U.S. patent application number 13/490402 was filed with the patent office on 2012-12-06 for training ensurance method and system for copmuter directed assembly and manufacturing.
This patent application is currently assigned to PARAMIT CORPORATION. Invention is credited to BALBIR S. RATAUL.
Application Number | 20120308969 13/490402 |
Document ID | / |
Family ID | 46262338 |
Filed Date | 2012-12-06 |
United States Patent
Application |
20120308969 |
Kind Code |
A1 |
RATAUL; BALBIR S. |
December 6, 2012 |
TRAINING ENSURANCE METHOD AND SYSTEM FOR COPMUTER DIRECTED ASSEMBLY
AND MANUFACTURING
Abstract
Methods, systems, and computer program products are provided for
ensuring assemblers are properly trained before performing assembly
instructions in a computer directed assembly system. To ensure the
requisite training, in some embodiments, the training history of
each assembler is checked before authorizing performance of an
assembly instruction. In one embodiment, a prerequisite training
sequence required to be completed before performing an assembly
instruction is specified to ensure proper training of the
assembler. In some embodiments, a training history associated with
the assembler is requested from a training database that includes a
set of training sequences previously performed by the assembler.
Based on the training history and other factors, a determination is
made whether the assembler has the prerequisite training sequence
necessary to perform the assembly instruction. As necessary, the
assembler is required to perform the prerequisite training sequence
before being authorized to perform the assembly instruction.
Inventors: |
RATAUL; BALBIR S.; (Morgan
Hill, CA) |
Assignee: |
PARAMIT CORPORATION
Morgan Hill
CA
|
Family ID: |
46262338 |
Appl. No.: |
13/490402 |
Filed: |
June 6, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61493958 |
Jun 6, 2011 |
|
|
|
Current U.S.
Class: |
434/224 |
Current CPC
Class: |
Y02P 90/04 20151101;
Y02P 90/265 20151101; G05B 19/41865 20130101; G05B 2219/24168
20130101; G05B 19/41805 20130101; G05B 2219/31001 20130101; Y02P
80/40 20151101; Y02P 90/205 20151101; Y02P 90/02 20151101; Y02P
90/20 20151101; Y02P 90/28 20151101; G05B 2219/31053 20130101; G05B
19/4188 20130101; Y02P 90/22 20151101 |
Class at
Publication: |
434/224 |
International
Class: |
G09B 19/00 20060101
G09B019/00 |
Claims
1. A computer-implemented method of ensuring an assembler is
properly trained to perform an assembly instruction in a computer
directed assembly system used in manufacturing, the method
comprising: specifying a prerequisite training sequence required to
be completed before performing an assembly instruction presented
through a user interface of a computer device; requesting a
training history associated with the assembler from a training
database that includes a set of training sequences previously
performed by the assembler; determining whether the training
history associated with the assembler includes the prerequisite
training sequence as specified; and requiring that the assembler
perform the prerequisite training sequence if the assembler's
training history is determined to not already have the prerequisite
training sequence.
2. The method of claim 1 wherein requiring that the assembler
perform the prerequisite training sequence comprises: incorporating
the prerequisite training into the training history for the
assembler held in the training database.
3. The method of claim 1 wherein the prerequisite training sequence
is identical to a sequence of actions for the assembly
instruction.
4. The method of claim 1 wherein the prerequisite training sequence
is satisfied with a task that is similar to a sequence of actions
for the assembly instruction.
5. The method of claim 1 further comprising: authorizing the
assembler to perform the assembly instruction displayed on the user
interface.
6. The method of claim 5 further comprising: guiding the assembler
to combine materials from a pocket of a matrix tray with a
component.
7. The method of claim 1 further comprising: requiring that the
assembler perform the prerequisite training sequence if the
prerequisite training sequence in the assembler's training history
exceeds a predetermined time interval.
8. A computer program product for ensuring an assembler is properly
trained to perform an assembly instruction in a computer directed
assembly system used in manufacturing, tangibly stored on a
computer readable medium, comprising instructions operable to cause
a programmable processor to: specify a prerequisite training
sequence required to be completed before performing an assembly
instruction presented through a user interface of a computer
device; request a training history associated with the assembler
from a training database that includes a set of training sequences
previously performed by the assembler; determine whether the
training history associated with the assembler includes a
prerequisite training sequence as specified; and require that the
assembler perform the prerequisite training sequence if the
assembler's training history is determined to not already have the
prerequisite training sequence.
9. The computer program product of claim 8 wherein instructions
that require the assembler perform the prerequisite training
sequence comprise instructions operable to cause the programmable
processor to: incorporate the prerequisite training into the
training history for the assembler held in the training
database.
10. The computer program product of claim 8 wherein the
prerequisite training sequence is identical to the to a sequence of
actions for the specified assembly instruction.
11. The computer program product of claim 8 wherein the
prerequisite training sequence is satisfied with a task that is
similar to a sequence of actions for the assembly instruction.
12. The computer program product of claim 8 further comprising
instructions operable to cause the programmable processor to,
authorize the assembler to perform the assembly instruction
displayed on the user interface.
