Manufacturing system and method for assembly of computer systems in a build-to-order environment

• US 6,236,901 B1
• Filed: 03/31/1998
• Issued: 05/22/2001
• Est. Priority Date: 03/31/1998
• Status: Expired due to Term

• Current Assignee: Dell USA LP (Dell Technologies Inc.)
• Original Assignee: Dell USA LP (Dell Technologies Inc.)
• Inventors: Goss, Lois
• Primary Examiner(s): Cuchlinski, Jr., William A.
• Assistant Examiner(s): Marc, McDieunel, Marc, McDieunel
• Application Number:
  US09/053,524
• Time in Patent Office: 1,148 Days
• Field of Search: 700/95, 700/2, 700/241, 700/232, 700/100, 700/102, 700/3, 700/79, 700/83, 700/117, 700/116, 700/112, 700/114, 700/76, 700/230, 700/242, 361/759, 361/756, 361/702, 361/692, 705/16, 713/1, 713/2, 713/100
• US Class Current: 700/95
• CPC Class Codes: B23P 21/00 Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32022 Ordering, remote ordering, enter article and operations needed, create jobfile
• CPC Class Codes: G05B 2219/32232 Inspection and correction, repair station are separate, transmit correction data
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Parallel organized unit-by-unit manufacturing and assembly systems and methods for computer systems and other products advantageously integrate into a build-to-order environment. Responsive to orders received, kit trays are prepared that each hold parts and components needed to build an ordered product. The kit tray is transferred to a work cell where a team builds the product. The product is then tested and repaired, with information regarding any problems provided to the responsible work cell.

Claims

1. A build-to-order product assembly system comprising:

a control unit capable of receiving a product order describing a product to be assembled, the control unit including a list of product components for the product to be assembled, wherein the product is a computer system including a chassis, a processor supported by the chassis and a memory coupled to the processor;

a kitting unit coupled to the control unit and receiving the list of product components, the kitting unit including;

a plurality of kit trays;

a plurality of stored product components; and

a product component list display device, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared;

an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of the product using the product components from the prepared kit tray;

a chassis preparation unit coupled to the control unit and receiving the list of product components, the chassis preparation unit including;

a plurality of chassis components; and

a chassis preparation work space in which a chassis is prepared for a computer system according to the list of product components; and

a joining area coupled to the kitting unit and to the chassis preparation unit, the joining area receiving a prepared chassis and a prepared kit tray the prepared chassis being added to the prepared kit tray before being sent to the assembly unit, wherein the control unit delivers the list of product components to the chassis preparation unit at a first time, and the control unit delivers the list of product components to the kitting unit at a second time, the first time and the second time being selected by the control unit so the prepared chassis and the prepared kit tray arrive at the joining area at approximately the same time.

2. The build-to-order product assembly system of claim 1 wherein each of the plurality of kit trays includes:

a plurality of foam-lined tray compartments to accommodate the product components; and

a lip to support the chassis on top of the tray.

3. The build-to-order product assembly system of claim 1 further comprising an extended test unit coupled to the assembly unit, the extended test unit receiving an assembled computer system from the assembly unit and including a plurality of extended test positions for quality testing the computer system.

4. The build-to-order product assembly system of claim 3 wherein the plurality of extended test positions are controlled and monitored by a smart burn-in monitoring system including a test status indicator providing test information about a computer system in a test position.

5. The build-to-order product assembly system of claim 4 wherein the smart burn-in monitoring system includes information about a computer system that fails a test in the extended test unit, the information being supplied to the first work cell.

6. The build-to-order product assembly system of claim 4 further comprising a repair unit including a repair work space, a computer system that fails a test in the extended test unit being received by the repair unit from the extended test unit, the repair unit being capable of supplying information about the computer system that fails a test to the first work cell.

7. The build-to-order product assembly system of claim 1 wherein the assembly unit includes a quick test cell coupled to the first work cell and operable to receive the assembled product, the quick test cell including a quick test work space for testing of basic functionality of the assembled product and providing at least one of information about failure of the test of basic functionality and the assembled product to the first work cell when the assembled product fails the test of basic functionality.

8. The build-to-order product assembly system of claim 7 wherein the first work cell includes the quick test cell.

9. The build-to-order product assembly system of claim 7 wherein the assembly unit further comprises:

a second work cell coupled to the quick test cell and including a work space allowing a second work cell to assemble the product using the product components from the prepared kit tray, the quick test cell being shared by the first work cell and the second work cell; and

a queue operable to accumulate at least one prepared kit tray and provide the prepared kit tray to one of the first work cell and the second work cell.

10. The build-to-order product assembly system of claim 1 wherein the first work cell includes a first operator and a second operator, the first operator installing a first one of the product components into the product while the second operator prepares a second product component for installation into the product.

11. The build-to-order product assembly system of claim 1 wherein the first work cell includes an electronic work instruction display operable to receive information about the product to be assembled and to display instructions about the product to be assembled.

