Mobile Transporter Layout Reconfiguration for Mixed-Model Assembly
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Solution Overview
Problem
Manufacturing plants face challenges in efficiently reconfiguring assembly lines to produce multiple product models simultaneously due to logistics and manufacturing constraints, leading to unbuildable vehicle features and increased downtime.
Innovation Solution
A system comprising mobile transporters and a factory configuration module that uses sensors and a supervisory control module to dynamically reposition equipment based on predetermined configurations and real-time inputs, allowing for efficient reconfiguration of factory layouts and equipment placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple product models are manufactured on the same assembly line with all parts and tools located line-side, then all vehicle models can be accommodated, but logistics complexity and manufacturing constraints increase
Solution Approach 1:
The assembly line is segmented into modular work cells that can be independently configured and reconfigured. Each work cell contains specific tools and parts for particular vehicle features, allowing the line to be divided into manageable segments that can be adapted for different models without reconfiguring the entire assembly line.
Solution Approach 2:
The assembly line configuration is made dynamic through movable work cells and adjustable tooling. Work cells can be repositioned along the assembly line, and tooling within each cell can be adjusted to accommodate different vehicle models, enabling the system to adapt to changing production requirements without complete reconfiguration.
2Adaptability or versatility
If model-specific racks and tools are located line-side for all vehicle models, then all models can be built, but manufacturing constraints increase
Solution Approach 1:
Each work cell along the assembly line is equipped with tools and parts specific to the local manufacturing needs. Instead of having all tools available at every station, each work cell has the specific tools and racks needed for its particular functions, reducing overall manufacturing constraints while maintaining the ability to build different vehicle features.
3Adaptability or versatility
If the assembly line is configured for multiple product models, then production versatility increases, but reconfiguration time and downtime increase
Solution Approach 1:
Alternative work cell configurations are pre-prepared and staged before reconfiguration is needed. When a model change is anticipated, the required tools, racks, and equipment are pre-positioned in the target locations, allowing for rapid switching between models with minimal downtime.
Solution Approach 2:
Manual reconfiguration of the assembly line is replaced with automated systems. Computer-controlled mechanisms automatically reposition work cells, adjust tooling, and reconfigure racks, eliminating the need for manual intervention and significantly reducing reconfiguration time.
Data Source
AI summary
A system for reconfiguring a factory having equipment at different workstations throughout the factory and a plurality of sensors disposed throughout the factory includes a factory configuration module configured to store a plurality of predetermined factory configurations and a plurality of mobile transporters configured to engage and transport the equipment to the different workstations throughout the factory based on the predetermined factory configurations and dynamic inputs, where the dynamic inputs include a status of the equipment, a status of the plurality of mobile transporters, sensor data output by the plurality of sensors, or a combination thereof.