Production system for garments or other products

• US 5,233,534 A
• Filed: 05/24/1991
• Issued: 08/03/1993
• Est. Priority Date: 05/24/1991
• Status: Expired due to Term

• Current Assignee: Gerber Scientific International Incorporated (Gerber Scientific LLC)
• Original Assignee: Gerber Garment Technology, Inc. (Gerber Scientific LLC)
• Inventors: Osthus, Harold L., Beausoleil, Vernon, Howitt, Richard
• Primary Examiner(s): Smith, Jerry
• Assistant Examiner(s): GORDON, PAUL P
• Application Number:
  US07/705,074
• Time in Patent Office: 802 Days
• Field of Search: 364/468, 364/131, 364/138, 364/470, 364/474.11, 364/478, 198/340, 198/341, 112/121.12, 112/155, 112/262.3
• US Class Current: 700/100
• CPC Class Codes: A41H 42/00 Multi-step production lines for making clothes
• CPC Class Codes: B65G 47/50 according to destination signals stored in separate systems
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32121 Read identification of pallet, conveyor and enter data for manufacturing
• CPC Class Codes: G05B 2219/32145 Manual, enter identification, name workpiece and teach manufacturing data
• CPC Class Codes: G05B 2219/32147 Edit teached data to change operation parameters of workstations
• CPC Class Codes: G05B 2219/32174 Memory table parts classification and working, manufacturing conditions
• CPC Class Codes: G05B 2219/32175 Table with correlation between part codes and part classification
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A production system for garments or other products includes a plurality of work stations for performing a series of work operations in which parts of a garment or other product are progressively manufactured. A conveyorized transport system extends between the various work stations and the flow of work between the various stations is regulated by assigning class codes to each operation required for a garment and each operation available at the various work stations. The class codes for a given garment order are read sequentially from a data memory and as a requirement for each code or work operation arises in the course of producing the garment, the scheduler searches a second data memory to locate the work stations which offer the work operations corresponding to the class code sought. The scheduler then determines from among the available work stations the specific work station to which the garment pieces are sent for performing the required work operation.

Claims

1. A production system for garments or other products comprising:

a plurality of work stations having operating means for performing a series or work operations in which parts of a garment or other product are progressively manufactured, each work station being capable of performing at least one operation in a series to manufacture one or more products;

controlled transporting means connected with the plurality of work stations for conveying the product in various states of manufacture from station to station to perform the series of work operations in sequence;

control means connected in controlling relationship with the transporting means and including first memory means for storing a product order in terms of the series of work operations for a selected style of product, each work operation in the series being associated with a class code unique to the operation;

second memory means for storing data defining the work operations assigned to each of the various work stations in the system, the assigned operations at a given station being defined in terms of the class codes whereby a search of the second memory for a class code reveals the stations assigned to perform a selected work operation; and

scheduling means for searching the class codes in second memory means to identify the work stations assigned to perform a given work operation in a series for a given product order, and then selecting from the work stations assigned, one work station for accomplishing the given work operation for the order.

2. A production system for garments or other products as defined in claim 1 wherein the controlled transporting means is connected with the scheduling means for conveying selected product from one work station to the next work station in response to the selections of the scheduling means.

3. A production system for garments or other products as defined in claim 1 wherein:

editing means are provided for editing the second memory means and changing the class codes and corresponding work operations assigned to the various work stations.

4. A production system for garments or other products as defined in claim 1 wherein:

editing means are provided for editing the first memory means and changing the class codes and corresponding work operations comprising a given product order.

5. A production system for garments or other products as defined in claim 1 wherein:

a storage station is included among the plurality of work stations for temporarily storing garments or other product between work operations; and

the controlled transporting means is also connected with the storage station for conveying product between a work station and the storage station.

6. A production system for garments or other products as defined in claim 1 wherein:

at least some of the work stations include equipment operated by a human operator to perform work operations on the product.

7. A production system for garments or other products as defined in claim 1 wherein:

some of the work stations are capable of performing work operations of a defined class code on only selected product orders; and

the second memory means stores, in addition to the class codes of operations assigned to the work stations, other information identifying selected product orders of which the work station is capable.

8. Apparatus for controlling a transport system which conveys garments or other products in various states of manufacture between a plurality of work stations at each of which there exists a capability of performing at least one of a series of work operations which collectively result in manufacture of the product, comprising:

first memory means for storing in terms of operation codes the series of work operations required to be performed to manufacture a given product;

second memory means for storing in terms of operation codes the work operations in association with the work stations capable of performing the respective operations; and

scheduling means connected with the first and second memory means for reading from the first memory means operation codes for the operations required to manufacture a product, for scanning the operation codes of the second memory means to locate work stations capable of performing the work operations required for manufacture and for selecting from among the located work stations the particular work stations to actually perform the work operations.

