Source: http://www.google.com/patents/US8108061?dq=Etreppid+Technologies,+LLC
Timestamp: 2015-05-29 10:51:46
Document Index: 588639976

Matched Legal Cases: ['art.\n9', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'arts 16', 'art 16', 'arts 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'arts 16', 'art 16', 'arts 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16', 'art 16']

Patent US8108061 - System and method for detecting part abnormality in a manufacturing assembly ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAccording to one aspect of the invention a system and method for minimizing assembly line manufacturing including an override is provided. Each workstation is equipped with a docking station. A first database is in communication with the programmable controller and the docking station, and the docking...http://www.google.com/patents/US8108061?utm_source=gb-gplus-sharePatent US8108061 - System and method for detecting part abnormality in a manufacturing assembly lineAdvanced Patent SearchPublication numberUS8108061 B2Publication typeGrantApplication numberUS 12/418,840Publication dateJan 31, 2012Filing dateApr 6, 2009Priority dateApr 6, 2009Also published asUS20100256793Publication number12418840, 418840, US 8108061 B2, US 8108061B2, US-B2-8108061, US8108061 B2, US8108061B2InventorsGary Lee, Bruce Peter Fleming, Chris Rudolf LoatesOriginal AssigneeToyota Motor Engineering & Manufacturing North America, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (10), Classifications (19), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetSystem and method for detecting part abnormality in a manufacturing assembly line
US 8108061 B2Abstract
According to one aspect of the invention a system and method for minimizing assembly line manufacturing including an override is provided. Each workstation is equipped with a docking station. A first database is in communication with the programmable controller and the docking station, and the docking station is also in communication with the workstation tools as well as the programmable controller. The override is disposed on a docking station. The system includes a checklist of tasks that each workstation tool is to perform. Accordingly the first database will receive the checklist for each part and will record whether or not each particular part had each of its tasks performed properly. The override may be actuated so as to allow a part to flow downstream the assembly line even though the all the tasks were not completed properly, thus minimizing manufacturing disruptions.
a programmable controller for actuating the tools in a predetermined manner and controlling the transfer of the part;
a first database in communication with the programmable controller;
a checklist including a list of tasks and sequence of processes to be performed at each workstation; and
at least one docking station selectively disposed along the assembly line, wherein each of the at least one docking station is in communication with each other, the workstation, the programmable controller, and the first database, and wherein the docking station monitors each of the workstation tools and compares the performance of each of the workstation tools with the checklist so as to determine if each of the workstation tools has completed its assigned task, the docking station including:
an interface having a first display for displaying the status of each task and a scanner in communication with the docking station, the scanner operable to obtain the identification of the user;
an override, wherein the override is operable to advance the part for further processing even though the workstation tasks have not been completed on the part, and wherein the docking station transmits the checklist information to the first database; and
a computer processing unit for processing the first database so as to create a report, the report including a record of the status of each part as the part leaves the workstation, and the identity of the operator who actuated the override.
2. The system as set forth in claim 1, wherein the interface includes an input device operable to provide information to the programmable controller, and wherein information received by the input device is transmitted to the first database.
3. The system as set forth in claim 2, wherein the interface is one selected from the group consisting of a touch screen, a keyboard, and a voice recognition device.
4. The system as set forth in claim 3, wherein the scanner is a card reader.
5. The system as set forth in claim 4, wherein the input device is a menu, and the menu presents a list of reasons for disabling a tool.
6. The system as set forth in claim 1, wherein the report further includes the reason why the override was actuated so as to allow the part to continue downstream the assembly line.
7. The system as set forth in claim 1, wherein the first display further includes a second display for displaying the report so as to provide a visual indication of the status of any of the parts which have not been properly assembled.
8. The system as set forth in claim 7, wherein the second display is a code so as to provide for easy recognition of the status of a particular part.
