Systems and methods for flexible modular assembly manufacturing
AssigneeFord Global Technologies, LLC
InventorMahmoud Yousef Ghannam
Life of this patent
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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.
Claims20
An assembly system for producing one or more product variations of a product, the assembly system comprising:
- a station having a set of tools for assembling the one or more product variations of the product;
- and
- a conveyance system to carry an assembly item into and away from the station;
- a sensor positioned upstream of the station configured to detect an assembly item on the conveyance system and gather product information 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 product identity data of the assembly item from the sensor;
- determine a product variation of the assembly item based on the product identity data;
- determine a procedure to perform at the station based on a station type and the product variation;
- determine one or more tools of the set of tools required for the procedure;
- and
- generate an instruction, for display at the station, instructing selection of the one or more tools.
A method for assembling product variations on a conveyance system, the method comprising:
- receiving product identity data from a sensor positioned upstream of a station of the conveyance system;
- determining a product variation based on the product identity data;
- determining a procedure to perform at the station based on a station type and the product variation;
- determining one or more tools required to perform the procedure;
- generating an instruction, for display at the station, instructing selection of the one or more tools from a selection 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.
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 a product variation for the assembly item based on the product identity data;
- determine a procedure to perform at the assembly station based on a station type of the assembly station and the product variation;
- determine one or more tools of a set of tools stored at the assembly station required to perform the procedure;
- generate an instruction, for display at the assembly station, instructing selection of the one or more tools from the 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.
Dependencies are inferred from the claim text.