Continuous Flow Tool Tracking for Composite Part Manufacturing
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Solution Overview
Problem
Conventional manufacturing techniques for large and composite parts, such as aircraft structures, are not suited for continuous flow manufacturing due to the use of fixed-base machines and batch processing, which limits efficiency and flexibility.
Innovation Solution
A continuous flow manufacturing system that includes a tool with a machine-readable identifier, a plurality of workstations with production machines, and a computing device that retrieves and updates process data associated with each workstation, enabling the tracking and management of parts and tools throughout the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed-base machines and batch processing are used for manufacturing large and composite parts, then manufacturing precision and quality control are maintained, but productivity and flexibility deteriorate
Solution Approach 1:
The patent implements a dynamic manufacturing system where tools are movable between workstations rather than fixed. The tool carriages can be relocated along the production line, and the system adapts its configuration based on production needs. This dynamic approach enables continuous flow manufacturing while maintaining precision through controlled tool positioning and identification at each workstation.
Solution Approach 2:
The manufacturing system is divided into multiple discrete workstations (first, second, third workstations) that process parts sequentially. Each workstation has its own tool carriage and can operate independently, allowing the production line to be segmented into manageable units that can be optimized individually while contributing to overall continuous production.
2Loss of time
If batch processing is used for composite parts, then quality control is maintained, but cycle time and work in progress increase
Solution Approach 1:
The patent implements continuous flow manufacturing where parts move continuously through multiple workstations without batch interruptions. The system maintains continuous production flow by having multiple tools and workstations operating in parallel, eliminating idle time between batches and reducing work in progress inventory while maintaining quality through consistent process control.
Solution Approach 2:
The system uses machine-readable identifiers and computing devices to track tools and parts through the manufacturing process. This feedback mechanism monitors process data in real-time, enabling continuous quality control and process optimization without interrupting the continuous flow, thereby reducing cycle time while maintaining quality standards.
3Adaptability or versatility
If movable tools and continuous flow manufacturing are implemented, then productivity and flexibility improve, but device complexity and control requirements increase
Solution Approach 1:
The patent introduces computing devices and machine-readable identifiers as intermediaries between the physical manufacturing components and the control system. These intermediaries simplify the control architecture by providing standardized interfaces for tool identification, tracking, and coordination, thereby reducing the overall system complexity despite the increased flexibility and movability of manufacturing components.
Solution Approach 2:
The tool carriages are designed with universal functionality, capable of performing multiple manufacturing operations across different workstations. Each tool carriage can be programmed and configured for different tasks, reducing the need for specialized equipment at each station and simplifying the overall system architecture while maintaining high adaptability.
Data Source
AI summary
A continuous flow manufacturing system includes a tool, configured to hold a part. The system also includes a machine-readable identifier, associated with the tool and encoded with a tool-identification. The system further includes a plurality of workstations. Each one of the plurality of workstations includes a production machine, configured to perform a manufacturing operation on a part, and a reader, configured to read the machine-readable identifier. The system also includes a computing device, configured to retrieve process-data, associated with the tool-identification and a corresponding one of the plurality of workstations, and configured to update the process-data, subsequent to performing the manufacturing operation associated with the corresponding one of the plurality of workstations.