Patent ID: 8108061

Claim:
A system for minimizing disruptions in a manufacturing assembly line, the assembly line including a plurality of workstations sequentially arranged so as to progressively assemble a product from a part, and a transfer system for automatically transferring a part between workstations, wherein each of the plurality of workstations is equipped with tools and a sequence of processes so as to accomplish a predetermined task, the system comprising: 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.