Dynamic, lean insulated glass unit assembly line scheduler

• US 8,731,699 B2
• Filed: 09/29/2010
• Issued: 05/20/2014
• Est. Priority Date: 09/29/2009
• Status: Active Grant

• Current Assignee: HP3 Software, Inc.
• Original Assignee: HP3 Software, Inc.
• Inventors: Nagy, Akos, Plant, Philip
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): LAUGHLIN, NATHAN L
• Application Number:
  US12/893,824
• Publication Number:
  US 20110238195A1
• Time in Patent Office: 1,329 Days
• Field of Search: 700 99-102, 700/157, 294/30
• US Class Current: 700/100
• CPC Class Codes: E06B 3/67365 Transporting or handling panes, spacer frames or units during assembly E06B3/67304 - E06B3/67339 take precedence
• CPC Class Codes: E06B 3/67369 Layout of the assembly streets
• CPC Class Codes: Y10T 29/49829 Advancing work to successive stations [i.e., assembly line]

Abstract

A dynamic insulated glass unit (IGU) assembly line scheduler is provided for production control of an IGU assembly line. When calculating the IGU assembly line order and controls, the scheduler evaluates at least i) a changeable set of uniquely identifiable glass lite storage loading locations adjacent a loading station, ii) a changeable set of uniquely identifiable IGU storage locations adjacent a unloading station, iii) a changeable identifiable subset of the set of uniquely identifiable IGU storage locations, and iv) a assembly line change outs to be performed at least in the production of the IGUs for the next in line set of IGUs to be shipped from the IGU assembly line. The scheduler is configured to re-evaluate the IGU assembly order at least with the filling of each next in line set of IGUs to be shipped.

Claims

1. A dynamic insulated glass unit (IGU) assembly line scheduler for production control of an IGU assembly line,

wherein the IGU assembly line is configured to form IGUs of a plurality of distinct types wherein the distinct types require an IGU assembly line change out to be performed on the IGU assembly line when switching from the production of one type of IGU to a distinct type of IGU,

said IGU assembly line scheduler coupled to the IGU assembly line for dynamically scheduling the order of IGUs to be manufactured on the IGU assembly line,

wherein the IGU assembly line includes a loading station at a beginning of the IGU assembly line that includes a changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station, with each storage loading location adapted to receive a glass lite therein for subsequent processing on the IGU assembly line,

wherein the IGU assembly line includes an unloading station at an end of the IGU assembly line that includes a changeable set of uniquely identifiable IGU storage locations adjacent the unloading station with each storage loading location adapted to receive a IGU therein finished from the IGU assembly line, wherein a changeable identifiable subset of the set of uniquely identifiable IGU storage locations adjacent the unloading station defines the next in line set of IGUs to be shipped from the IGU assembly line;

wherein the scheduler is configured to calculate the IGU assembly order and controls for the IGU assembly line, wherein during the calculation the scheduler is configures to evaluate at least

i) the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station,

ii) the changeable set of uniquely identifiable IGU storage locations adjacent the unloading station,

iii) the changeable identifiable subset of the set of uniquely identifiable IGU storage locations, and

iv) the assembly line change outs to be performed on the IGU assembly line at least in the production of the IGUs for the next in line set of IGUs to be shipped from the IGU assembly line, and

wherein the scheduler is configured to re-evaluate the IGU assembly order at least with the filling of each next in line set of IGUs to be shipped from the IGU assembly line.

2. The dynamic IGU assembly line scheduler according to claim 1 wherein the scheduler is configured to re-evaluate the IGU assembly order at least following every IGU completed.

3. The dynamic IGU assembly line scheduler according to claim 1 wherein the changeable set of uniquely identifiable IGU storage locations adjacent the unloading station includes at least a plurality of harp racks mounted adjacent the unloading station, with each harp rack having a plurality of identifiable IGU storage loading locations adapted to receive a IGU therein finished from the IGU assembly line, wherein the changeable identifiable subset of the set of uniquely identifiable IGU storage locations adjacent the unloading station is formed by one harp rack.

4. The dynamic IGU assembly line scheduler according to claim 3 wherein the changeable set of uniquely identifiable IGU storage locations adjacent the unloading station further includes a buffer location with a plurality of uniquely identifiable IGU storage locations, wherein scheduler is configured to identify that finished IGUs from harp racks not yet mounted adjacent the unloading station be placed into the buffer until the associated harp rack is mounted adjacent the unloading station.

5. The dynamic IGU assembly line scheduler according to claim 4 wherein the assembly line change out include spacer type changes on the IGU assembly line.

6. The dynamic IGU assembly line scheduler according to claim 5 wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of harp racks mounted adjacent the loading station, with each harp rack having a plurality of identifiable glass lite storage loading locations adapted to receive a glass lite therein for forming part of an IGU on the IGU assembly line.

7. The dynamic IGU assembly line scheduler according to claim 6 wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of un-mounted harp racks accessible to the loading station, wherein the un-mounted harp racks are more time consuming to load glass lites from than the mounted harp racks.

