Versatile production system and pallet used for the system

• US 5,434,790 A
• Filed: 02/24/1993
• Issued: 07/18/1995
• Est. Priority Date: 10/29/1992
• Status: Expired due to Fees

• Current Assignee: PFU Limited (Fujitsu Limited)
• Original Assignee: PFU Limited (Fujitsu Limited)
• Inventors: Oda, Junichi, Terabayashi, Eiichi, Miyasaka, Kazumi, Sasaki, Katsunao, Ishiyama, Yasuaki, Saka, Nobuo, Terashima, Hiroyoshi
• Primary Examiner(s): Trammell, James P.
• Application Number:
  US08/022,026
• Time in Patent Office: 874 Days
• Field of Search: 364/132, 364/468, 364/478, 364/403, 364/402, 364/401, 364/474.11, 364/469-473, 235/375, 235/376, 414/273, 414/274, 414/403, 414/410, 340/825.3, 340/825.31, 198/341, 198/349, 198/349.5-349.95, 198/347-347.4
• US Class Current: 700/110
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/31031 Assembly, manipulator cell
• CPC Class Codes: G05B 2219/31086 Communication of carriage, agv data, workpiece data at each station
• CPC Class Codes: G05B 2219/31282 Data acquisition, BDE MDE
• CPC Class Codes: G05B 2219/31283 Communication memory, storage, ram, eprom on workpiece or pallet
• CPC Class Codes: G05B 2219/31315 Use of data by host, send work order to operator after pallet detection
• CPC Class Codes: G05B 2219/31316 Output test result report after testing, inspection
• CPC Class Codes: G05B 2219/31317 Outputs delivery ordersheet, relating to finished products, to packing cell
• CPC Class Codes: G05B 2219/32183 Test cell
• CPC Class Codes: G05B 2219/32389 Reception, assembly, testing, management workorder, schedule, history, file, packing
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A versatile production system in which a communication-memory unit is attached to a product, or to a pallet carrying the product, while the product is conveyed along the production line. The communication-memory unit communicates with a line host controller via line terminals located at production line assembling and testing sites in order to send information relating to the product from the communication-memory unit to the line host controller and to the communication-memory unit from the line host controller. Information can also be transferred from the communication-memory unit to the line terminals for output to a production worker and input by a production worker from a line terminal to the communication-memory unit. In this manner, the communication-memory unit contains manufacturing information relating to the product and this information is electronically updated at each production line site. The communication-memory unit can be emplaced in the side surfaces, top surfaces, or bottom surface of a pallet so as to allow communication and be detachable from the pallet. A pallet could also include an indented storage area or a basket-like enclosure to accommodate subassemblies or test equipment placed therein.

Claims

1. A versatile production system in which parts are assembled into products and operators perform work assignments issued on work orders, the versatile production system comprising:

a first site at which parts are assembled into products, an operator being positionable at the first site for assembling products at the first site;

a second site at which products are tested, an operator being positionable at the second site for testing products at the second site;

means for determining if a product at the second site is defective or non-defective;

a third and a fourth site;

production line conveying means for mechanically conveying a product, comprising;

means for conveying an assembled product from the first site to the second site,

means for conveying a product, determined to be defective by the means for determining, from the second site to the third site, and

means for conveying a product, determined to be non-defective by the means for determining, from the second site to the fourth site;

a line host controller which electronically outputs and receives data;

first and second line terminals, electronically connected to the line host controller, the first line terminal corresponding to the first site and the second line terminal corresponding to the second site, which electronically receive data output by the line host controller, electronically send data to the line host controller and output human-readable data, the line host controller outputting work orders through the first and second line terminals to issue work assignments to operators at the first and second sites;

a line host controller terminal, electronically connected to the line host controller, which inputs data to the line host controller and outputs data received from the line host controller;

a communication-memory unit, corresponding to an individual product and conveyed with the product by the production line conveying means, which communicates selectively with the first terminal when the communication-memory unit is positioned at the first site and communicates selectively with the second line terminals when the communication-memory unit is positioned at the second site to allow data to be written to the communication-memory unit from the respective first and second line terminals and data to be read from the communication-memory unit by the respective first and second line terminals, the line host controller outputting work orders to issue work assignments based on data written to the communication-memory unit and data read from the communication-memory unit.

2. A versatile production system according to claim 1, wherein the communication-memory unit is attached to the product.

3. A versatile production system according to claim 2, wherein the communication-memory unit is detachable from the product.

4. A versatile production system according to claim 1, further comprising optical communication means for allowing the communication-memory unit to optically communicate with the first and second line terminals.

5. A versatile production system according to claim 1, further comprising wireless communication means for allowing the communication-memory unit to wirelessly communicate with the first and second line terminals.

6. A versatile production system according to claim 1, wherein the communication-memory unit comprises one of a magnetic tape, a magnetic card and a semiconductor memory chip.

7. A versatile production system according to claim 1, wherein the first and second line terminals each comprise:

an input unit comprising at least one of a keyboard and a bar code reader; and

an output unit comprising at least one of a CRT monitor and a printer.

8. A versatile production system according to claim 1, wherein the product is placed on a pallet, the pallet with the product placed thereon is transferred by the production line conveying means and the communication-memory unit is attached to the pallet.

