Autonomous Parts Replenishment for Just-in-Time Buffer Queues
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Solution Overview
Problem
Industrial manufacturing processes face inefficiencies due to uncertainties in part delivery and resource allocation across multiple queues, which can lead to increased buffer sizes and reduced productivity.
Innovation Solution
Implementing a method for autonomous provision replenishment using self-driving material-transport vehicles equipped with sensors and a fleet-management system that determines pick-up and drop-off paths dynamically based on real-time consumption and obstruction data, allowing for efficient delivery of parts directly to intermediate stocking queues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parts are stored in a buffer or queue prior to being consumed by the manufacturing process, then uncertainties in delivery are accounted for, but the buffer size increases and manufacturing efficiency decreases
Solution Approach 1:
The system uses autonomous self-driving vehicles that independently navigate, sense obstructions, and deliver parts without human intervention. The vehicles autonomously monitor their own status and make decisions about path selection and obstacle avoidance, enabling the system to serve itself and reducing the need for large buffers.
Solution Approach 2:
The system continuously monitors delivery status, queue levels, and vehicle positions, using this feedback to dynamically adjust delivery timing and routing. This real-time feedback enables just-in-time delivery that adapts to actual process needs, maintaining reliability while minimizing buffer sizes.
2Adaptability or versatility
If the same forklift and operator deliver parts to different stages, then resource allocation is flexible, but uncertainties in delivery increase and productivity decreases
Solution Approach 1:
The fleet of self-driving vehicles is designed to perform multiple functions - each vehicle can deliver any type of part to any stage in the manufacturing process. This universal capability allows the system to flexibly allocate resources across multiple queues while maintaining consistent, uncertainty-free delivery performance through automated operation.
3Productivity
If a just-in-time process is implemented with minimal buffer, then manufacturing efficiency is improved, but uncertainties in delivery cannot be adequately accounted for
Solution Approach 1:
The system replaces manual forklift operations with autonomous self-driving vehicles equipped with sensors and navigation systems. This substitution eliminates human reaction time and decision-making variability, enabling truly just-in-time delivery with minimal buffers while maintaining high reliability through consistent automated performance and real-time monitoring.
Data Source
AI summary
Systems and methods for autonomous provision replenishment are disclosed. Parts used in a manufacturing process are stored in an intermediate stock queue. When the parts are consumed by the manufacturing process and the number of parts in the queue falls below a threshold, a provision-replenishment signal is generated. One or more self-driving material-transport vehicles, a fleet-management system, and a provision-notification device.