Apparatus for consolidating manufacturing of computing devices

• US 6,516,242 B1
• Filed: 01/18/2000
• Issued: 02/04/2003
• Est. Priority Date: 01/18/2000
• Status: Expired due to Term

• Current Assignee: Dell USA LP (Dell Technologies Inc.)
• Original Assignee: Dell USA LP (Dell Technologies Inc.)
• Inventors: Brown, Mark D.
• Primary Examiner(s): Tran, Khoi H.
• Application Number:
  US09/484,712
• Time in Patent Office: 1,113 Days
• Field of Search: 700/213, 700/216, 700/228, 700/230, 700/95, 700/112, 700/113, 700/116, 294/070.1, 198/339.1, 198/346.2, 198/346.3, 414/222.07
• US Class Current: 700/216
• CPC Class Codes: G05B 19/00 Programme-control systems
• CPC Class Codes: G05B 19/44 pneumatic
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202

Abstract

A system of manufacturing of computing devices. The system and method advantageously provide a work cell and process for physically consolidating the transformation process of a computer system (motherboard prep, chassis prep, assembly, EMR, burn, test and boxing) during manufacturing of the same in one work area. The new consolidating manufacturing assembly work cell provides a streamlined process, automation, furniture, fixtures and intelligent controls which physically consolidate the steps of the transformation process. The work cell includes a new combination of equipment for: (1) Material Handling, (2) performing the assembly steps, (3) detecting and repairing electrical and mechanical problems, and (4) performing burn and test. Further, the integration of the transformation process into one consolidated work cell for the manufacture of computer systems enables a new and more versatile manufacturing process. Accordingly, these transformation process steps can be carried out by the same operator/team without having to move a computer system being manufactured to various different parts of the factory during its transformation.

Claims

1. A consolidated computer system manufacturing cell, the manufacturing cell comprising:

an overhead delivery conveyor for delivery of a kit of parts according to a customer order;

a conveyor elevator for transporting the kit of parts from the overhead delivery conveyor to a first work surface of the manufacturing cell;

an assembly area proximate to the conveyor elevator, said assembly area suitable for use in assembling a computer system from the kit of parts received;

a plurality of burn slots disposed within the manufacturing cell for receiving computer systems assembled at the assembly area; and

a dispatch elevator for dispatching an assembled computer system to an available burn slot of the plurality of burn slots, the dispatch elevator configured to receive an assembled computer system in a first orientation and further configured to dispatch the computer system in a second orientation within the available burn slot for burn processing of the assembled computer system.

2. The manufacturing cell of claim 1, further including:

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;

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

first storage configured to receive a plurality of kit trays;

second storage configured to receive a plurality of stored product components; and

a product component list display device, the product component list display device configured to display 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 including a first manufacturing cell having a work space for assembly of the product using product components from the prepared kit tray.

3. A consolidated manufacturing cell for use in the manufacture of custom configured computer systems, the manufacturing cell comprising:

a work surface including at least one section configured to receive a kit of parts and for use during an assembly of a computer system from the kit of parts;

an elevator including a cargo surface suitable for receiving an assembled computer system and being disposed with respect to the work surface for vertical movement between at least a first vertical level and a second vertical level;

at least one burn slot vertically disposed with respect to the work surface, the at least one burn slot further for receiving an assembled computer system during a prescribed burn processing thereof; and

a controller for controlling an operation of the elevator to deliver an assembled computer system from the work surface at the first vertical level to an available burn slot of the at least one burn slot at the second vertical level.

4. The manufacturing cell of claim 3, further including:

a detector for detecting a presence of an assembled computer system upon the cargo surface of the elevator, wherein the controller further controls the operation of the elevator in response to a detection of the assembled computer system by the detector.

5. The manufacturing cell of claim 3, wherein the elevator is centrally disposed within the work surface.

6. The manufacturing cell of claim 3, wherein the first vertical level substantially corresponds to a vertical level of the work surface and the second vertical level substantially corresponds to a vertical level of the available burn slot.

7. The manufacturing cell of claim 3, wherein the controller controls the operation of the elevator for delivery of the assembled computer system within the available burn slot in a prescribed orientation, the prescribed orientation including power and communication ports of the assembled computer system being accessible from an exterior of the consolidated manufacturing cell.