12. The build-to-order product assembly system of claim 11 wherein the electronic work instruction display is coupled to the control unit and receives the information about the product to be assembled from at least one of the control unit and the prepared kit tray.

13. The build-to-order product assembly system of claim 1 wherein the product component list display device is one of a pick-to-lights system and a component display screen.

14. The build-to-order product assembly system of claim 1 wherein the kitting unit is coupled to the assembly unit by a conveyor.

15. A manufacturing system for assembly of computer system in a build-to-order environment comprising:

a kitting unit housing kit trays and computer system components, the kitting unit;

including a code for generating a signal to indicate a list of components for assembling an ordered computer system; and

displaying the list of components in a pick-to-lights system to at least one kitting operator to allow respective kit trays to be prepared with computer system components for the ordered computer system by pulling selected computer system components from those housed at the kitting unit;

an assembly unit constructed to receive prepared kit trays from the kitting unit, the assembly unit having a plurality of work cells operable in parallel, at least one work cell;

providing work space and tools to allow a team of work cell operators to assemble an ordered computer system using the computer system components from a prepared kit tray; and

providing an integrated quick test, shared by at least one other work cell, to allow a quick test operator to test the assembled computer system for basic functionality; and

an extended test unit constructed to receive assembled computer system from the work cells, the extended test unit providing work space and tools to allow at least one extended test operator to quality test assembled computer systems.

16. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising:

a chassis preparation unit;

receiving a list of chassis and motherboard components for assembling the ordered computer system, and

displaying the list of chassis and motherboard components to at least one chassis preparation operator for pulling chassis and motherboard components from chassis and motherboard components housed at the chassis preparation unit;

preparing the chassis by assembling the chassis and motherboard components for the ordered computer system; and

a joining unit operable to receive prepared chassis and prepared kit trays, the joining unit;

identifying corresponding prepared kit trays and prepared chassis; and

placing a prepared chassis on the corresponding prepared kit tray before the prepared kit tray is sent to the assembly unit.

17. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein the motherboard components include a motherboard and at least one of a processor and a memory.

18. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising a queue operable to accumulate prepared kit trays and provide them to one of the plurality of work cells.

19. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein the quick test operator provides at least one of:

(1) information about failure of the test of basic functionality, and (2) an assembled computer system to the work cell that assembled the computer system when the computer system fails the test of basic functionality.

20. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein ones of the plurality of work cells includes an electronic work instruction display operable to receive information about the computer system to be assembled and to display instructions about the computer system to be assembled.

21. The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising a repair unit:

receiving a computer system that fails a test in the extended test unit;

repairing the computer system; and

supplying information about the computer system that fails the test to the work cell that assembled the computer system.

22. A method of assembling a build-to-order product comprising:

receiving and display a list of components for assembling an ordered product;

providing a kit tray;

coding the kit tray;

generating a signal from the coded kit tray to indicated a list of product components;

identifying the product components from the list in a pick-to-lights system;

selecting the identified product components;

placing the product components in the kit tray;

transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and

assembling the ordered product in the assembly unit using the product components from the prepared kit.

23. The method of claim 22 wherein the assembly unit includes a plurality of work cells operable in parallel, the method further comprising routing prepared kit trays to one of the work cells;

and wherein preparing the kit tray includes;

pulling components from a plurality of stored components and according to the list of components for assembling an ordered product; and

placing pulled components in the kit tray.

24. The method of claim 23 further comprising:

routing a prepared kit tray to an available work cell;

testing the assembled product for basic functionality in a quick test cell associated with the work cell;

transferring the assembled product to an extended test unit operable to receive assembled products; and

performing a quality test on assembled products in the extended test unit.

25. The method of claim 22 wherein the ordered product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

26. The method of claim 25 further comprising:

preparing a chassis for the ordered computer system;

transferring the prepared chassis to the assembly unit; and

joining the prepared chassis to a corresponding prepared kit tray prior to assembling the ordered product.

27. The method of claim 26 wherein the preparing the kit tray and the preparing the chassis occur in parallel.

28. The method of claim 22 further comprising queuing at least one prepared kit tray prior to the routing.

29. The method of claim 22 further comprising returning the assembled product to the work cell where the assembled product was assembled when the assembled product fails a basic functionality test.

30. The method of claim 22 further comprising repairing, in a repair unit, an assembled product that fails the extended test.

31. The method of claim 22 further comprising providing information about the failure of the assembled product to the work cell where the assembled product was assembled.

32. The method of claim 22 wherein the available work cell includes the quick test cell, and wherein the assembling the ordered product and the testing the assembled product are performed by an operator.

