STORAGE SYSTEM
HELD OF THE INVENTION
BACKGROUND OF THE INVENTION
[002] Products which take final shape as a result of assembly of plurality of components /
parts ace assembled in an assembly area, generally, following a particular seqhence. One of the
ixamples of such. products is a vehicle, such as two wheeled, three wheeled, four wheeled
vehicle etc. The agency (OEM) which manufactures I assembles the products, receives different
necessary components from different suppliers. These suppliers supply parts to the agency in
A masses. Then agency manufactures the find product (ha1 product includes partial assembly, sub
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a3 assembly) and dispatches either for sale or to next station of assembIy.
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a I.*- [003] Location where a pmduct, partially or fully, is assembIed is called an assembly -+ station 1 assembly line I assembly area. A11 the necessary components / parts required for a
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E product at the assembly area are provided an individual or group of individuals to complete the .
g task of assembly of parts. Many a times, all the necessary components I parts required at the
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2 assembly area for assembling of each product z& grouped and provided in separate storage box
7 o (container). The system of grouping and providing all the necessary components / parts at the
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1 assembly area is popular where the grouping of the components 1 parts takes place at one
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0 location and the assembly work takes place at distinct location. This system is more popular in
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batch type production systems.
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2* . . e [OOQ] However, there is no quick inspection method to check whether all the parts /
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7 components necessary for assembling the product are dispatched to the assembly area or not also
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no quick inspection method is known to ensure that all the parts / components are assembled to
the product or not.
[OOS] The object of the present invention is to provide for an assembly system which
incorporates a quick inspection method to check whether all the parts 1 components necessary for
assembling the product are dispatched to the assembly area or not.
SUMMARY OF THE INVNETIQN'
[006] The present invention is an assembly system for a vehicle which includes a main
storage unit, having a pIurality of sub-storage units; each of which stores one type of assembly
part. The assembly system also includes an assembIy pallet, which comprises of a plurality of
storage provisions, each of which is adapted to receive on'e type of assembly part. The substorage
unit in the main storage unit and provision in the assembly pallet for a particular
assembly part has a predetermined correlation.
h [007] In one of the embodiments, the dissimilar assembly parts for a vehicle are grouped at
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rn 'one location and the vehicle is assembled using the grouped assembly pads at a location distinct
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L . fiom the location where assembly parts are grouped.
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.+C- I .. [OOS] In another embodiment, the sub storage units of the main storage unit andor the
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CV storage provisions of the assembly paIIet have a matrix arrangement comprising rows and
E s columns andlor a circular amgement.
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7 [009] In yet another embodiment of the invention, the sub storage units of the main storage
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9 unit and the storage provisions have a similar geometrical arrangement, like both main storage
i l w and the assembly pallet has a matrix arrangement or the circular amgement.
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0 [OOIO] In one embodiment, the location of the assembly part in the sub storage unit and
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9 location of assembly part in the assembly pallet is geometrically similar, like if one assembly -+ V part is placed in a sub storage unit at first row and first column in matrix arrangement, then the
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same assembly pan is placed at storage provision which is at first row and first column in matrix
arrangement of the assembly pallet.
[0011] In another embodiment, more than one sub storage units of the main storage unit are
in same sequence of storing assembly parts, as that of storing the assembly parts in the storage
provisions of the assembly pallet.
[0012] In a further embodiment, the sub storage units and corresponding storage provisions
for any assembly part have a wrnrnon colour code.
[O013] In one embodiment, more than one storage lcbrrespond to same sub-storage
unit. Additionally, in an alternate embodiment, the corresponding storage provisions are located
adjacent to each other.
[0014] In another embodiment, more than one sub-storage units corresponds to the same
storage provisions.
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[0015] In yet another embodiment, the storage provisions includes one or more sub-storage
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rn provisions to store one type of assembly parts.
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a I [0016] In one embodiment, more than one assembling pallets can store all the necessary
.+C-I assembly parts required for assembling the product.