8. The manufacturing cell of claim 3, wherein the controller controls the operation of the elevator for retrieval of a prescribed computer system from a corresponding burn slot in response to an indication that burn processing for the prescribed computer system is completed.

9. The manufacturing cell of claim 8, wherein the controller controls the operation of the elevator for delivering the prescribed computer system to the work surface during the retrieval.

10. The manufacturing cell of claim 3, wherein the at least one burn slot includes a plurality of burn slots disposed vertically from one another.

11. The manufacturing cell of claim 3, wherein the cargo surface of the elevator is configured to rotate between at least a first rotational position and a second rotational position about an axis, and wherein the at least one burn slot includes a plurality of burn slots radially disposed about the axis.

12. The manufacturing cell of claim 3, wherein the cargo surface of the elevator is configured to rotate between at least a first rotational position and a second rotational position about an axis, and wherein the at least one burn slot includes burn slots disposed radially about the axis and burn slots disposed vertically from one another.

13. The manufacturing cell of claim 12, wherein the at least one burn slot includes eight burn slot columns radially disposed about a central vertical axis of the elevator, further including three vertically disposed burn slots per column.

14. The manufacturing cell of claim 3, further including:

a means for displaying information to at least one operator, the information relating to the manufacture of a custom configured computer system.

15. The manufacturing cell of claim 14, wherein the display means includes a flat panel display.

16. The manufacturing cell of claim 15, wherein the display means includes an interactive flat panel display for enabling interactive communications between an operator and the manufacturing cell controller.

17. The manufacturing cell of claim 3, wherein the work surface includes a testing section suitable for use during a testing of the computer system.

18. The manufacturing cell of claim 17, further including a means for testing the computer system, wherein testing of the computer system includes one of the following selected from the group consisting of:

federal communication commission (FCC) testing and high potential (HIPOT) testing.

19. The manufacturing cell of claim 3, wherein the work surface includes a wipe-down section suitable for use during a wipe-down of the computer system.

20. The manufacturing cell of claim 3, wherein the work surface includes an electrical mechanical repair (EMR) section suitable for use during an EMR repair of the computer system.

21. The manufacturing cell of claim 3, wherein the work surface includes a mother board preparation section suitable for use during preparation of a mother board for the computer system from the kit of parts.

22. The manufacturing cell of claim 3, wherein the work surface includes a boxing section suitable for use during a boxing of the computer system with a prescribed shipping box.

23. The manufacturing cell of claim 3, further including:

a means for monitoring an available capacity of the consolidated manufacturing cell and for signaling a delivery of a kit of parts to be received at the work surface in response to a prescribed measure of available capacity.

24. The manufacturing cell of claim 23, wherein the prescribed measure of available capacity is a function of available burn slots and burn time.

25. The manufacturing cell of claim 24, wherein the prescribed measure of available capacity is a function of the presence of a kit of parts being assembled on the work surface.

26. The manufacturing cell of claim 25, wherein the prescribed measure of available capacity is a function of at least one of the following selected from the group consisting of:

a prescribed average burn processing time of computer systems

present within the at least one burn slot;

an availability of the at least one burn slot; and

a presence of a kit of parts being assembled on the work surface.

27. The manufacturing cell of claim 3, further including:

an overhead lift system for delivering a kit of parts from an overhead conveyor to the work surface.

28. The manufacturing cell of claim 3, wherein the kit of parts includes a tote and tray which includes component parts and a chassis according to a given customer order.

29. The manufacturing cell of claim 3, further including:

a means for indicating a completion of burn processing of a prescribed assembled computer system; and

a means responsive to the indication means for signaling a preparation of a shipping box for the prescribed assembled computer system.

30. The manufacturing cell of claim 3, further including:

an overhead shipping box chute for receiving a prescribed shipping box therein, the overhead chute being positioned in proximity to the work surface such that the prescribed shipping box is within easy reach of an operator for placement of the prescribed shipping box onto the work surface.

31. The manufacturing cell of claim 30, further including:

a conveyor system for routing a boxed computer system from the consolidated manufacturing cell to at least one of the following selected from the group consisting of a direct ship area and a shipping distribution center.

32. The manufacturing cell of claim 3, wherein the controller includes means for interfacing with a main build-to-order factory computer.

33. The manufacturing cell of claim 32, wherein each custom configured computer system is identified by a system descriptor record (SDR), further wherein the main build-to-order factory computer and the controller track the manufacturing of computer systems via respective system descriptor records.