8. The dynamic IGU assembly line scheduler according to claim 7 wherein the scheduler is configured to further evaluate at least the loading time of glass lites from the mounted harp rack positions and the un-mounted harp rack positions when calculating the IGU assembly order and controls for the IGU assembly line.

9. The dynamic IGU assembly line scheduler according to claim 8 wherein the scheduler includes a user adjustable weighting factor that is adjusted between the extremes of always scheduling the next in line set of IGUs to be shipped from the IGU assembly line and minimizing the assembly line change outs to be performed on the IGU assembly line.

10. The dynamic IGU assembly line scheduler according to claim 1 wherein the scheduler includes a user adjustable weighting factor that is adjusted between the extremes of always scheduling the next in line set of IGUs to be shipped from the IGU assembly line and minimizing the assembly line change outs to be performed on the IGU assembly line.

11. The dynamic IGU assembly line scheduler according to claim 1 wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of harp racks mounted adjacent the loading station, with each harp rack having a plurality of identifiable glass lite storage loading locations adapted to receive a glass lite therein for forming part of an IGU on the IGU assembly line.

12. The dynamic IGU assembly line scheduler according to claim 11 wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of un-mounted harp racks accessible to the loading station, wherein the un-mounted harp racks are more time consuming to load glass lites from than the mounted harp racks.

13. The dynamic IGU assembly line scheduler according to claim 12 wherein the scheduler is configured to further evaluate at least the loading time of glass lites from the mounted harp rack positions and the un-mounted harp rack positions when calculating the IGU assembly order and controls for the IGU assembly line.

14. A dynamic insulated glass unit (IGU) assembly line scheduler for production control of an IGU assembly line, wherein the IGU assembly line is configured to form IGUs of a plurality of distinct types wherein the distinct types require an assembly line change out to be performed on the IGU assembly line when switching from the production of one type of IGU to a distinct type of IGU,

said IGU assembly line scheduler coupled to the IGU assembly line for dynamically scheduling the order of IGU to be manufactured on the IGU assembly line,

wherein the IGU assembly line includes a loading station at a beginning of the IGU assembly line that includes a changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station formed by at least a plurality of harp racks adjacent the loading station with each harp rack having a plurality of glass lite storage locations, with each storage loading location adapted to receive a glass lite therein for subsequent processing on the IGU assembly line,

wherein the IGU assembly line includes an unloading station at an end of the IGU assembly line that includes a changeable set of uniquely identifiable IGU storage locations adjacent the unloading station with each storage loading location adapted to receive a IGU therein finished from the IGU assembly line, with the changeable set of IGU storage locations formed at least by harp racks each having a plurality of storage locations, wherein a changeable identifiable subset of the set of uniquely identifiable IGU storage locations adjacent the unloading station formed by one harp rack defines the next in line set of IGUs to be shipped from the IGU assembly line;

wherein the scheduler is configured to calculate the IGU assembly order and controls for the IGU assembly line, wherein during the calculation the scheduler is configures to evaluate at least

i) the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station,

ii) the changeable set of uniquely identifiable IGU storage locations adjacent the unloading station,

iii) the changeable identifiable subset of the set of uniquely identifiable IGU storage locations, and

iv) the assembly line change outs to be performed on the IGU assembly line at least in the production of the IGUs for the next in line set of IGUs to be shipped from the IGU assembly line, and

wherein the scheduler is configured to re-evaluate the IGU assembly order at least with the filling of each next in line set of IGUs to be shipped from the IGU assembly line.

15. A dynamic insulated glass unit (IGU) assembly line scheduler for production control of an IGU assembly line, wherein the scheduler is configured to calculate the IGU assembly order and controls for the IGU assembly line, wherein during the calculation the scheduler is configures to evaluate at least the following:

i) A changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station,

ii) A changeable set of uniquely identifiable IGU storage locations adjacent the unloading station,

iii) A changeable identifiable subset of the set of uniquely identifiable IGU storage locations, and assembly line change outs to be performed on the IGU assembly line at least in the production of the IGUs for the next in line set of IGUs to be shipped from the IGU assembly line;

wherein the scheduler is configured to re-evaluate the IGU assembly order at least following every IGU completed;

wherein the changeable set of uniquely identifiable IGU storage locations adjacent the unloading station includes at least a plurality of harp racks mounted adjacent the unloading station, with each harp rack having a plurality of identifiable IGU storage loading locations adapted to receive a IGU therein finished from the IGU assembly line, wherein the changeable identifiable subset of the set of uniquely identifiable IGU storage locations adjacent the unloading station is formed by one harp rack;

wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of harp racks mounted adjacent the loading station, with each harp rack having a plurality of identifiable glass lite storage loading locations adapted to receive a glass lite therein for forming part of an IGU on the IGU assembly line;

wherein the changeable set of uniquely identifiable glass lite storage loading locations adjacent the loading station includes at least a plurality of un-mounted harp racks accessible to the loading station, wherein the un-mounted harp racks are more time consuming to load glass lites from than the mounted harp racks; and

wherein the scheduler is configured to further evaluate at least the loading time of glass lites from the mounted harp rack positions and the un-mounted harp rack positions when calculating the IGU assembly order and controls for the IGU assembly line.