Guided Forklift Truck Steering Automation in Manufacturing Cells

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Solution Overview

Problem

Manufacturing environments, especially those producing complex products like heavy-duty working vehicles, face challenges in accurately forecasting demand and minimizing lead time due to labor-intensive and time-consuming processes for changing over between different product lines, as well as difficulties in handling large and heavy components.

Innovation Solution

A manufacturing cell layout with a main aisle and stations arranged in two rows, utilizing a guided forklift truck to streamline the movement of containers between storage units and stations, allowing operators to focus on relocation tasks without steering the truck, and incorporating conveyor systems and manipulators to facilitate the handling of heavy components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If operators manually steer the forklift truck to move containers, then the truck can be precisely positioned, but the operator's attention is diverted from relocation tasks and productivity decreases

Engineering Contradiction:

Improveoperator focus on relocation tasksVSAvoidcontainer relocation efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The forklift truck performs steering operations autonomously using automatic guidance systems, freeing the operator to concentrate solely on container relocation tasks. The system self-navigates along predefined paths while the operator manages the lifting and placing operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual steering control is replaced with automatic guidance systems that use sensors, markers, or navigation technologies to guide the forklift truck along predetermined paths, eliminating the need for operator intervention in steering while maintaining precise positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If traditional manufacturing layouts are used with scattered storage locations, then all components can be stored, but lead time increases due to excessive container moves between storage and stations

Engineering Contradiction:

Improvecomponent storage capacityVSAvoidlead time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The manufacturing area is segmented into distinct zones with storage units positioned adjacent to each production station, creating localized material supply points that minimize transport distance and time while maintaining adequate storage capacity for all components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Containers are pre-positioned in storage units located next to the stations where they will be used, so that when production is ready, the materials are already in place or immediately accessible, eliminating delays associated with long-distance transport during production.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If more storage units are added to increase container availability, then component accessibility improves, but the complexity of the manufacturing cell increases

Engineering Contradiction:

Improvecomponent accessibilityVSAvoidmanufacturing cell complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Storage units are designed with universal characteristics that allow them to serve multiple stations or product lines. The same storage unit can store different types of containers depending on production needs, reducing the total number of specialized storage locations required while maintaining component accessibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If changeover procedures are simplified, then productivity improves, but the ability to handle diverse product lines may be compromised

Engineering Contradiction:

Improvechangeover speedVSAvoidproduct line flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The manufacturing cell configuration is made dynamic and reconfigurable, allowing storage units and station assignments to be easily adjusted between different product lines. This enables quick changeovers while maintaining the ability to accommodate diverse manufacturing requirements through flexible reconfiguration rather than permanent fixed arrangements.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS8108989B2Manufacturing cell and elements of the cell

Publication Date: 2012.02.07 CROWN EQUIP CORP

AI summary

A manufacturing cell has a plurality of stations arranged in two rows having a main aisle therebetween. Each of the plurality of stations has a station-aisle interface that provides an interaction area to the main aisle. The manufacturing cell also comprises a plurality of storage units that are located within the cell along the main aisle and a guided forklift truck that traverses the main aisle without requiring steering control of a stock handler operating the forklift truck within the main aisle to relocate containers from the storage units to designated station-aisle interfaces and to remove containers from the designated station-aisle interfaces when work is completed at the corresponding stations.