9. The system as set forth in claim 8, wherein the code is based upon color.
10. The system as set forth in claim 1, wherein the report further includes process abnormalities comprising tool malfunction, improper task performance by an operator, the occurrences of override actuation, and the reasons why the override was actuated.
11. A method for monitoring parts being assembled in workstations along an assembly line comprising the steps of:
establishing an assembly line by arranging workstations in a predetermined manner so as to complete a part in a logical and sequential manner;
tooling each of the workstations in the assembly line so as to enable a predetermined task to be accomplished at each of the workstations;
providing a transfer system to transfer a part between each of the workstations;
providing a programmable controller operable to control each the tools and the transfer system;
establishing a first database in communication with the programmable controller; and
providing a docking station in communication with the programmable controller and the first database, the docking station, wherein the docking station is in communication with each of the workstation tools;
providing a checklist including a list of tasks that each workstation tool is to perform, and wherein the docking station is also in communication with each of the workstation tools so as to determine if each of the workstation tools has completed its assigned task; and
providing an interface including a first display for displaying the status of each task, and an override, wherein the workstation operator is able to actuate the override so as to advance the part for further processing even though the workstation tasks have not been completed on the part; and wherein the docking station transmits the checklist information to the first database so as to create a record of the status of each part as the part leaves the workstation thereby recording which tool has not completed its assigned task.
12. The method as set forth in claim 11, further including the step of obtaining the identification of the person who actuated the override, wherein the identification of the person who actuated an override is stored in the first database.
13. The method as set forth in claim 12, further including the step of obtaining a reason for why the override was actuated, wherein the reason why the override was actuated is stored in the first database.
14. The method as set forth in claim 13, further including the step of reporting the actuation of an override along with the reason why the override was actuated so as to enable a operator to perform necessary tasks on the overridden part so as to ensure that the overridden part is properly assembled.
The present invention relates to a system and method for minimizing disruptions in a manufacturing assembly line due to defective parts, and improper installation and/or part assembly. More particularly the invention relates to a system and method for minimizing disruptions in a manufacturing assembly line by providing an override which allows a defective part to proceed along the assembly line. The system also identifies the operator who actuated the override and the reason the override was actuated is reported such that the defect may be later cured.
Assembly lines are used to mass assemble parts into a product such as a vehicle. Assembly lines are configured so as to sequentially and logically assemble the product from preassembled parts or raw material. It is common knowledge to establish an assembly line with a plurality of workstations. Each workstation performs a specific task that progressively assembles the finished product. Thus each workstation is tooled to accomplish its assigned task. As each workstation completes its assigned task, the part is transferred downstream the assembly line to the next workstation by a transfer system, such as a rail or a conveyor.
The workstation tools are usually monitored and controlled by a programmable controller (PC). The PC controls and detects the functions and operations of each tool so as to determine whether or not that workstation has properly completed its assigned task.
According to one aspect of the invention a system and method for minimizing disruptions in an assembly line manufacturing including an override is provided. The assembly line is controlled by a programmable controller (PC) which actuates the tools in a workstation in a predetermined manner. Each workstation is equipped with a docking station having an override. A first database is in communication with the PC and the docking station. The system also includes set of assembly instructions for assembling the part. The assembly instructions are provided to the PC and the first database.
FIGS. 3 a-3 e is a step-by-step illustration of how the docking station operates;
With reference to the figures a preferred embodiment of a system 10 for minimizing disruption in a manufacturing assembly line 12 is provided. With reference to FIG. 1, the manufacturing assembly line 12 includes individual workstations 14 arranged in a sequential manner so as to progressively assemble a product 16. Each workstation 14 is equipped with tools 18 so as to accomplish a predetermined task. The part 16 (shown as a vehicle) is automatically transferred along the assembly line 12 by a transfer system 22 such as a rail or a conveyor.
With reference now to FIGS. 3A-3E, the system 10 further includes a docking station 30 selectively disposed at a workstation 14 along the assembly line 12. The docking station 30 is in communication with the workstation 14 and monitors the workstation tools 18 so as to determine if the tasks assigned to the workstation 14 have been properly completed. Specifically, the docking station monitors the tools to determine if the tools have been used or are operating properly.
