DESC:METHOD AND SYSTEM FOR IMPROVING ASSEMBLY EFFICIENCY
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202321050182 filed on 25/07/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to operation of assembly lines. The present disclosure specifically relates to a system for improving assembly efficiency. Furthermore, the present disclosure relates to a method of improving assembly efficiency.
BACKGROUND
After the industrial revolution, the assembly lines have been commonly used for mass production of various articles including automobiles, heavy machinery, consumer electronics, household appliances, power tools, furniture and so on. The assembly lines, generally improve the productivity as the specialized workers are used for specific tasks having efficiency exceeding any single-worker assembly method. The assembly lines generally reduce the labour cost and provide consistent product quality while reducing wastage of material and achieving economies of scale.
Usually, the assembly lines are operated and/or worked upon by operators. The operators operate various tools associated with the assembly line to assemble a particular article on the assembly line. Such tools may have standard operating parameters for assembly of the particular article. It is pertinent to note that any variation from the standard operating parameter may cause the error in the assembly of the vehicle or may affect the quality of the article being assembled on the assembly line.
Generally, such errors are inspected by the human operators specializing in quality control. The quality control operator would monitor and inspect each of the article being assembled on the assembly line at various points of assembly and detect any assembly error (if any). Furthermore, the quality control operator would also determine remedies to be implemented in downstream processes of the assembly line. Such remedy may cause quality control issues in the articles assembled as the article with subpar assembly may pass-through the inspection. Alternatively, a corrective action may be taken at the node where the error occurred, however, such correction would require manual inspection each assembly step which would increase the assembly complexity and inefficiency in the assembly process. Moreover, the error detection in both the methodologies would depend on the inspection expertise of the quality control operator which may lead to quality and efficiency variation between different operators.
Therefore, there exists a need for an improved system that reduces error and increases efficiency in the assembly process and overcomes the one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a system for improving assembly efficiency of an assembly line.
Another object of the present disclosure is to provide a method of improving assembly efficiency of an assembly line.
In accordance with first aspect of the present disclosure, there is provided a system for improving assembly efficiency of an assembly line. The system comprises at least one sensor and a processing unit. The at least one sensor is coupled with each tool of a plurality of tools associated with the assembly line. The processing unit is configured to identify at least one tool from the plurality of tools associated with the assembly line, receive at least one contemporary value of a parameter associated with the identified tool from the at least one sensor, retrieve at least one ideal value of the parameter associated with the identified tool, compare the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter, and generate an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
The system, as disclosed by the present disclosure is advantageous in terms of monitoring the assembly line for timely detection of any faults and/or quality issues in an article being assembled on the assembly line. Beneficially, the system of the present disclosure is advantageous in terms of improving the efficiency of the assembly line. Beneficially, the system of the present disclosure is advantageous in terms of reducing the downtime of the assembly line. Beneficially, the system of the present disclosure is advantageous in terms of reducing overall cost of assembling articles on the assembly line. Beneficially, the system of the present disclosure is advantageous in terms of minimizing the labour cost, operational cost and energy cost of operating the assembly line. Beneficially, the system of the present disclosure is advantageous in terms of improving the quality of the articles being assembled on the assembly line ensuring high precision and consistency.
In accordance with second aspect of the present disclosure, there is provided a method of improving assembly efficiency of an assembly line. The method comprises identifying at least one tool from a plurality of tools associated with the assembly line, receiving at least one contemporary value of a parameter associated with the identified tool, retrieving at least one ideal value of the parameter associated with the identified tool, comparing the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter, generating an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1a illustrate a block diagram of a system for improving assembly efficiency of an assembly line, in accordance with an aspect of the present disclosure.
FIG. 1b illustrate a block diagram of a system for improving assembly efficiency of an assembly line, in accordance with an embodiment of the present disclosure.
