High-volume production line

A method of processing workpieces, comprising the steps of:

• i) providing a production line, the production line comprising:
• a control means,
• an input,
• an output,
• a main conveyor line directly connecting the input and the output arranged such that a workpiece may travel directly downstream along the main conveyor line from the input to the output,
• a plurality of loops located in series along the main conveyor, each loop branching from the main conveyor via a respective branching conveyor located at a relatively upstream location of the main conveyor line and returning to a relatively downstream location of the main conveyor line via a respective return conveyor, and each loop comprising a respective processing module located between the respective branching conveyor and return conveyor, such that a workpiece may be diverted from the main conveyor line to a loop via its respective branching conveyor, be processed by its respective processing module and returned to the main conveyor line via its respective return conveyor;
• ii) determining the number X of loops which are operational loops, an operational loop being a loop in which the respective branching conveyor, return conveyor and processing module are all fully operational, where X is an integer greater than 1;
• iii) commencing a set-up phase by commencing to convey the plurality of unprocessed workpieces to the input in a sequential fashion, and thereafter onto the main conveyor line;
• completing the set-up phase by diverting workpieces from the main conveyor line so that iv) each operational loop has at least one workpiece located thereon;
• v) commencing an operational phase comprising controlling the branching conveyors so that each branching conveyor diverts every Xth workpiece received at that respective branching conveyor away from the main conveyor line to its respective operational loop;
• vi) processing workpieces received at respective processing modules;
• vii) returning the processed workpieces to the main conveyor line;
• and
• viii) conveying the processed workpieces to the output.