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E L [OO17] ' In another embodiment, the assemble system consists of an alerting system for
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9 BRIEF DESCRIPTION OF THE DRAWINGS
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[0018] The invention itself, together with further features and attended advantages, will
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& become apparent fiom consideration of the following detailed description, taken in conjunction
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d with the accompanying drawings. One or more embodiments of the present invention are now
2 * described, by way of example only, with reference to the accompanied drawing wherein like * rn reference numerals represent like elements and in which:
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[0019] Figure 1 illustrates a schematic view of a storage system, according to an
embodiment.
[0020] The drawings referred to in this description are not to be understood as being drawn
to scale except if specifically noted, and such drawings are only exemplary in nature.
DETAILED DESCRIPTION OF TEE ACCOMPANYING DRAWINGS
[0021] While the invention is susceptible to various modifications and alternative forms,
specific embodiment thereof has been shown by way of example in the drawing and will be
described below. It should be understood, howeyer that it is not intended to limit the invention to
the particular forms disclosed, but on the contrary, the invention is to cover all modifications,
equivalents, and alternative falling within the spirit and the scope of the invention.
[0022] The terms "comprises", "comprising", or any other variations thereof, are intended to
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cover a non-exclusive inclusion, such that a setup, device or method that comprises a list of
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rn ' components or steps d m not include only those co'mponents or steps but may include other
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L components or steps not expressly listed or inherent to such setup or device or method. In other
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Y words, one or more elements in a system or apparatus proceeded by "comprises. .. -.+- without more constraints, preclude the existenceof other elements or additional e.le.m a"e'dnotse sin ntohte,
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E system or apparatus.
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2 [0023] Figure 1 'illustrates a storage system 100. As shown in the Figure 1, the storage
7 o system 100 comprises of a main storage unit I04 and an assembly pallet 102.
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LU [0024] The main storage unit 104 includes plurality of sub-storage units. The plurality of
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& sub-storage units are depicted by (106% 106b, 106c, 106d, 106e, 106f) in the Figure 1 and
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d collectively referred to as 106 hereinafter.'The sub-storage units 106 are primarily intended for
9 e storing the assembly parts which are required to assemble a product. Assembly parts are depicted * ~ r ) by (1 IOa, 1 lob, I IOc, 1 10d, 1 10e, 1 1 Of) in the Figure 1 and collectively referred to as 1 10
hereinafter. 1 10a represents one type of assembIy parts, 1 lob represents second type of assembly
parts, 1 10c represents third type of assembly parts, and so on.
[0025] The plurality of sub-storage units 106 may have different shape and size. Shape and
size of each of the sub-storage unit 106 depends upon the shape and size of the assembly part
110 which is to be stored in that sub-storage unit 106. For example, one type of assembly.parts
1 10a are stored in one sub-storage unit 106a. Similarly, a second type of assembly parts 1 IOb are
stored in the second sub-storage unit 106b and so on. Each sub-storage unit (lo&, 106b, 106c,
106d, 106e, 106f) from arndng the plurality of sub-storage units 106 is adapted to store one type
of assembly parts, Size of each of the sub-storage units 106 also depends on the quantity of
assembly parts 110 to be stored in that sub-storage unit. Thus, size and shape of the sub-storage
units (106% 106b, 106c, 106d, 106e, and 106f) could be same or different.
[002q The assembly pallet 102 comprises a plurality of storage provisions. The plurality of
storage provisions are depicted by 108~1, IOSb, t08c, 108d, loge, 108f in Figure 1 kind
collectively refed to as 108 hereinafter. Eachof the storage provision 108a, 108b, 108c, 108d,
loge, 108f from among the plurality of storage provisions 108 is primarily intended to store at
least one assembly part 110 from the sub-storage units 106 of the main storage unit 104. The size
and shape of each ofthe storage provision IOSa, I OXb, 108c, 108d, 108e, 108f from among the
plurality of storage provisions 108 depends upon the size and shape of the assembly part which is
to be stored in that storage provision 108 of the assembly pallet 102. For example, one type of
assembly part 1 10a can be stored in particular storage provision l O8a of the assernbl y pallet 102.
