit (WCU)) are properly calibrated and, if they are not, this is done first. Schematic block diagrams of the WCU and WSU are provided in Figure 12 of the drawings, and options for each of the elements thereof is provided hereinafter. In the learning mode, the system effectively ‘learns’ the data set representative of a process comprising a complete set of process steps. Referring to Figures 10A and 10B ofthe drawings, during a learning process, an authorised user may first (at step 100) enter or select and identifier representative of the process to be stored. Next, at step 102, the authorised user, wearing the wearable unit 1, performs the process at least once, and preferably a number of times. The sensor readings obtained continuously (i.e. location, motion, speed, orientation, etc) are received from the computation unit 2 in the form of data sets, each data set being representative of the entire set of movements involved in each performance of the process. At this stage, the authorised user may select (at step 104) the ‘best’ performance of the process and select that respective data set to be stored by the data management system 3 in association with the process identifier. Alternatively, a data set comprising ranges of sensor readings obtained during repeated performance of the process may be stored to represent the process in the data management system 3. Using multiple instances of the same process, the system 3 analyzes the range of movements and determines (at step 106) which parts of the activity are process related and which are not process related, and also identifies the start and end of the process. Then, at step 108, it calculates a process cycle time based only on the process related activity. Subsequently, and if required, an authorized user can re-assign elements of the data set as process related or not. Indeed, it is envisaged, at least in some exemplary embodiments, that settings will be able to be entered manually in order, for example, to calibrate the system. Once the process has been learned, the learning mode ends, an associated user and job profile is created and saved. The system can then either be used to ‘learn’ another process or it can be switched (at step 110) to “operational” mode. Referring to Figure 10C of the drawings, once the system is configured, it can enter the “Operational” mode.

In addition to a complete set of movement data, component identifiers may also be associated with one or more of each step in the process and included in the ‘learned’ data set. Thus, for example, RFID (or other readable) tags may be provided in each location of a stock area, each tag being representative of an associated component identifier. The sensor unit 12 may then incorporate a tag reading device which is communicably coupled to the computation unit 2.

The computation unit 2 is communicably coupled, by wired or wireless data communication means, to the wearable unit, the data management system 3 and the user interface 4. As explained above, it receives the raw sensor data from the control unit 10 of the wearable unit 1. It also receives, or otherwise accesses, the stored data set for a specified process. Thus, the computation unit 2 has access to the range of motion data associated with a process, the component identifier(s) associated with each step of the process, and data representative of a process cycle time. Referring to Figures 11 and 11A of the drawings, in use and for each instance of the process, the computation unit 2 receives (at step 200) sensor data from the control unit 10 of the wearable unit 1. Using the data set received/accessed from the data management system 3, it monitors the incoming sensor data against the data in the data set as the process is being performed. In other words, it ‘tracks’ (at step 202a) the progress of the process using the incoming sensor data against the stored data set. It also stores (at step 202b) the incoming sensor data in the memory module 18 (i.e. the CU stores all data in the data management system).

During the tracking stage, the computation unit 2 utilises machine learning, neural networks, and/or artificial intelligence (Al) algorithms to monitor the user’s movements (derived from the motion and additional data) for any abnormal movements (step 204) and, if such abnormal movement is detected, generates an alert (step 206). In other words, each movement performed by the user is compared with the respective ‘taught’ movement for that stage of the process and any deviation therefrom (or deviation by a predetermined amount) causes an alert to be generated. Users (e.g. operator, technical engineer, manager, etc can subscribe to two kinds of alerts he/she wants to receive by using a uer interface 4. When an event has occurred which requires an alert, the system sends a notification to users over a dashboard, smartphone application, email, wearable unit, phone call, text/chat message, etc., although the present invention is not strictly intended to be limited in this regard and other forms of notification will be apparent to a person skilled in the art.