FIG. 2 illustrates a flow chart of a method of improving assembly efficiency of an assembly line, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a system and method for improving assembly efficiency of an assembly line and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “tools” and “plurality of tools” are used interchangeably and refers to various devices and equipment used to facilitate and perform assembly of article on the assembly line. The plurality of tools may be hand tools, power tools, pneumatic tools, measuring tools, inspection tools, fixture tools, jig tools, conveyance tools, material handling tools, fastening tools, cutting tools and so on. It is to be understood that the plurality of tools may include screwdrivers, wrenches, pliers, hammers, electric screwdrivers, drills, impact wrenches, riveting tools, air screwdrivers, air drills, air wrenches, callipers, micrometres, gauge blocks, assembly fixtures, jigs, conveyor belts, roller conveyors, cranes, trolleys, pallet jacks, nail guns, staple guns, riveters, CNC machines and so on.
As used herein, the terms “sensor” and “sensor arrangement” are used interchangeably and refer to a configuration of sensors in the system to measure, monitor or detect specific parameters, conditions and/or events pertaining to the plurality of tools. The sensors may be proximity sensors, position sensor, displacement sensor, temperature sensor, force sensor, torque sensor, vision sensor, flow sensor, level sensor, humidity sensor, optical sensor, gas sensor, magnetic sensor, ultrasonic sensor, light sensor and so on. The sensors may include inductive proximity sensor, capacitive proximity sensor, photo electric sensor, linear variable differential transformers, rotary encoders, potentiometers, piezoelectric sensors, strain gauge sensors, thermocouples, resistance temperature detectors, infrared sensors, load cells, torque sensors, cameras, machine vision sensors, accelerometers, vibration transducers, mass flow meters, volume flow meters, ultrasonic level sensors, capacitive level sensors, hygrometers, fiber optic sensor, oxygen sensor, carbon dioxide sensor, hall effect sensors, rangefinders, photodiodes and so on.
As used herein, the terms “processing unit” and “data processing unit” are used interchangeably and refer to a computational element that is operable to respond to and processes instructions. Optionally, the processing unit includes, but is not limited to, a microprocessor, a micro-controller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing circuit. Furthermore, the term “processor” may refer to one or more individual processors, processing devices and various elements associated with a processing device that may be shared by other processing devices. Furthermore, the processing unit may comprise ARM Cortex-M series processors, such as the Cortex-M4 or Cortex-M7, or any similar processor designed to handle real-time tasks with high performance and low power consumption. Furthermore, the processing unit may comprise custom and/or proprietary processors.
As used herein, the terms “memory unit”, “data storage unit” and “memory module” are used interchangeably and refer to electronic storage units capable of storing any structured or unstructured data in a required format for later retrieval and usage. The memory module may be read only. Alternatively, the memory module may be read and write capable.
As used herein, the term “communication unit” refers to an arrangement of interconnected programmable and/or non-programmable components that are configured to facilitate data communication between one or more electronic devices and/or databases, whether available or known at the time of filing or as later developed. Furthermore, the communication unit may utilise, but is not limited to, a public network such as the global computer network known as the Internet, a private network, Wi-Fi, a cellular network including 2G, 3G, 4G, 5G LTE etc. and any other communication system or systems at one or more locations. Additionally, the communication unit may execute wired or wireless communication that can be carried out via any number of known protocols, including, but not limited to, Internet Protocol (IP), Wireless Access Protocol (WAP), Frame Relay, or Asynchronous Transfer Mode (ATM). Moreover, any other suitable protocols using voice, video, data, or combinations thereof, can also be employed. Moreover, the communication unit may communicate using TCP/IP communications protocols. Furthermore, the communication unit may also communicate using IPX, Appletalk, IP-6, NetBIOS, OSI, any tunnelling protocol (e.g., IPsec, SSH), or any number of existing or future protocols. It would be appreciated that internal components of system would utilise communication methods including Controller Area Network, Local Interconnect Network, FlexRay, Ethernet, Modbus, Profibus, DeviceNet, Ethernet/IP, Modbus TCP/IP, Profinet and so forth. Similarly, it would be appreciated that the system would utilise communication methods including Wi-Fi, cellular network, and Bluetooth for communication with external modules/units/components.
