Method and system for real-time statistical process monitoring

A method of monitoring the operation of a stamping press for forming parts, the method comprising:

• operating the stamping press so as to produce a predetermined number of baseline parts while collecting a set of baseline process signatures for each part;
• defining a plurality of features based on the set of baseline process signatures for each part, each feature representing a parameter incapable of being directly measured by a single sensor associated with the process of forming the parts;
• establishing operating limits associated with each of the features based on the set of baseline process signatures for each part, the operating limits representing limits within which the process is in control or producing acceptable parts;
• operating the stamping press so as to produce a plurality of predetermined number of production parts while collecting a set of production process signatures for each part;
• extracting feature values from the set of production process signatures in real-time to obtain a corresponding set of production feature values;
• comparing the set of production feature values to the operating limits;
• and
• detecting an out-of-control process or the formation of unacceptable parts based on the comparison for the purposes of process control.

For use with a stamping press for forming parts, a system for monitoring the process of forming the parts, the system comprising:

• means for collecting a set of production process signatures for each part while the stamping press is operating and producing a predetermined number of production parts;
• means for defining a plurality of features based on the set of production process signatures, each feature representing a parameter incapable of being directly measured by a single sensor associated with the process of forming the parts;
• means for extracting feature values from the set of production process signature in real-time to obtain a corresponding set of production feature values;
• and
• means for comparing the set of production feature values to predetermined operating limits in real-time, the operating limits representing limits within which the process is in control or acceptable parts are formed, for the purpose of process control.