Quality Control System And Method Thereof

• US 20090149983A1
• Filed: 04/01/2008
• Published: 06/11/2009
• Est. Priority Date: 04/01/2008
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Lee, Gary, Buse, Sorin, Dennis, Jason J.
• Granted Patent: US 7,953,508 B2
• Time in Patent Office: Days
• US Class Current: 700/111
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/32179 Quality control, monitor production tool with multiple sensors
• CPC Class Codes: G05B 2219/32181 Monitor production, assembly apparatus with multiple sensors
• CPC Class Codes: G05B 2219/45055 Assembly
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A quality control system and method for monitoring an assembly operation is provided. The method can include: (1) providing an assembly line having a plurality of machines being assembled thereon; (2) providing a tool for performing an assembly operation; (3) performing a plurality of the assembly operations with the tool; (4) measuring a measurable parameter indicative of the performance of the tool for at least a subset of the plurality of assembly operations; (5) storing the measured values in an electronic format with a data collection device; (6) analyzing the measured values; and (7) providing a signal based on the analysis with the signal indicative of at least satisfactory or unsatisfactory performance of the tool. In some instances, the data collection device can provide for storing additional information and/or data with any particular stored measured value.

Claims

1. A method for monitoring an assembly operation, the method comprising:

providing a machine assembly line having a plurality of machines being assembled;

providing a tool for performing an assembly operation, the assembly operation resulting in a measurable parameter indicative of the performance of the tool;

performing a plurality of the assembly operations with the tool;

measuring the measurable parameter indicative of the performance of the tool for at least a subset of the plurality of assembly operations, each measurement providing a value;

storing the measured values within a data collection device in an electronic format;

analyzing the measured values;

comparing the analysis of the measured values to at least one predefined value; and

providing a signal based on the comparison of the analysis of the measured values to the at least one predefined value, the signal indicative of a satisfactory or unsatisfactory performance of the tool.

2. The method of claim 1, wherein the data collection device provides for storing additional data with any particular stored measured value.

3. The method of claim 1, wherein the tool is a power wrench for tightening a threaded fastener.

4. The method of claim 3, wherein the measurable parameter is torque.

5. The method of claim 4, wherein measuring of the measurable parameter is performed with an electronic torque wrench.

6. The method of claim 5, further including providing the signal to a first responder if the signal is indicative of unsatisfactory performance of the tool.

7. The method of claim 6, wherein the signal is provided to the first responder by an email and/or page.

8. The method of claim 6, further including providing the signal to a second responder if the unsatisfactory signal provided to the first responded is not responded to within a predetermined amount of time.

9. The method of claim 8, wherein the signal is provided to the second responder by an email and/or page.

10. The method of claim 1, further including uploading the stored values from the data collection device to a computer wherein the steps of analyzing and comparing the stored values are carried out by the computer.

11. A method for monitoring the assembly of motor vehicles on a motor vehicle assembly line, the method comprising:

providing a motor vehicle assembly line having a plurality of motor vehicles being assembled;

providing a tool for performing an assembly operation, the assembly operation resulting in a measurable parameter indicative of the performance of the tool;

performing a plurality of the assembly operations with the tool;

measuring the measurable parameter indicative of the performance of the tool for at least a subset of the plurality of assembly operations, each measurement providing a value;

storing the measured values within a data collection device in an electronic format;

analyzing the measured values;

comparing the analysis of the measured values to at least one predefined value;

providing a signal based on the comparison of the analysis of the measured values to the at least one predefined value, the signal indicative of a satisfactory or unsatisfactory performance of the tool;

sending the signal to a first level responder if the signal is indicative of unsatisfactory amount performance of the tool; and

sending the signal to a second level responder if the unsatisfactory signal is not responded to by the first level responder within a predetermined amount of time.

12. The method of claim 11, wherein the data collection device provides for storing additional data with any particular stored measured value.

13. The method of claim 11, wherein the tool is a power wrench for tightening a threaded fastener.

14. The method of claim 13, wherein the measurable parameter is torque.

15. The method of claim 14, wherein measuring of the measurable parameter is performed with an electronic torque wrench.

16. The method of claim 11, wherein the tool is a robot for placing exterior panels onto the motor vehicle.

17. The method of claim 16, wherein the measurable parameter is the distance between adjacent panels.

18. The method of claim 17, wherein measuring of the measurable parameter is performed with an electronic caliper.

19. A method for monitoring the assembly of motor vehicles on a motor vehicle assembly line, the method comprising:

providing a motor vehicle assembly line having a plurality of motor vehicles being assembled;

providing a power wrench for performing tightening a threaded fastener, the tightening of the threaded fastener resulting in a torque on the threaded fastener that is indicative of the performance of the power wrench;

tightening a plurality of threaded fasteners with the power wrench;

measuring the torque on at least a subset of the threaded fasteners that have been tightened with the power wrench, the measuring providing a torque value indicative of the performance of the power wrench;

storing the measured torque values within a data collection device in an electronic format;

uploading the stored torque values to a central computer;

analyzing the measured torque values with the central computer;

comparing the analysis of the measured torque values to at least one predefined torque value using the central computer;

providing a signal based on the comparison of the analysis of the measured torque values to the at least one predefined torque value, the signal indicative of a satisfactory, cautionary or unsatisfactory amount of torque applied to the tightened threaded fasteners;

sending the signal by email to a first level responder if the signal is indicative that cautionary or unsatisfactory torque has been applied to the tightened threaded fasteners; and

sending the signal by email to a second level responder if the cautionary or unsatisfactory signal is not responded to by the first level responder within a predetermined amount of time.

20. The method of claim 19, wherein the data collection device provides for storing additional data with any particular stored measured value.