As used herein, the term “terminal device” refers to a computing unit comprising processing, networking and user interfacing capabilities. The terminal device may be a fixed device or may be a handheld computing device. The terminal device may include a specialized terminal device. The terminal device may include a smartphone, a tablet, a handheld terminal and so forth.
As used herein, the term “assembly line controller” refers to control system configured for management and operation of an assembly line. The assembly line controller may be responsible for coordinating and controlling various tasks, machinery, tools and processes on the assembly line. The assembly line controller may perform at least one of: process coordination, automation control, monitoring, quality control, and safety management on the assembly line. Furthermore, the assembly line controller may comprise processing module, input/output module, memory module, communication module and human machine interface module. It is to be understood that a human operator/manager of the assembly line may interact with human machine interfaces of the assembly line controller to control at least one operation on the assembly line. The processing module of the assembly line controller may comprise at least one of: programmable logic controllers, distributed control systems, supervisory control and data acquisition systems, embedded controllers and so on.
As used herein, the term “assembly line” refers to a manufacturing system in which a product or an article is assembled in a sequential manner as it moves along a mechanized path. It is to be understood that the assembly line is designed to increase efficiency, productivity, and consistency by having workers or machines perform specific tasks at designated stations. Each station adds parts or components to the product, progressively building it until it is fully assembled. The assembly line may be operated and controlled by an assembly line controller.
As used herein, the term “parameter” refers to measurable factors associated with each of the tools that define the operation and/or operational condition of the particular tool. The parameters associated with each of the plurality of tool may be utilized to control the operation of the particular tool. In an example, for a screwdriver, number of rotations to tighten a particular screw is a parameter associated with said screwdriver.
As used herein, the term “contemporary value” refers to a numerical value of a parameter associated with the particular tool during the operation of the particular tool on the assembly line for assembly of a specified article/product. In an example, for a screwdriver, the number of rotations being performed for tightening of a screw at a particular instance of article/product is the contemporary value of the parameter for the screwdriver. In other words, the contemporary value of the parameter is required to be understood as a real-time value being received the at least one sensor during the operation of the tool on the assembly line.
As used herein, the term “ideal value” refers to a numerical value of a parameter associated with the particular tool that should occur on operating the particular tool according to a standard operating procedure specified for an article/product. In an example, for a screwdriver, the number of rotations that should be performed for tightening of a screw of a particular article/product is the ideal value of the parameter for the screwdriver. In other words, the ideal value of the parameter is required to be understood as a standard operating procedure established parameter value of the tool on the assembly line for the specified article/product.
As used herein, the term “threshold value” refers to at least one numerical value of a parameter associated with the particular tool within which the operation of the particular tool would yield error free and consistent assembly of the specified article/product.
As used herein, the term “error signal” refers to an electronic signal generated by the processing unit, when the contemporary value of the parameter associated with the identified tool is beyond at least one threshold value, to indicate an error in the assembly process of the article on the assembly line.
As used herein, the term “user” refers to a human operator present on the assembly line. The user may include at least one tool operator, at least one assembly line operator, at least one supervisor and so on.
As used herein, the term “corrective action signal” refers to an electronic control signal generated by the processing unit, based on the error signal. The corrective action signal comprises instructions which may be executed by the assembly line controller to initiate at least one corrective action for resolving the error in the assembly process. The instructions in the corrective action signal may be decided by the processing unit based on the information in the error signal. In an example, the instructions in the corrective action signal may be decided by the processing unit based on at least one magnitude deviation of the contemporary value of the parameter from the ideal value of the parameter associated with the tool.
As used herein, the term “corrective action” refers to an action performed on the assembly line to rectify the error. The corrective action may also prevent the recurrence of errors or defects in the assembly process of the article on the assembly line.
As used herein, the term ‘communicably coupled’ refers to a bi-directional connection between the various components of the system. The bi-directional connection between the various components of the system enables exchange of data between two or more components of the system.
