Workpiece-Carrier Loading Sequence for Mixed-Model Furniture Lines
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Solution Overview
Problem
Current industrial plants for mass-producing assembled furniture face inefficiencies in preparing components, leading to high production costs and complex storage requirements, especially when producing products with various models, as manual preparation and large storage spaces are needed.
Innovation Solution
A method and apparatus for in-line loading of workpieces, where components are subdivided into subsets and loaded onto a train of workpiece-carriers in a predefined sequence, using robots or manipulators to automate the process, allowing for efficient feeding of components onto a production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual preparation of bays is used, then workers can find and prepare necessary workpieces, but the preparation time becomes very long and production cost increases
Solution Approach 1:
The system segments the preparation process by dividing workpieces into different bays organized by component type (e.g., panels, hardware). Each bay is automatically prepared with specific components needed for future production sequences, eliminating manual searching and preparation time while maintaining organizational flexibility.
Solution Approach 2:
The system performs preliminary action by automatically preparing bays in advance with required workpieces before production needs them. The control unit pre-organizes components in each bay based on the production sequence, so when components are needed, they are already ready and waiting, eliminating preparation delays during actual production.
2Ease of operation
If large storage spaces are provided for workpiece movement, then workers can access components, but storage space requirements increase and more workers are needed
Solution Approach 1:
The storage system is segmented into multiple compact bays, each dedicated to specific component types. This segmentation allows efficient use of space by organizing workpieces vertically and categorically, reducing the overall footprint while maintaining easy access to all component types through the automated retrieval system.
Solution Approach 2:
The system implements self-service by using automated robots to retrieve and deliver workpieces from storage bays to the production line. This eliminates the need for workers to physically access and move workpieces through large storage areas, reducing both space requirements and labor needs while maintaining continuous component availability.
3Adaptability or versatility
If many different workpieces are stored for finished products with many variations, then product diversity is achieved, but the number of workpieces in warehouse increases and bay preparation complexity increases
Solution Approach 1:
The system handles product variations by segmenting workpieces into standardized component categories (panels, hardware, shelves) stored in separate bays. Each bay is organized by component type rather than by specific product model, allowing the same bay structure to serve multiple product variations. The control unit manages the complexity by tracking which components are needed for which products, simplifying the physical organization while maintaining product diversity capability.
4Productivity
If automated workpiece-carrier train system is implemented, then preparation time is reduced and production efficiency increases, but the system complexity increases
Solution Approach 1:
The workpiece-carrier train system implements universality by using a single automated train that serves multiple functions: transporting workpieces between bays, delivering components to the production line, and returning empty carriers for reloading. This multi-functional system replaces multiple separate material handling systems, reducing overall system complexity while maintaining high productivity and automation benefits.
Data Source
AI summary
An improved industrial plant and method is described, in particular a unit or apparatus for loading workpieces on a line and a method for loading workpieces on a line with a sequence. Movable workpiece-carriers arrive sequentially at sets of components and are loaded one after the other with components to form the desired sequence.