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US 11,703,829 B2Granted
Systems and methods for flexible modular assembly manufacturing
AssigneeFord Global Technologies, LLC
InventorMahmoud Yousef Ghannam
Life of this patent
Estimating the term…
Abstract
A system and method are described herein for tracking and instructing assembly of flexible modular products on a single assembly line. The systems enable methods for tracking components and procedures as well as tools used in the assembly of components using various sensors and devices along the line. The systems also enable methods for instructing and tracking usage of tools for procedures. Data from various sensors, stations, nodes, and relating to each particular assembly item are stored in a distributed ledger that is verified and secured for use as a production log including each action taken on the assembly item which may later be used for audit purposes as well as to increase confidence in the assembly of product variations on the assembly line.
Claims19
An assembly system for producing a plurality of product variations of a product, the assembly system comprising:
- a station having a plurality of tools for assembling the plurality of product variations of the product, wherein a set of tools is compatible with a specific product variation among the plurality of product variations, wherein each product variation is a different combination of (1) a first component selected among a plurality of first components, (2) a second component selected among a plurality of second components, and (3) a third component selected among one or more third components, wherein a first set of tools is compatible with a first product variation among the plurality of product variations of the product, and a second set of tools is compatible with a second product variation among the plurality of product variations of the product, wherein one of the first set of tools and the second set of tools include at least one tool that is not included in the other one of the first set of tools and second set of tools, wherein the station is configured to manufacture all product variations with different combinations of the first component, the second component and the third component;
- a conveyance system to carry an assembly item into and away from the station;
- a sensor positioned upstream of the station configured to detect the assembly item on the conveyance system and gather product identity data related to the assembly item;
- and
- a computing device comprising:
- a processor;
- and
- a non-transitory memory having instructions stored thereon that, when executed by the processor, cause the processor to:
- receive the product identity data of the assembly item from the sensor;
- determine that a product variation of the assembly item is the first product variation based on the product identity data;
- determine a procedure to perform at the station based on a station type and the first product variation;
- determine one or more tools of the first set of tools required for the procedure, wherein the one or more tools are compatible with the first product variation;
- generate an instruction, for display at the station, instructing selection of the one or more tools of the first set of tools;
- determine a used tool of the first set of tools at the station based on tool data;
- generate an audit log describing the used tool and the procedure performed at the station;
- and
- store the audit log in a distributed ledger with an identifier associated with the assembly item.
14 more elements
A method for assembling a plurality of product variations of a product on a conveyance system, the method comprising:
- receiving product identity data from a sensor positioned upstream of a station of the conveyance system;
- determining that a product variation is a first product variation among the plurality of product variations based on the product identity data, wherein each product variation is a different combination of (1) a first component selected among a plurality of first components, (2) a second component selected among a plurality of second components, and (3) a third component selected among one or more third components, wherein the station is configured to manufacture all product variations with different combinations of the first component, the second component and the third component;
- determining a procedure to perform at the station based on a station type and the first product variation;
- determining one or more tools required to perform the procedure, wherein a set of tools is compatible with a specific product variation among the plurality of product variations, wherein the one or more tools are among a first set of tools that is compatible with the first product variation among the plurality of product variations of the product, wherein a second set of tools is compatible with a second product variation among the plurality of product variations of the product, wherein one of the first set of tools and the second set of tools include at least one tool that is not included in the other one of the first set of tools and second set of tools;
- generating an instruction, for display at the station, instructing selection of the one or more tools from the first set of tools stored at the station;
- determining a tool selected at the station to perform the procedure;
- and
- storing an audit log in a distributed ledger, the audit log comprising the product identity data, the product variation, and the tool selected at the station.
5 more elements
A non-transitory computer-readable medium having instructions stored thereon that, when executed by one or more processors, cause the one or more processors to:
- receive product identity data for an assembly item from a sensor positioned upstream of an assembly station along a conveyance system;
- determine that a product variation is a first product variation among a plurality of product variations for the assembly item based on the product identity data, wherein each product variation is a different combination of (1) a first component selected among a plurality of first components, (2) a second component selected among a plurality of second components, and (3) a third component selected among one or more third components, wherein the station is configured to manufacture all product variations with different combinations of the first component, the second component and the third component;
- determine a procedure to perform at the assembly station based on a station type of the assembly station and the first product variation;
- determine one or more tools of a set of tools stored at the assembly station required to perform the procedure, wherein a set of tools is compatible with a specific product variation among the plurality of product variations, wherein the one or more tools are among a first set of tools that is compatible with the first product variation among the plurality of product variations, wherein a second set of tools is compatible with a second product variation among the plurality of product variations, wherein one of the first set of tools and the second set of tools include at least one tool that is not included in the other one of the first set of tools and second set of tools;
- generate an instruction, for display at the assembly station, instructing selection of the one or more tools from the first set of tools stored at the assembly station;
- determine a tool selected at the assembly station to perform the procedure;
- and
- store an audit log in a distributed ledger, the audit log comprising the product identity data, the product variation, and the tool selected.
5 more elements
Dependencies are inferred from the claim text.