Figure 1a, in accordance with an embodiment describes a system 100 for improving assembly efficiency of an assembly line. The system 100 comprises at least one sensor 102 and a processing unit 106. The at least one sensor 102 is coupled with each tool of a plurality of tools 104 associated with the assembly line. The processing unit 106 is configured to identify at least one tool from the plurality of tools 104 associated with the assembly line, receive at least one contemporary value of a parameter associated with the identified tool from the at least one sensor 102, retrieve at least one ideal value of the parameter associated with the identified tool, compare the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter, and generate an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
The system 100 is advantageous in terms of monitoring the assembly line for timely detection of any faults and/or quality issues in an article being assembled on the assembly line. Beneficially, the system 100 of the present disclosure is advantageous in terms of improving the efficiency of the assembly line. Beneficially, the system 100 of the present disclosure is advantageous in terms of reducing the downtime of the assembly line. Beneficially, the system 100 of the present disclosure is advantageous in terms of reducing overall cost of assembling articles on the assembly line. Beneficially, the system 100 of the present disclosure is advantageous in terms of minimizing the labour cost, operational cost and energy cost of the assembly line. Beneficially, the system 100 of the present disclosure is advantageous in terms of improving the quality of the articles being assembled on the assembly line ensuring high precision and consistency.
It is to be understood that the at least one sensor 102 is configured to sense the parameter associated with the corresponding tool of the plurality of tools 104 associated with the assembly line. Furthermore, it is to be understood that there may be more than one parameter associated with a particular tool of the plurality of tools 104, therefore, there may be more than one sensor associated with such tool. It is to be understood that the at least one sensor 102 is configured to sense the at least one contemporary value of the parameter associated with the tool of the plurality of tools 104.
The processing unit 106 is configured to identify the at least one tool from the plurality of tools 104 associated with the assembly line. The identification of the at least one tool from the plurality of tools 104 is done by the processing unit 106 using at least one of: radio frequency identification, barcodes or QR codes, computer vision, near field communication, Wi-Fi, Bluetooth, proximity detection, touch detection and so on. Furthermore, the identification of the at least one tool from the plurality of tools 104 may be done by the processing unit 106 by analyzing data which being received from the at least one tool. Furthermore, the identification of the at least one tool from the plurality of tools 104 may be done by the processing unit 106 using ultrasound and/or acoustic identification techniques. In an example, the processing unit 106 is configured to identify that a particular tool from the plurality of tools 104 is a power screwdriver.
The processing unit 106 is configured to receive at least one contemporary value of the parameter associated with the identified tool from the at least one sensor 102. It is to be understood that the at least one sensor 102 is communicably coupled with the processing unit 106.
The processing unit 106 is configured to retrieve at least one ideal value of the parameter associated with the identified tool. In an embodiment, the system 100 comprises a memory unit 108, wherein the memory unit 108 is configured to store the at least one ideal value of the parameter and the at least one threshold value associated with each of the plurality of tools 104. Beneficially, the at least one ideal value of the parameter and the at least one threshold value associated with each of the plurality of tools 104 may be stored in the memory unit 108 for retrieval by the processing unit 106. Beneficially, the memory unit 108 is communicably coupled with the processing unit 106. It is to be understood that the processing unit 106 is configured to retrieve at least one ideal value of the parameter associated with the identified tool from the memory unit 108.
The processing unit 106 is configured to compare the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter. It is to be understood that the at least one ideal value of the parameter is defined by the standard operating procedure specified for the article being assembled. The at least one contemporary value of the parameter may be different from the at least one ideal value of the parameter due to multiple operational factors such as human error, operational error, control error, machine error and so on. It is to be understood that the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is determined by comparing the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool.
