Methods for simultaneously producing different products on a single production line

• US 10,613,523 B2
• Filed: 09/08/2017
• Issued: 04/07/2020
• Est. Priority Date: 09/09/2016
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Burkhard, Ryan Andrew, Moore, Nathan E, Fikes, Elizabeth Marie, Royce, Daniel Richard, Ballman, Kyle Christopher
• Primary Examiner(s): Kasenge, Charles R
• Application Number:
  US15/698,681
• Publication Number:
  US 20180074477A1
• Time in Patent Office: 942 Days
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/4189 characterised by the transport system
• CPC Class Codes: G05B 2219/31274 Convey products, move equipment according to production plan in memory
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Methods for simultaneously producing different products on a single production line are disclosed. The method may be used to produce different fluent products and other types of products including assembled products. In some cases, the method includes providing a plurality of articles which are components of the products to be produced. The method further involves providing a track system and a plurality of vehicles for the articles. At least some of the vehicles may be independently routable around the track system. The method further includes simultaneously sending one article-loaded vehicle to a unit operation station where a step in the production of a product is performed and another article-loaded vehicle to a unit operation station where a step in the production of a different product is performed.

Claims

1. A method for simultaneously producing different products on a single production line, said method comprising the steps of:

(a) providing a track system comprising a track on which vehicles are propellable, wherein at least some of said vehicles are independently routable, and wherein a plurality of unit operations stations are disposed along the track system, wherein the track system comprises a primary transport portion that defines a primary path comprised of track that forms a closed loop that is configured to permit at least one article-loaded vehicle to travel in a holding pattern, at least one secondary transport portion that extends from the primary transport portion and defines a secondary path comprised of track that intersects the primary path at an ingress location and an egress locations;

(b) providing a control system comprising one or more controller units;

(c) providing a plurality of articles, said articles comprising a first article and a second article, said first and second articles comprising components of the products to be produced;

(d) providing a plurality of vehicles;

(e) receiving demand for finished products to be made and utilizing the control system to provide one or more routes for the plurality of vehicles, wherein the routes are determined based on a status of one or more unit operation stations;

(f) loading said first article on a vehicle to form an article-loaded vehicle;

(g) loading said second article on a vehicle to form an article-loaded vehicle; and

(h) simultaneously sending one of said article-loaded vehicles to a unit operation station where a step in the production of a product is performed and another one of said article-loaded vehicles to a unit operation station where a step in the production of a different product is performed;

wherein said method further comprises recirculating at least one article-loaded vehicles in a holding pattern on said primary loop.

2. A method for producing different fluent products according to claim 1 wherein:

in step (a) said unit operation stations comprise at least two filling unit operation stations;

in step (c) said articles comprise empty containers, said containers comprising a first container and a second container;

in step (f) loading said first article on a vehicle comprises loading said first empty container on a vehicle to form a container-loaded vehicle;

in step (g) loading said second article on a vehicle comprises loading said second empty container on a vehicle to form a container-loaded vehicle; and

step (h) comprises simultaneously sending one of said container-loaded vehicles to a filling unit operation station where a fluent product is dispensed into said first container and another one of said container-loaded vehicles to a filling unit operation station where a different fluent product is dispensed into said second container.

3. A method for producing different assembled products according to claim 1 wherein said unit operation stations perform a step in the assembly of a product.

4. A method for simultaneously producing different products on a single production line, said method comprising the steps of:

(a) providing a track system comprising a track on which vehicles are propellable, wherein the track system comprises a primary transport portion that defines a primary path comprised of track that forms a closed loop that is configured to permit at least one article-loaded vehicle to travel in a holding pattern;

at least one secondary transport portion that extends from the primary transport portion and defines a secondary path comprised of track that intersects the primary path at an ingress location and an egress location;

wherein at least some of said vehicles are independently routable, wherein a plurality of unit operations stations are disposed along the track system, and wherein said unit operation stations comprise at least two filling unit operation stations;

(b) providing a control system comprising one or more controller units;

(c) providing a plurality of articles, said articles comprising a first article and a second article, said first and second articles comprising components of the products to be produced, and wherein said articles comprise empty containers, said containers comprising a first container and a second container;

(d) providing a plurality of vehicles;

(e) receiving demand for finished products to be made and utilizing the control system to provide one or more routes for the plurality of vehicles, wherein the routes are determined based on a status of one or more unit operation stations;

(f) loading said first article on a vehicle to form an article-loaded vehicle, wherein loading said first article on a vehicle comprises loading said first empty container on a vehicle to form a container-loaded vehicle;

(g) loading said second article on a vehicle to form an article-loaded vehicle, loading said second article on a vehicle comprises loading said second empty container on a vehicle to form a container-loaded vehicle; and

simultaneously sending one of said article-loaded vehicles to a unit operation station where a step in the production of a product is performed and another one of said article-loaded vehicles to a unit operation station where a step in the production of a different product is performed, and wherein said method further comprises recirculating at least one article-loaded vehicles in a holding pattern on said primary loop.

5. A method for producing different assembled products according to claim 4 wherein said unit operation stations perform a step in the assembly of a product.