Routable Track Assembly for Mixed Custom and Mass Production
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Solution Overview
Problem
Current manufacturing processes are inefficient for producing diverse products and customized items, as they require multiple high-speed lines or significant downtime for changes, and are labor-intensive for customization, making it impractical to handle a high number of product variations.
Innovation Solution
An automated track system with independently routable vehicles delivers components to unit operation stations, allowing for the simultaneous production of customized and mass-produced products by routing vehicles along a primary and secondary transport path, enabling flexible production of different products and compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple high-speed manufacturing lines are employed to provide diverse product lines, then product variety is improved, but cost and space requirements increase
Solution Approach 1:
The patent implements a single manufacturing line that can produce multiple different products by dynamically reconfiguring the assembly process. The system uses a modular architecture where components can be selectively added or removed from the product stream based on customer orders, allowing one line to replace multiple dedicated lines and achieve diverse product output without proportionally increasing the number of physical manufacturing lines
Solution Approach 2:
The manufacturing line employs dynamic reconfiguration capabilities where the assembly process can be changed in real-time based on product requirements. The system can pause, reconfigure, and resume production to accommodate different product types, enabling a single line to adapt its function dynamically rather than being fixed for a specific product type
2Adaptability or versatility
If manufacturing line changes are made to produce different products, then product adaptability is improved, but production downtime increases
Solution Approach 1:
The system prepares for product changes by maintaining a library of pre-configured component sets and assembly instructions. Before a changeover is needed, the required components and programming are staged and ready, allowing the manufacturing line to transition quickly between products without extensive setup time or production downtime
3Adaptability or versatility
If customized products are produced with high level of customization, then customer choice is improved, but labor intensity increases
Solution Approach 1:
The manufacturing system automatically receives customer customization specifications and self-configures the assembly process without requiring manual intervention. The control system interprets customer orders, selects appropriate components, and orchestrates the assembly sequence automatically, enabling high-level customization to be achieved through automated decision-making rather than manual labor
4Adaptability or versatility
If products are produced in advance to accommodate customization, then customer choice is improved, but warehouse complexity increases
Solution Approach 1:
The patent segments the product customization process into modular components that can be independently manufactured and stored in simple, organized inventory. Rather than storing complete customized products in complex warehouse configurations, the system produces and stores standardized base products and components, then assembles final customized products on-demand, dramatically reducing warehouse complexity and space requirements
Data Source
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Figure 1C~1D
AI summary
A system and method for producing customized products intermixed with mass produced products are disclosed. The system and method utilize an automated track system and a plurality of vehicles that are independently routable along the track system. The track system includes a primary transport path and at least one secondary transport path. At least some vehicles may be independently routable along the track system to deliver first and second vehicles, with the respective first and second articles, to at least one of at least two unit operation stations. The first article and the second article are routable so that: the first article is routable to form a customized product; and the second article is routable separate from the first article to form part of a stream of mass produced products.