Similarly, a second type of assembly part 110b can be stored in the storage provision 108b of the
assembly pallet 102 and so on. In an embodiment, all'the storage provisions I08 are shaped and
sizedsuchthatitcanstoreonlyonetypeofassembtypart 110.hanembodiment,thestorage .
provisions 108 are having different shape and size with respect to its neighboring storage
provisions 108. For example, the size and shape of the storage provision 108b on the assembly
pallet 102 is such that it cannot accommodate the assembly parts 1 1 Oa, 1 1 Od, 1 1 Qc. '
[0027] . In an embodiment, ithe assembly pallet 102 is configured to store all the necessary
assembly parts 1 10 required for assembling a product at one assembly station 1 assembly area. In
an embodiment, more than one assembling pallets 102 are used to 3tor.e all the necessary
assembly parts 1 10 required for assernbIing a product at one assembly station / assembly area.
[0028] Thus, for a paRicu!ar type of assembIy part I10 there exist at least one sub-storage .
unit 106a, 106b, L06c, 106d, 106e, 106f in the main storage unit 104 and at least one storage
provision 108a, 1 Ogb, 108c, 108d, loge, IO8f in the assembly pallet 102. The storage provisions
108 in the assembly pallet 102 and the sub-storage units 106 on the rnain storage unit ,104 for a
particular assembly part: 1'10 is having a predefined relation. In an embodiment, the location of
the storage provisions 108% 108b, 108c, 108d, 108e, I08f in the assembly pallet 102 and the
sub-storage unit 106a, 1 06b, 106c, 1 06d, 106e;. 106f on the main storage unit 1 04 for a particular
assembly part 1 10% 1 10d, 1 10c, 1 10d, l'10e is same. For example, assembly parts 1 lOa are
stored in the sub-storage unit 106a of the main storage unit 104, and the psition of the substorage
unit 106a on the rnain storage unit 104 is first column and first row, then, the position of
storage 108a storing the same assembly part 1 lOa on the assembly pallet 102 will also
be first column and first row of the assembly 102. Similarly, an assembly part 1 lob is
stored in the sub-storage unit 106'6 df the main storage unit 104, and the position of the substorage
unit 106b on the main storage unit 104 is second 'column and first row, then, the position
of storage provision l08b storing the assembly part, l .lob on the assembly pilet 102 will also be
second column and first row of the assernbIy'paIlet 102.
[0029I h an embodiment, the position of the storage provision 10Sa, 108b, 108c, 108d,
108e, 108f in the assembly pallet 102 and the sub-storage unit 106a, 106b, 106c, 106d, 106e,
1 06f on the main storage unit 104 for a particular. assembly part 1 1 0% 1 1 Qd, 1 1 Oc, 1 1 Od, 1 10e is
same. in an embodiment, sequence of the storage provisions 108 in the assembly pallet 102
storing the assembly parts 1 10 is same as that of the sub-storage unit 106~11, 06b, 106c, 106d,
I06e, 106f on the main storage unit 104. In an embodiment, array of the storage provisions f 08
in the assembly pallet 102 storing the assembly patis 1 10 is same as that of the sub-storage units
106 on the main storage unit 104. In an embodiment, the predefined relationship of the storage
provisions 1b8 to the sub-storage units 106 can be based on any other logic.
[0030] In an ernbodimenlt, same colour code is assigned to the sub-storage units 106a, 106b,
106c, 1 06d, 106e, 1 06f of the main storage unit 1 04 and to the corresponding storage provisions
108a, 108b, 108c, 108d, 108e, 108f of the assembly pallet 102 for particular type of assembly
part. For example, the sub-storage unit fO6e storing an assembly part 1 f Oe is assigned with a
green color, the same peen colour is' also assigned to the storage provision 108e storing the
assembly part 1 IOe in the assembly pallet 102.
