System and processes for performing quick changeovers on assembly lines

• US 6,788,987 B2
• Filed: 07/25/2001
• Issued: 09/07/2004
• Est. Priority Date: 03/07/2001
• Status: Expired due to Fees

• Current Assignee: Siemens Electronics Assembly Systems LLC (ASM International NV)
• Original Assignee: Siemens Electronic Assembly Systems Incorporated
• Inventors: Slechta, Scott, Merwin, Mari, Vasquez, Juan
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): JARRETT, RYAN A
• Application Number:
  US09/915,157
• Publication Number:
  US 20020124394A1
• Time in Patent Office: 1,140 Days
• Field of Search: 700/95, 700/97, 700/105, 700/106, 700/83, 700/117, 700/121, 345/700, 345/705-715, 434/72, 434/107, 434/108, 434/219, 434/224, 434/369, 434/428, 434/430
• US Class Current: 700/106
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G05B 2219/32064 Production change over
• CPC Class Codes: H05K 13/0857 Product-specific machine setup; Changeover of machines or assembly lines to new product type
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/53313 Means to interrelatedly feed plural work parts from plural sources without manual intervention

Abstract

An improved method for instructing how to most efficiently effect a product changeover on an assembly line includes the steps of providing an instructional animation which schematically shows the steps which are to be taken by a plurality of workers to effect the changeover. Preferably, the animation is a computer animation, and includes color-coded representations of the various workers and the steps that should be taken in a particular sequence. Preferably, the workers are also provided with instructional badges which could be carried by the workers, and which are also color-coded. The animation will also include access to these color-coded instruction to provide further feedback to both the worker, and the supervisory personnel of the steps an individual worker should be taking during a particular point in the assembly in changeover. Further, the present invention includes a method of identifying a required changeover time including the steps of preparing a table showing the number of components which need to be changed, and then providing an identification of the required time for that particular changeover. The components are all preferably used in combination in a method of changing over an assembly line.

Claims

1. A method of changing an assembly line between the manufacture of two different products comprising the steps of:

1) identifying assembly line components which must be changed to effect a changeover at the assembly line between the manufacture of two different product;

2) preparing an animation showing steps which should be taken by a number of individuals associated with the changeover to effect the changeover, the animation showing movement and steps the individuals will need to make to complete the changeover; and

3) showing the animation to the individuals prior to the changeover to assist in providing instruction to the individuals of the movement and steps necessary during the changeover.

2. A method as set forth in claim 1, wherein the animation is unique for the changeover between two products.

3. A method as set forth in claim 1, wherein a timeline is provided alone with the animation to provide feedback of an order and timing for the particular steps involved in the changeover.

4. A method as set forth in claim 3, wherein the animation is utilized during the changeover to provide feedback on the changeover compared to a prediction of the time to complete the changeover.

5. A method of changing an assembly line between the manufacture of two different products comprising the steps of:

1) identifying assembly line components which must be changed to effect a changeover at the assembly line between the manufacture of two different products;

2) preparing an animation showing steps which should be taken by a number of individuals associated with the changeover to effect the changeover;

3) showing the animation to the individuals prior to the changeover to assist in providing instruction to the individuals of the steps necessary during the changeover; and

4) the animation including a representation of icons associated with each of the individuals involved in the changeover, and instructions for any one of the individuals are selectively provided as part of the animation.

6. A method as set forth in claim 5, wherein the animation is a computer animation, and the individuals may select an icon associated with each of the individuals to highlight the instructions for the particular individual.

7. A moving visual instructional animation comprising:

a schematic representation of an assembly line which is to be changed;

a number of visual icons associated with individuals who are to effect a changeover, the visual icons moving through a sequence of steps which are to be taken during the changeover to effect the changeover; and

a timeline provided as part of the animation to provide instruction of a timing for each of the steps.

8. An animation as set forth in claim 7, wherein the animation is provided as a computer animation.

9. An animation as recited in claim 7, wherein the icons are color-coded icons having representations distinct for several of the individuals.

10. An animation as recited in claim 9, wherein different instruction sheets are provided within the animation and are coded to the coding provided for each of the individuals such that the individuals can review the instruction sheets.

11. A system for instructing a plurality of individuals in a changeover comprising:

an animation showing steps to be taken during a changeover, said animation including a schematic representation of an assembly line, and said animation including a number of representations of the individuals who are to effect the changeover, the representations of the individuals being coded such that distinct individuals can identify themselves in the animation; and

said animation also including representations of instruction sheets to be carried by the individuals, the instruction sheets being coded to the coding of the representations of the individuals in the animation.

12. A system as set forth in claim 11, wherein the representations and the sheets are color-coded for the individuals.

13. A system as set forth in claim 11, wherein a timeline is included in the animation and shows the steps to be taken at particular periods of time during the changeover.

14. A system as set forth in claim 13, wherein the timeline further shows a representation of when a last unit of a prior products should be manufactured and the first unit of a new products should be manufactured.

15. An instructional system for providing instructions to a plurality of individuals on an assembly line comprising:

a plurality of color-coded instructions, each of the color-coded instructions being provided with instructional steps which are to be taken by the individual during a changeover; and

each of the individuals on a changeover being associated with a particular color coding and provided with a badge, the color-coded instructions being provided to the individual based upon the individual'"'"'s associated color coding.