RFID-Enabled Shared Storage for Assembly Error Reduction
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Solution Overview
Problem
In small series assembly, the high cost and inefficiency of dedicated assembly workstations for each worker arise from the need for individual storage facilities, leading to increased production costs and error rates due to shorter training phases and multi-step worker responsibilities.
Innovation Solution
A method utilizing a holding device with an identification device triggered by a movable code carrier, allowing multiple workers to share the same storage module, with RFID transponders attached to workers' hands to track and control their access, preventing errors and reducing costs by eliminating the need for multiple workstation-specific setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If each worker is assigned a dedicated storage facility with all necessary storage modules, then each worker can access their required parts and tools without interference, but the investment costs and device complexity increase significantly
Solution Approach 1:
The storage facility is designed to serve multiple workers simultaneously by incorporating multiple provision modules that can be dynamically assigned to different workers based on their current assembly tasks. The system universally supports multiple users through centralized control and identification technology.
Solution Approach 2:
An identification device acts as an intermediary between workers and the storage facility. This mediator recognizes workers through code carriers and controls access to appropriate provision modules, enabling multiple workers to use the same storage facility without direct conflict or confusion.
2Ease of operation
If each worker has their own storage facility, then parts retrieval is simplified, but the investment costs increase due to the need for multiple identical storage systems
Solution Approach 1:
Multiple individual storage facilities are merged into a single centralized storage facility that serves multiple workers. The unified system combines multiple provision modules under one structure, reducing total investment while maintaining individualized access control through the identification device.
Solution Approach 2:
The storage facility is designed to universally serve multiple workers by dynamically allocating provision modules based on identification. This multi-functional design eliminates the need for duplicate storage systems for each worker, significantly reducing investment costs.
3Device complexity
If workers share a common storage facility without identification, then device complexity is reduced, but errors increase due to workers retrieving wrong parts or tools
Solution Approach 1:
The identification device provides feedback control by recognizing workers and automatically controlling which provision modules are accessible. This closed-loop system ensures workers can only access parts and tools designated for their current task, eliminating retrieval errors while maintaining system simplicity.
Solution Approach 2:
The identification device serves as an intermediary that mediates between workers and the common storage facility. It ensures reliable parts retrieval by controlling access based on worker identification, preventing errors without requiring complex individual storage systems.
4Ease of operation
If dedicated storage facilities are provided for each worker, then individual worker needs are met, but assembly time increases due to setup and training requirements
Solution Approach 1:
The storage facility transitions from a static, worker-dedicated design to a dynamic, task-oriented system. Provision modules are dynamically assigned and reassigned based on current assembly requirements and worker identification, enabling rapid adaptation without retraining and reducing assembly time.
Solution Approach 2:
The system performs preliminary actions by pre-assigning provision modules to workers based on their identification and current task requirements. This advance preparation eliminates setup time during assembly operations, as workers immediately access their designated parts without training or configuration delays.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables shared use of holding devices across multiple workstations, reducing investment costs and assembly time while minimizing errors by ensuring accurate part retrieval and automating the switching between assembly steps without the need for additional switches or cameras.
Implementation Method 1
provision modules have an identification device which can be triggered with a movable code carrier, in particular with an RFID transponder attached to a worker's hand
Data Source
Figure 1~2
Figure 3
AI summary
The apparatus has a frame (11) that is provided with extruded profiles which are interconnected by vertical components. The small component boxes (12) are mounted on the extruded profiles in slightly forward-tilted position. The small component box has an identification device which is triggered by a mobile code carrier during mis-operation of worker. The mobile code carrier is provided with radio frequency identification (RFID) transponder.