33. A build-to-order computer system comprising:

a chassis;

a processor support by the chassis; and

a memory coupled to the processor, the computer system assembled by;

receiving and displaying a list of components for assembling the build-to-order computer system;

providing a kit tray;

coding the kit tray;

generating a signal from the coded kit tray to indicate a list of product components;

identifying the product components from the list in a pick-to-lights system;

selecting the identified product components;

placing the product components in the kit tray;

transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and

assembling the ordered product in the available work cell using the build-to-order computer system components from the prepared kit.

34. A build-to-order product assembly system comprising:

a kitting unit receiving a list of product components, the kitting unit including;

a plurality of coded kit trays;

a plurality of stored product components; and

a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared;

an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray;

at least one of;

a quick test cell coupled to the first work cell, the quick test cell operable to receive the assembled product and perform a test of basic functionality of the assembled product; and

an extended test unit coupled to the assembly unit, the extended test unit operable to receive the assembled product from the assembly unit and perform a quality test of the assembled product; and

the at least one of a quick test cell and an extended test unit operable to provide information about failure of the respective test to the first work cell.

35. The build-to-order product assembly system of claim 34 wherein the information is used by the first work cell during a subsequent assembly of a product.

36. The build-to-order product assembly system of claim 34 wherein the information is used by the first work cell to repair the assembled product.

37. The build-to-order product assembly system of claim 34 further comprising a repair unit operable to receive an assembled product that fails a test in the at least one of a quick test cell and an extended test unit, and operable to provide additional information about failure of the respective test to the first work cell.

38. The build-to-order product assembly system of claim 34 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

39. A build-to-order product assembly system comprising:

a kitting unit receiving a first list of product components and a second list of product components, the kitting unit including;

a plurality of kit trays;

a plurality of stored product components;

a first product component list display device, the first product component list display device displaying the first list of product components so that a first kit tray with product components pulled from the stored product components and according to the first product component list display device can be prepared; and

a second product component list display device, the second product component list display device displaying the second list of product components so that a second kit tray with product components pulled from the stored product components and according to the second product component list display device can be prepared;

the product components of the first prepared kit tray having at least one difference with the product components of the second prepared kit tray; and

an assembly unit coupled to the kitting unit, the assembly unit operable to receive the first and the second prepared kit trays from the kitting unit, the assembly unit having a work cell including a work space for assembly of a product using the product components from one of the first and second prepared kit trays, assembly beginning when all of the components for the product are in the one of the first and second prepared kit tray, wherein all of the assembly of the product using the product components from one of the first and second prepared kit trays occurs in the assembly unit.

40. The build-to-order product assembly system of claim 39 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

41. The build-to-order product assembly system of claim 40 further comprising:

a chassis preparation unit receiving the first list of product components, the chassis preparation unit including;

a plurality of chassis components; and

a chassis preparation work space in which a chassis is prepared for a computer system according to the first list of product components; and

a joining area coupled to the kitting unit and to the chassis preparation unit, the joining area receiving a prepared chassis and the first prepared kit tray, the prepared chassis being added to the first prepared kit tray before being sent to the assembly unit.

42. The build-to-order product assembly system of claim 39 wherein the first product component list display device and the second product component list display device are the same device.

43. The build-to-order product assembly system of claim 39 further comprising at least one of:

a quick test cell coupled to the work cell, the quick test cell operable to receive the assembled product and perform a test of basic functionality of the assembled product; and

an extended test unit coupled to the assembly unit, the extended test unit operable to receive the assembled product from the assembly unit and perform a quality test of the assembled product;

the at least one of a quick test cell and an extended test unit operable to provide information about failure of the respective test to the work cell.

44. A build-to-order product assembly system comprising:

a kitting unit receiving a list of product components, the kitting unit receiving a list of product components, the kitting unit including;

a plurality of coded kit trays;

a plurality of stored product components; and

a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and

an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray, the assembly occurring in an order and with a number of steps reducing damage to the product components.

45. The build-to-order product assembly system of claim 44 wherein the first work cell includes an electronic work instruction display operable to receive information about the product to be assembled and to display instructions about the product to be assembled, the instructions including assembly steps ordered to reduce damage to the product components.

46. The build-to-order product assembly system of claim 44 wherein damage to product components is reduced by reducing the number of times components are touched by an operator.

47. The build-to-order product assembly system of claim 44 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

48. A build-to-order product assembly system comprising:

a kitting unit receiving a list of product components, the kitting unit including;

a plurality of coded kit trays, at least one of the kit trays including a plurality of component retaining features, the component retaining features operable to reduce impact to product components stored therein from kitting tray movement;

a plurality of stored product components; and

a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and

an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray.

49. The build-to-order product assembly system of claim 48 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor, the plurality of component retaining features of the at least one of the kit trays providing greater protection than the chassis for at least one product component.

50. The build-to-order product assembly system of claim 48 wherein at least one of the plurality of component retaining features includes a mechanically insulating material.

51. The build-to-order product assembly system of claim 50 wherein the mechanically insulating material is foam.