Assembly line control system

An assembly line comprising:

• a first station, having a first assembly that is a member of a first group of assemblies positioned proximate to said first station;
• a second station, downstream of said first station, having a second assembly that is a member of a second group of assemblies positioned proximate to said second station;
• a third station, downstream of said first and second stations, having a third assembly that is a member of said first group of assemblies positioned proximate to said third station;
• and
• a router adapted to transfer said first assembly from said first station to said third station bypassing said second assembly and said second station.

A system for the manufacturing of a plurality of assemblies, said system comprising:

• a conveyor system for moving said assemblies from a first position to a second position, said conveyor system having a plurality of paths interposed between said first and second positions;
• a computer adapted to assign said plurality of assemblies to lots and adapted to track the position of each assembly of said lots as each assembly moves between said first and second locations, said computer also adapted to determine when an assembly is separated from other assemblies of its lot;
• and
• said computer adapted to route at least one of said plurality of assemblies along an alternate path of said conveyor system so that an assembly that is separated from said other assemblies of its lot can rejoin said other assemblies of its lot to form a contiguous group with said other assemblies its lot.

A method of manufacturing a plurality of assemblies, said method comprising:

• forming lots of assemblies from said plurality of assemblies;
• moving said lots of assemblies from a first location to a second location;
• tracking a position of each assembly of a first lot of said lots as each assembly moves along a path between said first and second locations, wherein said tracking comprises, for each assembly of said first lot:
• creating a record recording its position at a plurality of stations;
• associating with said recorded position an assembly identifier unique for said each assembly;
• associating with said recorded position a lot identifier unique to said first lot;
• and
• accessing said record based on said assembly identifier and said lot identifier;
• determining whether an assembly of said first lot is separated from another assembly of said first lot;
• routing at least one of said plurality of assemblies along an alternate path so that said separated assembly re-unites with said another assembly of said first lot.

An assembly line for manufacturing a plurality of assemblies, said assemblies formed into lots, said assembly line comprising:

• a plurality of conveyors to move assemblies from a first point to a second point;
• a plurality of switching points interconnecting said plurality of conveyors to form a plurality of paths from said first point to said second point;
• a tracking device for tracking the position of each assembly of at least a first lot of assemblies as said each assembly moves between said first point and said second point;
• a controller for:
• determining whether an assembly of said first lot is separated from other assemblies of said first lot based on information received from said tracking device;
• and
• controlling said plurality of switching points and said plurality of conveyors so that said separated assembly of said first lot moves along a path which bypasses a second assembly of a second lot of assemblies positioned between said first and second points such that said separated assembly is re-united with said other assemblies of said first lot.

A method of manufacturing a plurality of automotive assemblies, said method comprising:

• forming lots of automotive assemblies from said plurality of automotive assemblies;
• moving said lots of automotive assemblies from a first location to a second location;
• tracking a position of each automotive assembly of a first lot of said lots as each automotive assembly moves along a path between said first and second locations;
• determining whether or not an automotive assembly of said first lot is separated from other automotive assemblies of said first lot;
• routing at least one of said plurality of automotive assemblies along an alternate path so that said separated automotive assembly re-unites with said other automotive assemblies of said first lot.

A method of manufacturing a plurality of assemblies, said method comprising:

• forming lots of assemblies from said plurality of assemblies;
• moving, in at least a substantially contiguous manner, said lots of assemblies from a first location to a second location;
• tracking a position of each assembly of a first lot of said lots as each assembly moves along a path between said first and second locations;
• determining whether or not an assembly of said first lot is separated from other assemblies of said first lot;
• routing at least one of said plurality of assemblies along an alternate path so that said separated assembly re-unites with said other assemblies of said first lot.