Multilevel Sorting Trays for Faster Garment Assembly Lines
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Solution Overview
Problem
The textile industry faces challenges in reducing production time for items like padded coats or jackets, which typically require two to three weeks from cutting to finishing, making it difficult to meet market demand.
Innovation Solution
An assembly line with a conveyance line and multiple processing stations, featuring multilevel sorting units with trays that can be selectively extracted, and identification means to streamline the assembly process, allowing for precise part identification and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional processing methods are used with storage at various processing islands, then quality items of clothing can be produced, but production time increases to two to three weeks
Solution Approach 1:
The production process is segmented into discrete processing stations arranged linearly along a conveyance line, with each station handling a specific operation. Sorting units are divided into multiple trays that can be independently extracted and processed, allowing parallel operations without storage delays.
Solution Approach 2:
Parts are pre-sorted into specific trays at sorting units before reaching processing stations. The identification means pre-determine which tray contains which parts, eliminating waiting time for part location and preparation at each processing station.
2Measurement precision
If multiple sorting units with multiple trays are used to organize parts, then part identification precision improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical identification systems with optical or electromagnetic identification means (such as barcodes, RFID tags, or color codes) that can be read remotely. This substitutes intricate mechanical tracking mechanisms with simpler sensing technologies.
Solution Approach 2:
Instead of physically tracking each part through the system, the invention uses informational copies (identification markers, codes, or tags) attached to parts and trays. These copies convey the necessary information about part location and destination without requiring complex physical tracking infrastructure.
3Productivity
If trays are selectively extracted from sorting units at each processing station, then assembly efficiency improves, but ease of operation decreases due to manual extraction requirements
Solution Approach 1:
The sorting units and trays are designed with dynamic characteristics, allowing easy insertion and extraction. The trays can be selectively removed from sorting units as needed, and the system adapts to different production rates and requirements, making operations more flexible and easier to perform.
Data Source
AI summary
An assembly line (1) comprising a conveyance line (5), a plurality of processing stations (S1-S3; N1-N13) and a plurality of multilevel sorting units (6) conveyed by the conveyance line (5). Each sorting unit is adapted to support the parts (P1-P3) of a manufactured article to be assembled progressively at the processing stations and comprises a plurality of superimposed trays which can be extracted selectively, wherein each tray is adapted to contain the parts of the manufactured article that are to be assembled at a respective processing station thereof.The assembly line also comprises means for identifying the tray to be extracted at at least one respective processing station.