Disposable product assembly systems and methods

Abstract

A machine for producing disposable products anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. An integrated production facility layout automatically orders and stocks raw material based on production plans, and commands a production machine to produce specific products of differing configurations, and automatically loads appropriately sized raw materials into the process.

We claim: 
     
         1 . A system for manufacturing disposable products, the system comprising:
 a production machine for producing a first configuration of disposable products and a second configuration of disposable products;   a first set of material rolls configured to produce said first configuration of disposable products;   a second set of material rolls configured to produce said second configuration of disposable products;   a controller communicatively coupled to said production machine;   said controller receiving a plurality of input signals, and, based upon said input signals, generating an output signal controlling whether said first configuration or said second configuration of disposable products is produced by said production machine;   said controller selectively coupling at least one of said first set of material rolls and said second set of material rolls with said production machine based upon at least one of said input and output signals, to selectively produce said first and said second configurations of disposable products.   
     
     
         2 . A system according to  claim 1 , wherein said input signals comprise at least one of scheduling input, sales and marketing input, purchasing input, receiving input, warehousing input, production input, maintenance input, shipping input, and accounting input. 
     
     
         3 . A system according to  claim 2 , said scheduling input reactive to at least one of sales and marketing input and purchasing input. 
     
     
         4 . A system according to  claim 1 , said first set of material rolls comprising a plurality of new material rolls having a first roll width, and said second set of material rolls comprising a plurality of new material rolls having a second roll width, said second roll width larger than said first roll width. 
     
     
         5 . A system according to  claim 1 , said first configuration of disposable products comprising disposable products having a first product width, said second configuration of disposable products comprising disposable products having a second product width, said second product width larger than said first, product width. 
     
     
         6 . A system according to  claim 1 , said system further comprising:
 a first turret unwind system carrying at least one material roll of said first set of material rolls;   a second turret unwind system carrying at least one material roll of said first set of material rolls;   said controller receiving input of machine speed, input of consumption of raw material, input of material remaining on each said turret unwind, and based upon said input, coupling at least one material roll of said second set of material rolls to said first turret unwind system, and coupling at least one material roll of said second set of material rolls to said second turret unwind system.   
     
     
         7 . A system according to  claim 1 , said system further comprising:
 a second production machine for producing said first configuration of disposable products; and   said second configuration of disposable products, said second production machine communicatively coupled to said controller.