9. A versatile production system according to claim 8, further comprising a product function checker which resides on the pallet and is electrically connected to the communication-memory unit, the product function checker comprising a processor, an input unit and an output unit, wherein one of a printer and a display device is connected to the first and second line terminals.

10. A versatile production system according to claim 8, wherein the pallet has respective side surfaces, a top surface and a bottom surface and the communication-memory unit is emplaced, so as to be detachable, in a surface selected from the group comprising each of the respective side surfaces, the top surface and the bottom surface.

11. A versatile production system according to claim 10, wherein the pallet has an indented storage area which accommodates subassemblies or equipment loaded therein.

12. A versatile production system according to claim 11, wherein the pallet includes an enclosure.

13. A pallet for use in a versatile production system according to claim 10, wherein the pallet has an enclosure.

14. A versatile production system according to claim 8, wherein the communication-memory unit is detachable from the pallet.

15. A versatile production system as in claim 1, further comprising:

a plurality of first sites, including an initial first site and a final first site, which are sequentially arranged from the initial first site to the final first site, a product being partially assembled from parts at each of the plurality of first sites so that a completed product is formed at the final first site by sequentially passing through each of the plurality of first sites;

a plurality of line terminals, at least one line terminal corresponding to each of the plurality of first sites;

wherein

the production line conveying means conveys a partially assembled product sequentially through each of the plurality of first sites from the initial first site to the final first site and conveys a completed product formed at the final first site to the second site, and

the communication-memory unit selectively communicates with a respective line terminal when the communication-memory unit is positioned at one of the first sites and second site corresponding to the respective line terminal.

16. A versatile production system according to claim 15, wherein the communication-memory unit is attached to the product.

17. A versatile production system according to claim 16, wherein the communication-memory unit is detachable from the product.

18. A versatile production system according to claim 15, further comprising optical communication means for allowing the communication-memory unit to optically communicate with the line terminals.

19. A versatile production system according to claim 15, further comprising wireless communication means for allowing the communication-memory unit to wirelessly communicate with the line terminals.

20. A versatile production system according to claim 15, wherein the communication-memory unit comprises one of a magnetic tape, a magnetic card and a semiconductor memory chip.

21. A versatile production system according to claim 15, wherein the line terminals each comprise:

an input unit comprising at least one of a keyboard and a bar code reader; and

an output unit comprising at least one of a CRT monitor and a printer.

22. A versatile production system according to claim 15, wherein the product is placed on a pallet, the pallet with the product placed thereon is transferred by the production line conveying means and the communication-memory unit is attached to the pallet.

23. A versatile production system according to claim 22, wherein the communication-memory unit is detachable from the pallet.

24. A versatile production system according to claim 22, further comprising a product function checker which resides on the pallet and is electrically connected to the communication-memory unit, the product function checker comprising a processor, an input unit and an output unit, wherein one of a printer and a display device is connected to the plurality of line terminals.

25. A versatile production system according to claim 22, wherein the pallet has respective side surfaces, a top surface and a bottom surface and the communication-memory unit is emplaced, so as to be detachable, in a surface selected from the group comprising each of the respective side surfaces, the top surface and the bottom surface.

26. A versatile production system according to claim 22, wherein the pallet includes an indented storage area which accommodates subassemblies or equipment loaded therein.

27. A versatile production system according to claim 22, wherein the pallet includes an enclosure.

28. A versatile production system according to claim 15, wherein at least one of the plurality of first sites ascends and descents in accordance with the height of a product.

29. A versatile production system as in claim 15, further comprising a plurality of second sites, wherein:

at least one line terminal corresponds to each of the plurality of second sites;

the product line conveying means conveys a product from the final first site to any one of the plurality of second sites and at least one of the plurality of second sites ascends and descents in accordance with the height of the product; and

the communication-memory unit selectively communicates with a respective line terminal when the communication-memory unit is positioned at one of the first sites and second sites corresponding to the respective line terminal.

30. A versatile production system in which parts are assembled into products and operators perform work assignments issued on work orders, the versatile production system comprising:

a first site at which parts are assembled into products, an operator being positionable at the first site for assembling products at the first site;

a second site at which products are tested, an operator being positionable at the second site for testing products at the second site;

means for conveying an assembled product from the first site to the second site;

a line host controller which electronically outputs and receives data;

first and second line terminals, electronically connected to the line host controller, the first line terminal corresponding to the first site and the second line terminal corresponding to the second site, which electronically receive data output by the line host controller, electronically send data to the line host controller and output human-readable data, the line host controller outputting work orders through the first and second line terminals to issue work assignments to operators at the first and second sites;

a line host controller terminal, electronically connected to the line host controller, which inputs data to the line host controller and outputs data received from the line host controller;

a communication-memory unit, corresponding to an individual product and conveyed with the product by the production line conveying means, which communicates selectively with the first terminal when the communication-memory unit is positioned at the first site and communicates selectively with the second line terminals when the communication-memory unit is positioned at the second site to allow data to be written to the communication-memory unit from the respective first and second line terminals and data to be read from the communication-memory unit by the respective first and second line terminals, the line host controller outputting work orders to issue work assignments based on data written to the communication-memory unit and data read from the communication-memory unit.