[0031l The predefined relation between the storage provisions 108 in the assembly pallet 102
.and the sub-storage units 106 on the main storage unit 104 for a particular assembly part I 10
helps the operator in quick filling of the assembly pallet 102. The predefined relationship also
helps the operator to avoid the placing of assembly part 1 10 in wrong storage provisions 108 in
the assembly pallet 102. The predefined relationship also helps the operator to avoid placing of
m e assembly parts 11 0 in multiple storage provisions 108 in the assembly pallet 102 when it is
not desired. The predefined relationship aIso helps when the operator is unskilled or not filly
skilled.
10032J In an embodiment, the arrangement of sub-storage units 106 on the main storage unit
104 is not limited to rows and column type of army. In an embodiment, the arrangement of substorage
units 106 on the main storage unit I04 is a circular array. h an embodiment, the
arrangement of sub-storage units 106 on the main storage unit 104 can be any other array. In an
embodiment, the arrangement of the storage provisions 108 on the assembly pallet I02 is not
limited to rows and column type of array. In m embodiment, the arrangement of the storage
provisions 108 on the assembly pallet I02 is a circular array. In an embodiment, the arrangement
of the storage provisions 108 on the assembIy paIlet 502 can be my other array.
[0033] During operation, an operator retrieves first assembly part l IOa hrn the sub-storage
unit 106a of the main storage unit 104 and places it in the corresponding storage provision 108a
of the assembly pallet 102. Then, the operator has to retrieve second assembIy part 1 10b from
the sub-storage unit 106b of the main storage unit 104 and places it in the corresponding storage
provision 108b of the assembly pallet 102 and so on. Once,the pallet is full, it is ready for
sending it to the assembly station / assernbIy area. If all the storage provisions 108 of the
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c3 assembly pallet 102 are not filled, is an indication that aSI the parts are not stored into the
assembly pallet 102 and such assembly pallet I02 can be rejected and send back for filling. Thus,
it is ensured by easy visual inspection that all the necessary assembly parts 110 required at an
assembly station / assembly area are sent.
[0034] The operator at assembly station I assembly area retrieves the assembly parts from the
storage provisions 108 of the assembly pallet 102 for assembly of. the product. In an
embodiment, a standard chart which resembles to the assembly pallet 102 is provided / displayed
at an assembly area. The chart indicates the Instmctio'ns at the corresponding locations in the
chart regarding each of the assembly parts 110 stored in the storage provisions 108 of the
assembly pallet 102. For example, the chart will have simiIar painted storage provisions as that
of the storage provisions 108 of the assembly pallet 102. Each painted storage provision 108 of
the chart shall desciibe the location on the product where the assembly part 110 stored in the
corresponding storage provision 108 of the assembly pallet 102 be assembled. Each .
storage provision of the chart may also describe the essential instructions regarding the assembly
part 110 'stored in the corresponding storage provision 108 of the assembIy pallet 102.
[0035] Once the product is assembled and if all the storage provisions 108 of the assembly
pallet 102 are not empty, is an indication that all the parts are not assembled to the product and
such product is not final and can 'be rejected and corrective action 'can be taken. Thus, it is
ensured by easy visual inspektion that a11 the necessary assembly parts 110 required at the
assembly station / assembly area are assernbIed to the product.
100361 In an embodiment, mare than one $torage provisions 108 of the assembly pallet 102
corresponds to one sub-storage unit 106 on the main storage unit 104. For example, where the
.same type of the assembly parts 110 are required for assembly of the product, in such cases,
operator stores the assembly part 110a h m the sub-storage unit 106a to the storage provision
108a of the assembly pallet 102 and again operator stores the assembly part 1 10a from the same
sub-storage unit lO6a to the storage provision 108b of the .assembly pallet 102. Here, storage
provision 108a and the storage provision 108b store same type of assembly parts and hence have
? simiIar size and shape. In an embodiment, where more than one storage provisions 108
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corresponds to one sub-storage units 106, such more than one storage.provisions 108 are locates
adjacent to each other.