The docking station 30 further includes a first display 33. The first display 33 provides the status of each task assigned to the workstation 14. Specifically, the first display 33 provides all of the tools 18 of a particular workstation 14 (as indicated by the alphanumeric beginning with the letter “T”). The level of severity is indicated by a scale between “0” and “3”, wherein “0” indicates that the tool 18 is performing properly, and “3” indicates the most severe of tool 18 malfunctions. Accordingly, the display will alert the operator in the event that the workstation 14 task has not been completed.
The first display 30 may include a second display 34 that may be color coded so as to provide workstation 14 operators with the status of a particular part 16 as it is being processed along the assembly line 12. For instance, the second display may include a number of visual indicators corresponding to each tool or tools assigned to the workstation. The coding may be represented in red, green, and orange, wherein red indicates that the part 16 is not completed and the line will or has been stopped, green indicates that the part 16 is completed, and orange indicates that the part 16 is not completed but the line in progress, meaning that parts 16 are being automatically transferred downstream the assembly line 12.
With reference to FIG. 3 c, an override 32 is provided. The override 32 may be actuated so as to allow the system 10 to advance a part 16 downstream the assembly line 12 even though the tasks have not been satisfactorily performed at the workstation 14. Thus the override 32 helps minimize disruptions in the manufacturing process. Preferably the override 32 may also be operable to identify the person who actuated the override 32. For instance, the override 32 may be a magnetic card reader operable to read the identity of the card holder. In another embodiment, the override 32 is a button that is operable to obtain the fingerprint of a person. In yet another embodiment, the docking station 30 requests the identification of the operator before actuating the override 32.
With reference again to FIG. 2, the docking stations 30 are in communication with each other through a communication system 10 such as an internal Ethernet system 10 or other known communication systems. The status of each docking station 30 may be forwarded downstream, thus providing operators downstream with notice as to parts 16 or tasks which may need curing. It is also anticipated that the communication system 10 may interconnect the docking station 30 with the first database 26, and the PC 24. Thus, the PC 24 may be changed so as to reconfigure the tools 18 at each workstation 14.
The docking station 30 includes sensors (not shown) which detect the status and progress of the tools 18. A checklist 28 is provided for each workstation 14. The checklist 28 includes a list and sequence of tasks for each workstation 14. The checklist 28 may be updated when the tools 18 are reconfigured. The sensors provide information to the docking station 30 relating to tool 18 performance. Sensor information is compared with the checklist 28 to ensure that all the tasks of the checklist 28 have been completed. As the tools 18 perform their tasks, each task in the checklist 28 is checked off to show the progression of progress each tool 18 has made on a particular part 16 in a workstation 14.
The performance of the tools 18 may be represented in the first display 33 using the color or numeric code described above. As stated above, the second display 34 may be provide a green, an orange or red indicator to show the status of a particular tool 18. If a red indicator is provided, the line stops and the operator must either complete or correct the checklist items or actuate the override 32. The override 32 allows the part 16 to advance forward to the next workstation 14 downstream thereby preventing the disruption of a manufacturing process because of an abnormal process, an abnormal manufacturing of a particular part 16, or the failure of a operator to complete a task in accordance with the assembly instructions. An orange code provides notice that the override 32 was actuated and that the docking station 30 automatically forwarded the information downstream so as to provide workstations 14 downstream with an opportunity to cure the defective part 16.
With reference to FIG. 3 b, the docking station 30 may further include an interface 36 operable to provide feedback to the first database 26. The interface 36 may be a touch screen, and present a list of common reasons why the part 16 was advanced forward and the operator who actuated the override 32. The first database 26 collects and processes the information using a computer processing unit 38 so as to generate a report 40.