Furthermore, the computation unit 2 monitors incoming component identifiers (indicative that a user has selected a component for use in the process), compares (at step 208) the identifier data against the learned process data set, which includes such identifier data and the stage in the process at which the respective component is required, and, if the received identifier data does not match the identifier data specified for that stage of the process in the associated learned data set, it generates an alert (step 210), thus catching quality errors in real time. When each process is complete, the computation unit 2 calculates (at step 212) the process cycle time.

As stated above, the computation unit 2 stores the incoming sensor data in the memory module 18 and/or data management system 3. It also stores the calculated process cycle time associated with each occurrence of the process, and any alerts that were generated during performance of a process (together with data representative of the cause of the alert).The stored data for each occurrence of the process may be transmitted to the data management system 3 (in “operational” mode) for longer term storage. This cumulative data can subsequently be analysed on a larger scale for use in process improvement strategies and other business decisions. Thus, the main task of the data management system 3 in “operational” mode, is to store the learned data sets associated with specified processes, store the data output by the computation unit 2, and store system and user specific settings. Storage of such data may be achieved in a local server or in the Cloud, or both using different storage formats. However, the data management system 3 is further configured to ‘learn’ when in “operational” mode, by monitoring the incoming sensor data from each occurrence of the process and adjust the associated data set/process cycle time accordingly. Ergonomic movements can be learned, through successful repeated performance of a process, and new data sets generated, as well as providing useful training data for future use. Training data may be exported to other elements of the system. In addition, training data may be used as input to algorithms running in the system.

The user interface 4 may comprise a central dashboard and/or individual user dashboards, depending on the configuration of the system and user requirements. By means of the user interface 4, users and/or managers can select which alerts should be raised and to which user access levels. Individual user dashboards can be used to alert respective users to abnormal movements or inaccurate component selection. This may be achieved by a warning on a local screen and/or an audible alert. Indeed, in some exemplary embodiments, the control unit 10 may be caused to vibrate, for example, and/or information displayed on a (e.g. touchscreen) display, in the event that an abnormality is detected. Furthermore, via the data management system 3, a user (or authorised user) can select and configure reports to be generated and displayed on individual user dashboards and/or a central dashboard. The user interface 4 is further configured to enable users (or authorised users) to set system parameters and/or re-assign parts of a process data set as process related or not. Mobile apps, phone calls, direct messages, etc can also be used here. Quality/efficiency targets can be set and monitored, as required. Furthermore, cumulative alert/quality data is stored by the data management system 3 and can be used to generate quality control reports for use in process improvement strategies and problem identification.

The control unit 10 of each wearable unit 1 may be configured for two-way communication with each other control unit 10 within a defined area. Antennas may be provided around the working environment, such that each user location can be detected. In the event that a user falls or loses consciousness, the apparatus can detect a catastrophic abnormality, and generate an alert for detection by a nearby user.

Thus, more generally, aspects of the present invention provide a performance monitoring and control system including a wearable unit, that can be used to measure process cycle times, monitor for quality errors, extraordinary and, potentially, catastrophic events. The does not just learn each step of a process, as in prior art systems, but generates and stores a data set representative of an entire process, including the movements between “steps”. This data set is used to monitor the ongoing (repeated) performance of the process. The system is further configured to monitor the ongoing (repeated)performance of the process by one or multiple users, and adjust the Optimum’ data set over time, with a view to optimising the process and process cycle times. Thus, the system is configured to ‘track’ each user’s movements and ‘learn’ the optimum data set associated with a process, as well as reporting any unusual, non-routine movements. Each wearable unit may be configured for two-way communication with the other wearable units within a region, thereby enabling the provision of a safety and wellbeing function, whereby if the system detects that a user is compromised, nearby users can be alerted. Ongoing data representative of the repeated performance of a process can be visualised, using Gantt charts, histograms, scatter plots, matrix plots, dot plots, probability distribution plots, box plots, interval plots, line plots, pie charts, time series plots, spider plots, etc, as well as providing statistical analysis, e.g. regression analysis, control charts, hypothesis tests, anova analysis, variable and gage R&R and control charts.

