Burn Rack Vertical Columns for Cascade Information Handling System Manufacturing
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Solution Overview
Problem
Manufacturing information handling systems with varied configurations leads to inefficiencies in assembly-line processes due to high variation in burn time, resulting in increased order cycle time, reduced order purity, and higher costs.
Innovation Solution
Implementing a single piece flow first-in-first-out (FIFO) process for the burn rack by determining an acceptable burn time that accounts for normal variations, allowing for cascade loading and unloading of systems in vertical columns, ensuring that similar configurations are kept adjacent and reducing the complexity of managing burn times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional progressive assembly line is used for information handling systems with varied configurations, then adaptability to different customer orders is improved, but productivity decreases due to high variation in burn time and multiple inefficiencies
Solution Approach 1:
The burn rack is segmented into multiple vertical columns, each functioning as an independent FIFO queue. This segmentation allows different configuration types to be processed in parallel columns, reducing the impact of burn time variation on overall productivity while maintaining adaptability to various configurations.
Solution Approach 2:
The system changes the parameter of burn rack organization from horizontal/sequential to vertical/column-based FIFO structure. This parameter change transforms the burn process into multiple parallel streams, improving productivity by reducing the accumulation effect of burn time variations while preserving configuration adaptability.
2Manufacturing precision
If high variation components are removed from the assembly line to a separate assembly process, then manufacturing precision is improved, but device complexity increases due to separate and suboptimal assembly process components
Solution Approach 1:
The patent merges the burn process back into the main assembly line by implementing vertical columns within the burn rack that maintain FIFO flow. This eliminates the need for separate accumulation areas and complex tracking systems, reducing device complexity while achieving burn time consistency through the column-based structure.
Solution Approach 2:
The burn rack vertical columns serve multiple functions: they act as FIFO queues, organize different configurations, track burn status, and enable parallel processing. This multi-functionality reduces the need for separate specialized components, simplifying the overall assembly process while maintaining manufacturing precision.
3Adaptability or versatility
If a burn rack with multiple variations of information handling systems is used, then adaptability to different configurations is improved, but loss of time increases due to distally spread orders and difficulties gathering related systems
Solution Approach 1:
The burn rack is divided into vertical columns that function as separate FIFO queues. Systems with the same configuration type are grouped in the same column, so when burn completes for a column, all systems in that column are ready simultaneously. This segmentation eliminates the time loss associated with gathering distally spread systems.
Solution Approach 2:
The patent transitions from horizontal arrangement to vertical column arrangement in the burn rack. This dimensional change allows systems to be organized by configuration type within columns while maintaining physical proximity, enabling efficient gathering of related systems without sacrificing configuration adaptability.
4Ease of manufacture
If traditional progressive assembly processes are used, then ease of manufacture is maintained, but productivity decreases due to burn area inefficiency and excessive capital investment
Solution Approach 1:
The burn rack implementation introduces dynamic loading and unloading of vertical columns based on burn completion. This dynamic approach allows continuous flow while maintaining simplicity, as columns are loaded and unloaded in FIFO order without complex scheduling, improving productivity while preserving ease of manufacture.
Solution Approach 2:
The vertical column FIFO structure enables continuous loading and unloading operations without interruption. As one column completes burn, the next column is ready, maintaining continuous useful action throughout the burn process. This eliminates idle time and improves productivity while keeping the process simple and easy to manufacture.
Data Source
AI summary
Information handling system manufacture through a burn rake that burns images and tests information handling systems is managed with a cascade first-in-first-out manufacture by allowing a predetermined burn time for each information handling system at each burn location. The predetermined burn time includes a projected burn time, a burn variation buffer and a standard repair time buffer that ensures a complete burn for substantially all information handling systems. Increasing the number of systems having a complete burn supports first-in-first out loading and unloading of information handling systems at burn locations so that the burn manufacture process occurs in a consistent cascade that proceeds down the length of the burn rack from a first end to a second end.