The processing unit 106 is configured to generate an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value. It is to be understood that the at least one threshold value are defined by the standard operating procedure specified for the article being assembled. Beneficially, the processing unit 106 is configured to generate the error signal when the at least one contemporary value of the parameter is beyond the at least one threshold value from the at least one ideal value of the parameter. Advantageously, the error signal may not be generated by the processing unit 106 when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is within the at least one threshold value. In an example, the processing unit 106 is configured to identify that the particular tool from the plurality of tools 104 is the power screwdriver. The parameter associated with the power screwdriver may be number of rotations to tighten a particular screw. The ideal value of the rotation for tightening the particular screw may be 10 rotations. The threshold values of the rotation may be 9 rotations and 11 rotations. When the contemporary value of the rotations is being received as 8 rotations, the processing unit 106 compares the contemporary value of the rotations with the ideal value of the rotations to determine the deviation of the contemporary value of rotations from the ideal value of rotations and generates the error signal as the deviation of the contemporary value of the rotations from the ideal value of rotations is beyond the threshold values. In other words, the contemporary value of the parameter does not lie within the threshold values of the parameter, thus, the error signal is generated by the processing unit 106. It is to be understood that for the above example, if the contemporary value of the rotations is being received as 11 rotations, the processing unit 106 compares the contemporary value of the rotations with the ideal value of the rotations to determine the deviation of the contemporary value of rotations from the ideal value of rotations and does not generates the error signal as the deviation of the contemporary value of the rotations from the ideal value of rotations is within the threshold values.
In an embodiment, the processing unit 106 is configured to determine an operational efficiency of the assembly line based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter. Beneficially, the operational efficiency is obtained by the determining the ratio of the number of deviations of the at least one contemporary value of the parameter from the at least one ideal value of the parameter and the total number of the at least one contemporary value of the parameter received from the at least one sensor 102 coupled with the plurality of tools 104 pertaining to the assembly of the particular article. Beneficially, the determination of the operational efficiency of the assembly line enables measures to reduce assembly inefficiencies and thus, improve the assembly efficiency of the assembly line. More beneficially, the determination of the assembly efficiency may indicate performance of at least one user operating the plurality of tools 104 associated with the assembly line for assembly of the at least one article.
In an embodiment, the system 100 comprises a communication unit 110, wherein the communication unit is configured to transmit the error signal to at least one terminal device 112. Beneficially, the error signal may indicate an assembly error during the assembly process of the particular article. It is to be understood that the communication unit 110 is communicably coupled to the at least one terminal device 112.
In an embodiment, the terminal device 112 is configured to display at least one error to a user, based on the received error signal. Beneficially, the terminal device 112 displays at least one error to the user to indicate the assembly error during the assembly process of the particular article. Beneficially, such display of the error to the user provides error information to the user and may enable the user to formulate an error mitigation process.
In an embodiment, the processing unit 106 is configured to generate a corrective action signal, based on the error signal. Beneficially, the processing unit 106 is configured to assess a severity of the error based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter and generate the corrective action signal accordingly. It is to be understood that the corrective action signal may be an instruction signal. In an embodiment, the processing unit 106 is configured to generate a corrective action signal, based on the error signal and communicate the generated corrective action signal to the terminal device for displaying the same to the user. In such case, the user may approve the corrective action signal.
In an embodiment, the system 100 comprises an assembly line controller 114, wherein the assembly line controller 114 is configured to execute at least one corrective action, based on the corrective action signal. Beneficially, the assembly line controller 114 receives the corrective action signal and execute the at least one corrective action to correct the assembly error occurred during the assembly process of the particular article.
In an embodiment, the processing unit 106 is configured to identify at least one article ongoing on the assembly line. Beneficially, the processing unit 106 is configured to identify the at least one article ongoing (being assembled) on the assembly line. In an embodiment, the processing unit 106 may employ electronic identification of the at least one article ongoing on the assembly line. The electronic identification may comprise QR code-based identification, barcode-based identification, serial number-based identification, and so on. In another embodiment, the processing unit 106 may employ at least one image-sensing and computer vision-based identification of the at least one article ongoing on the assembly line. Beneficially, the identification at least one article ongoing on the assembly line may enable accurate determination of the article to be associated with the error and accordingly the corrective action may be implemented. In other words, the identification at least one article ongoing on the assembly line would enable the processing unit 106 to determine which particular article has suffered the assembly error.