9. Apparatus for controlling a transporting system as defined in claim 8 wherein:

the first memory means stores the work operations with sequencing information defining the sequence in which the work operations are to be performed to manufacture a product; and

the scheduling means reads the first memory means and selects the particular work stations to actually perform the operations in the sequence defined by the sequencing information.

10. Apparatus for controlling a transporting system as defined in claim 9 wherein:

the sequencing information is defined by the sequence of the operation codes within the first memory means.

11. Apparatus for controlling a transport system as defined in claim 8 which conveys products between the plurality of the wok stations which perform work operations and between other stations which receive product from work stations or send product to work stations in the manufacture of product without performing work operations on the product, wherein the scheduling means also selects from among said other stations stations to receive or send product as the work loads at the work stations vary.

12. Apparatus for controlling a transport system as defined in claim 8 wherein:

the second memory means stores the operation codes and additional information pertaining to manufacture of a product and the capability of the work stations that perform work operations; and

the scheduling means scans the operation codes and the additional information to select the work stations to actually perform the work operations.

13. A method of controlling workflow in a production system having a plurality of work stations, each performing one or more work operations which operations result in manufacture of product from parts thereof comprising:

assigning class codes to each of a series of work operations required to be performed at the various work stations to manufacture a number of different products, each series of operations being associated respectively with one of the products;

storing the class codes of the series in a first memory for subsequent use in filling orders for the products;

storing in a second memory in association with each work station the class codes for the work operations available at each station;

reading from the first memory the series of class codes for work operations required to fill an order for a given product;

scanning the class codes in the second memory to determine from among all of the work stations the work stations available to perform the series of work operations required to fill the order for the given product; and

then

scheduling the workflow between the available work stations as determined by the scanning to fill the order for the given product.

14. A method of controlling workflow in a production system as defined in claim 13 wherein:

the step of storing the class codes in the first memory includes storing the series of class codes for work operations required to fill an order for a given product in combination with a sequence in which the work operations are to be performed by the available work stations;

the step of reading includes reading the series of class codes from the first memory and the stored sequence; and

the step of scheduling includes scheduling workflow between work stations in accordance with the stored sequence.

15. A method of controlling workflow as defined in claim 14 wherein an additional step comprises:

performing the series of work operations in the stored sequence to fill the order for the given product.

16. A method of controlling workflow in a production system having a plurality of work stations as defined in claim 13 wherein:

the steps of scanning and scheduling are performed after each work operation to select the work station to perform the next work operation in the series.

17. A method of controlling workflow in a production system as defined in claim 13 wherein:

the step of storing in a second memory includes storing additional information pertaining to a capacity to accomplish the work operations at the work stations; and

the step of scanning includes scanning the additional information pertaining to the capacity; and

the step of scheduling includes selecting from among the available work stations a particular work station to fill the order based upon both the class cods and the additional information in the second memory.

18. A method of controlling workflow in a production system as defined in claim 13 further including the step of editing the class codes stored in the second memory to reflect changes in work operations available at the work stations.

19. A production system for garments or other products comprising:

a plurality of work stations having operating means for performing a series of work operations in which parts of a garment or other product are progressively manufactured, each work station being capable of performing at least one operation in the series to manufacture one or more products;

control means including first memory means for storing a product order in terms of the series of work operations for a selected style of product, each work operation in the series being stored with a class code unique to the operation;

second memory means for storing data defining the work operations available at each of the various work stations in the system, the available operations at a given station being defined in terms of the class codes whereby a search of the second memory for a class code reveals the stations available to perform a selected work operation; and

scheduling means for searching the class codes in the second memory means to identify the work stations available to perform a given work operation in a series for a given product order, and then selecting from among the available work stations a particular work station for accomplishing the given work operation for the order.

20. A production system for garments and other products as defined in claim 19 wherein:

a controlled transporting means interconnects each of the work stations for conveying the parts of a garment or other product in various states of assembly between the stations; and

the scheduling means is operatively connected with the controlled transporting means for conveying a part to a particular work station in accordance with the selection.

21. A production system as defined in claim 19 further including editing means for editing the second memory means and changing the class codes to indicate different work operations available at the work stations.