[0037] The mode transfer of the assembly pallet 102 from the first location to the assembly
line may be using any suitable mode. For example, the assembly parts may be sent to assembly
line from the first location using monorail systems, lift systems, transport systems, bucks, ships,
planes, by manual means or the like.
100381 In an embodiment, storage provision comprises one or more sub-storage provisions to
store one type of assembly parts. In an embodiment, storage provision comprises one or more
sub-storage provisions to store different type of assembly parts. For example, an assembly 'part
"X" there wilI be two sub-storage provisions adapted to store the assembly part "X'.
[0039] In another embodiment, there is provided an alert system for alerting the operator
about the missing pa&. The alert system alerts the operator if operator forgets to put one or more
assembly parts 110 in the assembly pallet 102 leaving behind one or more empty storage
provision. The alert'can be send to the operator in the form of audio andlor visual signal.
[0040] While considerable emphasis has been placed herein on the particular features of this
invention, it will be appreciated that various modifications can be made, and Bat many changes
can be made in the preferred embodiments without departing ftom the principles . . of the
invention, These and other modifkations in the nature of the invention or the preferred
embodiments will be apparent to those skilled in the art h m the discfosure herein, whereby it is
to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as
illustrative of the invention and not as a limitation.
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CLAIMS
1. An assembly system for a vehicle comprises:
- a main storage unit, the main storage unit comprises of plurality of sub-storage
units; each sub storage unit stores one type of assembly part,
- a assembly. pallet, the assembly pallet comprises plurality"o f storage provisions,
each storage provision is adapted to receive one type of assembIy part,
wherein the sub-storage unit in the main storage unit and provision in the
assembIy pallet for a particular assembIy part is having a predetermined
correlation.
2. The assembly system according to the cIaim 1, wherein dissimilar assembly parts for a I
vehicle are grouped at one location and the vehicle is assembled using the grouped
assembly parts at a location distinct from the location where assembiy parts are grouped,
the assembly system
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3. The assembly system according to any of the claims 1 or 2, wherein the sub storage units I
of the main storage unit and I or the storage provisions of the assembly pallet have a
matrix arrangement comprising rows .and columns.
4. The assembly system according to any of .the claims 1 or 2, wherein the sub storage units
sf the main storage unit and I or the storage provisio'ns of the assembly patlet have'a
cikular arrangement.
5. The assembly system according to any of the claims 1 to 4, wherein the sub storage units
of the main storage unit and the storage provisions has a similar geometrical arrangement.
,6. The assembly system according to the claim 5, wherein location of the assembly part in
the sub storage unit and location of assembly part in the assembly pallet is geometrically
similar.
7. The assembly system according to any of the claims 1 to 6, wherein more than one sub
storage units of the main storage unit are in same sequence of storing assembly parts, as
that of storing the assembly parts in the storage provisions of the assembly pallet.
. . 8. The assembly system according to any of the claims 1 to 7, wherein the sub storage units
and corresponding storage provisions for any assembIy part have a common colour code.
9. The assembly system according to any of the claims 1 to 8, wherein more than one
storage provisions correspond to same sub-storage unit.
10. The assembly. system according to the claim 9, wherein more than ,one storage provisions
correspond to one sub-storage unit, such that the corresponding storage provisions are
A located adjacent to each other.
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L 11. The askmbly system according to any of the claims 1 to 8, wherein more than one suba
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~r storage units correspond to same .- storage provisions.
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E 12. The assembly system according to any of the .claims 1 to 1 1, wherein the storage
5 provisions comprises one or more sub-storage.provisions to store one type of assembly
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2 parts.
13. The assembly system according to any of the claims 1 to 12, wherein more than one
, .assembling pallets are adapted to store. all the necessary assembIy parts required for
assembling the product.
14. The assembly system according to any of the claims 1 to 13 comprising:
- an alerting system for alerting if any assembly parts are missing fiom the
assembling pallets.