In an embodiment, the at least one corrective action comprises re-operation of the at least one identified tool, diversion of at least one product associated with the error signal from the assembly line, and halting the assembly line. Beneficially, the at least one corrective action is determined by the processing unit 106 based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter and generate the corrective action signal accordingly. Beneficially, the re-operation of the at least one identified tool may be executed as the corrective action to correct minute assembly errors occurred on the assembly line during the assembly process of the particular article. Furthermore, the diversion of at least one product associated with the error signal from the assembly line may be executed as the corrective action to correct significant assembly errors occurred on the assembly line during the assembly process of the particular article. Furthermore, the halting of the assembly line may be executed as the corrective action to correct severe assembly errors occurred on the assembly line during the assembly process of the particular article.
In an exemplary embodiment, the article being assembled on the assembly line may be a vehicle, particularly, two-wheeler vehicle. In such example, a frame may be received on the assembly line and a swingarm may be assembled on the frame during the assembly process. In such example, the at least one tool of the plurality of tools 104 may be a power wrench for tightening at least one nut-bolt. In such example, the parameter associated with the power wrench may be number of rotations to tighten the nut-bolt. In such example, the ideal value of the number of rotations (parameter) may be 30 rotations for tightening the nut-bolt to assemble the swingarm with the frame. In such example, the threshold number of rotations may be 2 rotations. In such example, during the assembly of the particular swingarm on the particular frame, if the contemporary value of the number of rotations of the power wrench is 27 rotations, then the processing unit 106 would compare the 27 number of rotations with the 30 number of rotations of the power wrench. In such example, the deviation is determined as 3 rotations and since the deviation of 3 rotations is beyond the threshold of 2 rotations, the error signal would be generated indicating the assembly error in the process of assembly.
Figure 1b, in accordance with an embodiment describes that the system 100 comprises the at least one sensor 102 and the processing unit 106. The at least one sensor 102 is coupled with each tool of the plurality of tools 104 associated with the assembly line. The processing unit 106 is configured to identify the at least one tool from the plurality of tools 104 associated with the assembly line, receive the at least one contemporary value of the parameter associated with the identified tool from the at least one sensor 102, retrieve the at least one ideal value of the parameter associated with the identified tool, compare the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter, and generate the error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value. Furthermore, the system 100 comprises the memory unit 108, wherein the memory unit 108 is configured to store the at least one ideal value of the parameter and the at least one threshold value associated with each tool of the plurality of tools 104. Furthermore, the system 100 comprises a memory unit 108, wherein the memory unit 108 is configured to store the at least one ideal value of the parameter and the at least one threshold value associated with each of the plurality of tools 104. Furthermore, the processing unit 106 is configured to determine an operational efficiency of the assembly line based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter. Furthermore, the system 100 comprises a communication unit 110, wherein the communication unit is configured to transmit the error signal to at least one terminal device 112. Furthermore, the terminal device 112 is configured to display at least one error to a user, based on the received error signal. Furthermore, the processing unit 106 is configured to generate a corrective action signal, based on the error signal. Furthermore, the system 100 comprises an assembly line controller 114, wherein the assembly line controller 114 is configured to execute at least one corrective action, based on the corrective action signal. Furthermore, the processing unit 106 is configured to identify at least one article ongoing on the assembly line. Furthermore, the at least one corrective action comprises re-operation of the at least one identified tool, diversion of at least one product associated with the error signal from the assembly line, and halting the assembly line.
Figure 2, describes a flow chart of a method 200 of improving assembly efficiency of an assembly line. The method 200 starts at step 202 and finishes at step 210. At step 202, the method 200 comprises identifying at least one tool from a plurality of tools associated with the assembly line. At step 204, the method 200 comprises receiving at least one contemporary value of a parameter associated with the identified tool. At step 206, the method 200 comprises retrieving at least one ideal value of the parameter associated with the identified tool. At step 208, the method 200 comprises comparing the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter. At step 210, the method 200 comprises generating an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
In an embodiment, the method 200 comprises storing the at least one ideal value of the parameter and the at least one threshold value associated with each of the plurality of tools 104.
