Method for dynamically controlling a manufacturing process using product over-delivery

A method for controlling an output of a computerized manufacturing process, the method comprising:

• storing a product target parameter (TW) for a unit process in a computer memory of a computer system associated with manufacturing process equipment;
• storing control limit values (CL) in the computer memory for a product delivery statistic (Ra) of the product target parameter (TW);
• storing a unit product over-delivery target parameter (OT);
• monitoring a product delivery parameter (LW) for the unit process and continually storing values in the computer memory for the product delivery parameter and a sequence number of unit products produced;
• determining a cumulative over-delivery amount (BO) in the processor of the computer system by summing the difference between the product delivery parameter (LW) and the product target parameter (TW) for a number of product units previously produced up to a current sequence number;
• determining a net difference between the cumulative over-delivery amount (BO) and the unit product over-delivery target parameter (OT) in a processor of the computer system;
• providing a predetermined modifier (CLAM) that represents a fractional amount of the unit product over-delivery target parameter (OT) and adjusting the net difference by the predetermined modifier to obtain a control limit adjustment (CLA);
• adjusting the control limit values (CL) by the control limit adjustment (CLA) to obtain adjusted control limits;
• and
• using the computer to regulate product delivery to a staging system within the manufacturing process, so as to maintain the product delivery statistic (Ra) within the adjusted control limits for the unit process.

A method for controlling a continuous manufacturing process comprising:

• determining a cumulative over-delivery amount by summing a difference between a measured parameter for a number of previously produced unit products from a unit process and a target parameter for the unit process;
• determining a net difference between a target over-delivery amount and the cumulative over-delivery amount;
• and
• adjusting process control limits (CL) for a product delivery statistic of the unit products by providing a predetermined modifier (CLAM) that represents a fractional amount of the target over-delivery amount and multiplying the net difference by the predetermined modifier (CLAM) to obtain adjusted control limits for the unit process.