Optional elements for Figure 12 (Wearable Control unit and Wearable Sensor Unit):

Possible sensors:

Motion sensing and detection: Accelerometer, gyroscope sensor, inertial sensors

Auxiliary sensors: Temperature, pressure, gas, radiation, electromagnetic, chemical hazard, light, magnetic, hall effect, UV, proximity, electric field, acoustic, sound, vibration, finger print

Display: LCD, OLED, LED, liquid crystal, touch screen, AMOLED, EPD, QDLED, IMOD

Communication Device: Wireless radios using EM waves (such as Wi-Fi, Bluetooth), visible or invisible light, ultrasound, wired communication devices

Others: Satellite navigation devices (such as GPS, GLONASS, GALILEO, BEIDOU and etc.), electrical and mechanical switches and buttons, external sockets for additional memory or devices, active or passive antennas, indication LEDs, buzzer, vibration devices

Pre-Processing: The data from sensors can be processed before sending to WCU. The pre-processing can be either analog or digital. For analog processing, analog

ICs (such as operational amplifiers, mixers, active filters, limiters) and passive structures (such as filters, attenuators, phase shifters) can be used. For digital processing, digital processors such as microcontroller, FPGA, DSP, and other digital ICs can be used.

It will be apparent to a person skilled in the art, from the foregoing description, that modifications and variations can be made to the described embodiments without departing from the scope of the invention as defined by the appended claims.

Claims

1. A process performance monitoring apparatus, comprising:

- a wearable control unit;

- a wearable sensor unit comprising one or more motion sensors; and

- a management system configured, in a learning mode, to:

2. Apparatus according to claim 1, wherein the management system is further configured, in said learning mode, to receive and store component data representative of one or more components used in said process, and where in said process cycle said one or more components are used.

3. Apparatus according to claim 1 or claim 2, wherein the control unit and/or management system is configured, in an operational mode, to receive realtime motion sensor data representative of each performance of a process.

4. Apparatus according to claim 3=, wherein said control unit and/or management system is configured to store said motion sensor data in the form of a respective data set representative of each performance of said process.

5. Apparatus according to claim 3 or claim 4, wherein the control unit and/or management system is, in said operational mode, further configured to compare said real-time motion sensor data with stored motion sensor data, and generate and generate an alert in the event that said real-time motion sensor data varies by a predetermined amount from said stored motion sensor data.

6. Apparatus according to any of the preceding claims, further comprising a scanning device for scanning an identifier of a component used in the performance of a process and provide to said control unit and/or management system real-time component data representative of said identifier, said control unit and/or management system being configured to, in an operational mode, compare said real-time component data with said stored component data and generate an alert if said real-time component data does not match said stored component data.

7. Apparatus according to claim 6, wherein said scanning device is provided in or on the wearable control unit and/or the wearable sensor unit.

8. Apparatus according to any of the preceding claims, wherein the control unit and/or management system is configured to monitor the real-time motion sensor data and, in the event that the motion sensor data is interrupted for a predetermined period of time and/or changes abruptly, indicative of a user emergency, generate an alert.

9. Apparatus according to any of the preceding claims, adapted or configured to collect real-time motion sensor data and/or real-time component data for storage in the form of real-time process cycle records.

10. Apparatus according to any of the preceding claims, wherein the wearable

5 sensor unit comprises at least one motion sensor adapted to be mounted on a respective at least one user finger.

11 .Apparatus according to any of the preceding claims, wherein the wearable control unit comprises attachment means for mounting the control unit around a user’s limb or torso.

io

12. Apparatus according to any of the preceding claims, wherein the wearable control unit and the wearable sensor unit are adapted for wireless data communications therebetween.

13. Apparatus according to any of claims 1 to 11, wherein a hard wired data connection is provided between the or each motion sensor and the control

15 unit.

14. Apparatus according to any of the preceding claims, wherein the control unit is adapted for wireless data communications with a remote management system.