In an embodiment, the method 200 comprises determining an operational efficiency of the assembly line based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter.
In an embodiment, the method 200 comprises transmitting the error signal to at least one terminal device.
In an embodiment, the method 200 comprises displaying at least one error to a user, based on the received error signal.
In an embodiment, the method 200 comprises generating a corrective action signal, based on the error signal.
In an embodiment, the method 200 comprises executing at least one corrective action, based on the corrective action signal.
In an embodiment, the method 200 comprises identifying at least one article ongoing on the assembly line.
In an embodiment, the at least one corrective action comprises re-operation of the at least one identified tool, diversion of at least one product associated with the error signal from the assembly line, and halting the assembly line.
It would be appreciated that all the explanations and embodiments of the system 100 also apply mutatis-mutandis to the method 200.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A system (100) for improving assembly efficiency of an assembly line, wherein the system (100) comprises:
- at least one sensor (102) coupled with each tool of a plurality of tools (104) associated with the assembly line; and
- a processing unit (106) configured to:
- identify at least one tool from the plurality of tools (104) associated with the assembly line;
- receive at least one contemporary value of a parameter associated with the identified tool from the at least one sensor (102);
- retrieve at least one ideal value of the parameter associated with the identified tool;
- compare the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter; and
- generate an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
2. The system (100) as claimed in claim 1, wherein the system (100) comprises a memory unit (108), wherein the memory unit (108) is configured to store the at least one ideal value of the parameter and the at least one threshold value associated with each of the plurality of tools (104).
3. The system (100) as claimed in claim 1, wherein the processing unit (106) is configured to determine an operational efficiency of the assembly line based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter.
4. The system (100) as claimed in claim 1, wherein the system (100) comprises a communication unit (110), wherein the communication unit is configured to transmit the error signal to at least one terminal device (112).
5. The system (100) as claimed in claim 4, wherein the terminal device (112) is configured to display at least one error to a user, based on the received error signal.
6. The system (100) as claimed in claim 1, wherein the processing unit (106) is configured to generate a corrective action signal, based on the error signal.
7. The system (100) as claimed in claim 6, wherein the system (100) comprises an assembly line controller (114), wherein the assembly line controller (114) is configured to execute at least one corrective action, based on the corrective action signal.
8. The system (100) as claimed in claim 1, wherein the processing unit (106) is configured to identify at least one article ongoing on the assembly line.
9. The system (100) as claimed in claim 7, wherein the at least one corrective action comprises:
- re-operation of the at least one identified tool;
- diversion of at least one product associated with the error signal from the assembly line; and
- halting the assembly line.
10. A method (200) of improving assembly efficiency of an assembly line, wherein the method (200) comprises:
- identifying at least one tool from a plurality of tools associated with the assembly line;
- receiving at least one contemporary value of a parameter associated with the identified tool;
- retrieving at least one ideal value of the parameter associated with the identified tool;
- comparing the at least one contemporary value of the parameter with the at least one ideal value of the parameter associated with the identified tool to determine a deviation of the at least one contemporary value of the parameter from at least one ideal value of the parameter; and
- generating an error signal when the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter is beyond at least one threshold value.
11. The method (200) as claimed in claim 10, wherein the method (200) comprises determining an operational efficiency of the assembly line based on the deviation of the at least one contemporary value of the parameter from the at least one ideal value of the parameter.
12. The method (200) as claimed in claim 10, wherein the method (200) comprises transmitting the error signal to at least one terminal device.
13. The method (200) as claimed in claim 10, wherein the method (200) comprises generating a corrective action signal, based on the error signal.
14. The method (200) as claimed in claim 13, wherein the method (200) comprises executing at least one corrective action, based on the corrective action signal.
15. The method (200) as claimed in claim 10, wherein the method (200) comprises identifying at least one article ongoing on the assembly line.
16. The method (200) as claimed in claim 14, wherein the at least one corrective action comprises:
- re-operation of the at least one identified tool;
- diversion of at least one product associated with the error signal from the assembly line; and
- halting the assembly line.