In one embodiment, the interface 36 ascertains the identity of the operator upon actuation of the override 32. The first display 33 presents a list of reasons for which the part 16 has been advanced. The docking station 30 then transmits the checklist 28 information to include the items on the checklist 28 which have been completed or not completed as well as the identity of the operator who actuated the override 32 when such an incident occurs and the reasons for actuating the override 32.
For instance, the interface 36 may include a touch screen menu 54 providing a predetermined list of reasons for advancing parts 16. The interface 36 may be operable to navigate the menu 54 so as to selectively choose from one of the predetermined reasons. Naturally, the docking station 30 may include both an interface 36 for manually entering a reason and a menu 54 having a predetermined list of reasons.
With reference to FIG. 4, an embodiment of a report 40 is provided. The report 40 includes a history of process abnormalities such as tool malfunction, improper task performance by an operator, the occurrences of override actuation, the identity of the operator who actuated the override 32 and the reasons why the override 32 was actuated. The report 40 is very useful in the maintenance of the assembly line 12. Specifically, tool history may be examined to determine if a particular tool 18 should be replaced, or to provide a repair-person with a clearer understanding of why the process abnormality occurred. Additionally, the report 40 will identify workstation operators who have actuated an override 32 and the reasons why the operator allowed the part 16 to continue downstream. This information may be useful in training workstation 14 operators.
In the event a process abnormality, the LED will emit a yellow or red color depending on how severe the process abnormality is. The first display 33 displays all of the tool 18 tasks associated with each of the workstation 14 tools 18, i.e. tighten seat belt bolt, instrument panel reinforcement (IPR) bolt, and the like. Thus, FIG. 3 a shows that the tool 18 tightening the seat belt bolt 1 has not performed properly, i.e. the bolt was not tightened to a predetermined torque. The workstation 14 operator may then select the tool 18 so as override the tool 18, while allowing other tools to continue performing.
With reference now to FIG. 3 b, the menu 54 is displayed on the first display 33. The menu 54 presents a predetermined list of reasons for why the tool 18 should be overridden. The workstation 14 operator simply selects one of the predetermined reasons. The menu 54 also includes another option by bypass, labeled “other.” Upon selection of “other” the workstation 14 operator may manually enter a detailed reason.
A method for monitoring parts 16 being assembled at a workstation 14 along an assembly line 12 is also provided. The method includes establishing an assembly line 12 by arranging workstations 14 in a predetermined manner so as to complete a part 16 in a logical and sequential manner and providing a rail or robot to automatically transfer the part 16 along the assembly line 12. The method includes tooling each of the workstations 14 in the assembly line 12 so as to enable a predetermined task to be accomplished at each of the workstations 14 and providing a programmable controller 24 operable to control each of the tools 18 and the transfer of the part 16 along the assembly line 12.
The docking station 30 includes an interface 36, a display for displaying the status of each task, and an override 32. The workstation 14 operator is able to actuate the override 32 so as to advance the part 16 for further processing even though the workstation 14 tasks have not been completed on the part 16. The docking station 30 then transmits the checklist 28 information to the first database 26 so as to create a record of the status of each part 16 as the part 16 leaves the workstation 14 thereby recording which tool 18 has not completed its assigned task.
The method can further include the step of obtaining the identification of the operator who actuated the override 32 and storing the identification of said operator in the first database 26. The method can also include the step of obtaining a reason for why the override 32 was actuated and storing the reason why the override 32 was actuated in the first database 26. The first database 26 can then report 40 out the identification of a part 16 which has not been properly completed and the reason why the part 16 was allowed to go downstream on the assembly line 12 and the reason why it was allowed to move downstream.
From the foregoing it can be seen that the present invention provides a system 10 and method for preventing and reducing the disruption of the manufacturing of a particular part 16 by allowing that particular part 16 to advance along an assembly line 12 despite the part 16 not being completed properly. Thus instead of disrupting the manufacturing process an isolated incident wherein a part 16 is not completed properly can be identified and corrected later thus preventing loss in cost and hours in the manufacturing of a product 16.
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