Manufacturing system with an interconnected storage structure and manufacturing cells sharing a common robotic fleet

A manufacturing system comprising:

• a storage arrangement comprising:
• an automated storage and retrieval system (ASRS) structure comprising a three-dimensional array of storage locations distributed throughout a two-dimensional footprint of the ASRS structure at a plurality of storage levels within the ASRS structure, wherein the ASRS structure further comprises at least one track-equipped level comprising a two-dimensional gridded track layout;
• a supply of workpieces, toolpieces, and workpiece supports stored within the storage locations of the ASRS structure for use in manufacturing goods;
• and
• a fleet of robotic storage/retrieval vehicles navigable within the ASRS structure in at least two dimensions on the two-dimensional gridded track layout, each of said robotic storage/retrieval vehicles configured to carry storage units of compatible size and shape for storage in the storage locations of the ASRS structure, the storage units configured to hold at least the workpieces and tool pieces;
• a plurality of manufacturing cells positioned outside the ASRS structure, wherein each of the manufacturing cells comprises a plurality of modular components, the manufacturing cells configured in a continuous arrangement outside the ASRS structure, wherein the storage units are transferred to and from the storage locations of the ASRS structure and between the manufacturing cells, free of identification or scanning of the storage units, based on the continuous arrangement of the manufacturing cells;
• a track structure connected to the ASRS structure and laying out travel paths traversable by the robotic storage/retrieval vehicles from the ASRS structure, wherein at least a subset of the manufacturing cells is positioned along the track structure;
• and
• a computerized control system in operable communication with each of the storage/retrieval vehicles, the computerized control system configured to orchestrate movement of the storage/retrieval vehicles on a two-dimensional gridded track structure interconnecting each of the manufacturing cells and the ASRS structure, the computerized control system further configured to deliver the storage units just-in-time, grouped based on a work order, and in a specific sequence to the manufacturing cells for just-in-time manufacturing of subassemblies at any stage a manufacturing process:
• the manufacturing system configured to facilitate transportation of the workpieces, toolpieces, and workpiece supports between the manufacturing cells in any order and any sequence, instead of linearly with conveyors, thereby allowing any number of manufacturing processes to be completed multiple times in any order.

A method for executing a workflow in a manufacturing system, the method comprising:

• (i) in an automated storage and retrieval system (ASRS) structure of the manufacturing system, storing workpieces, toolpieces, and workpiece supports in respective storage locations of the ASRS structure, wherein the workpieces are stored in workpiece storage units at the storage locations, and the toolpieces are stored in toolpiece storage units at the storage locations;
• (j) using a fleet of robotic storage/retrieval vehicles navigable within the ASRS structure, extracting the workpiece storage units and selected workpiece supports from the ASRS structure according to requirements of manufacturing processes to be performed at manufacturing cell, positioned outside the ASRS structure and in a neighboring relation to the ASRS structure, and separately delivering the workpiece storage units and the selected workpiece supports to the manufacturing cells, free of identification or scanning of the storage units, based on the continuous arrangement of the manufacturing cells;
• (k) at each of the manufacturing celli, positioning the selected workpiece supports in working positions accessible by workers of the manufacturing cells;
• and
• (l) at each of the manufacturing cells, with the selected workpiece supports maintained in the working position:
• (i) transferring the workpieces from the workpiece storage units onto the selected workpiece supports, and
• (ii) performing process steps of the manufacturing processes on the workpieces held on the selected workpiece supports;
• (m) orchestrating, by a computerized control system, movement of the storage/retrieval vehicles on a two-dimensional gridded track structure interconnecting each of the manufacturing cells and the ASRS structure and deliver the storage units just-in-time, group based on a work order, and in a specific sequence to the manufacturing cells for just-in-time manufacturing of subassemblies at any stage a manufacturing process;
• and
• (n) facilitating transportation of the workpieces, tool pieces, and workpiece supports between the manufacturing cells in any order and any sequence, instead of linearly with conveyors, thereby allowing any number of manufacturing processes to be completed multiple times in any order.