13. The computer program product of claim 12 further comprising
instructions operable to cause the programmable processor to: guide
the assembler to combine materials from a pocket of a matrix tray
with a component.
14. An apparatus for ensuring an assembler is properly trained to
perform an assembly instruction from a computer directed assembly
system used in manufacturing, the apparatus comprising: a processor
capable of executing instructions; and a memory holding
instructions that when executed by the processor causes the
processor to: specify a prerequisite training sequence required to
be completed before performing an assembly instruction presented
through a user interface of a computer device; request a training
history associated with the assembler from a training database that
includes a set of training sequences previously performed by the
assembler; determine whether the training history associated with
the assembler includes the prerequisite training sequence as
specified; and require that the assembler perform the prerequisite
training sequence if the assemblers training history is determined
to not already have the prerequisite training sequence.
15. The apparatus of claim 14 wherein instructions that require the
assembler perform the prerequisite training sequence comprise
instructions that when executed by the processor causes the
processor to: incorporate the prerequisite training into the
training history for the assembler held in the training
database.
16. The apparatus of claim 14 wherein the prerequisite training
sequence is identical to a sequence of actions for the assembly
instruction.
17. The apparatus of claim 14 wherein the prerequisite training
sequence is satisfied with a task that is similar to a sequence of
actions for the assembly instruction.
18. The apparatus of claim 14 further comprising instructions
operable to causes the programmable processor to: authorize the
assembler to perform the assembly instruction displayed on the user
interface.
19. The apparatus of claim 18 further comprising instructions
operable to causes the programmable processor to: guide the
assembler to combine materials from a pocket of a matrix tray with
a component.
Description
(1) CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/493,958, filed Jun. 6, 2011, entitled,
"MANUFACTURING VERIFICATION METHOD AND SYSTEM" by Balbir S. RATAUL,
assigned to the assignee of this application and incorporated by
reference herein for all purposes. The subject matter of this
application further relates to the subject matter of the following
commonly assigned applications being filed on the same day as the
present application: (1) U.S. Ser. No. 13/______, Attorney Docket
00163-000100000 entitled, "COMPUTER DIRECTED ASSEMBLY METHOD AND
SYSTEM FOR MANUFACTURING"; (2) U.S. Ser. No. 13/______, Attorney
Docket 00163-000200000 entitled, "VERIFICATION METHODS AND SYSTEMS
FOR USE IN COMPUTER DIRECTED ASSEMBLY AND MANUFACTURE"; (3) U.S.
Ser. No. 13/______, Attorney Docket 00163-000400000 entitled,
"SYSTEM AND METHOD FOR MANAGING TOOL CALIBRATION IN COMPUTER
DIRECTED ASSEMBLY AND MANUFACTURING"; (4) U.S. Ser. No. 13/______,
Attorney Docket 00163-000500000 entitled, "INTERFACE METHOD AND
SYSTEM FOR USE WITH COMPUTER DIRECTED ASSEMBLY AND MANUFACTURING";
(5) U.S. Ser. No. 13/______, Attorney Docket 00163-000600000
entitled, "TRAINING ENSURANCE METHOD AND SYSTEM FOR COMPUTER
DIRECTED ASSEMBLY AND MANUFACTURING"; (6) U.S. Ser. No. 13/______,
Attorney Docket 00163-000700000 entitled, "RESOURCE SCHEDULING
METHOD AND SYSTEM FOR USE WITH COMPUTER DIRECTED ASSEMBLY AND
MANUFACTURE". Each of the above-referenced patent applications is
incorporated by reference herein for all purposes.
(2) Technical Field
[0002] The subject matter described herein relates to systems and
methods used in a manufacturing process. More particularly, the
subject matter described herein relates to methods and systems for
using computers and multimedia information to ensure assemblers are
trained before performing assembly of manufactured products.
(3) DESCRIPTION OF THE RELATED ART
[0003] A great deal of modern devices and equipment continue to be
manufactured using manual assembly. Increasingly, complex
mechanical, electrical, and electro-mechanical designs having
relatively small dimensions require skilled and trained assemblers
to perform a variety of assembly tasks, some done directly with
their hands or with the assistance of a variety of precision hand
tools. This type of manufacturing is often deemed light
manufacturing as it involves applying a certain degree of human
skill and know-how to combine fasteners, connectors, and other
materials in the creation of the final manufactured product. Light
manufacturing and manual assembly are also often preferred for
smaller production runs when costs associated with automation and
retooling cannot be amortized over the production run time frame
while maintaining profit margins.
[0004] To help reduce human error and other mistakes, conventional
light manufacturing methods incorporate a "Manufacturing Process
Instruction" (MPI) document in either a hard-copy form or displayed
on a computer monitor that each assembler refers to during the
assembly process. The MPI may be created by a manufacturer to
provide specific instructions for the assembly of a wide-range of
products from computers, household electronics, communication
equipment, or even sophisticated medical equipment. In each of
these categories, the quality and consistency of the final product
produced depends on whether the person involved with assembling an
assembly or subassemblies actually understands and accurately
follows the instructions within the MPI.
[0005] Since the MPI does not actually control the act of
assembling products, product quality may be inconsistent or lower
than desired. An assembler may initially follow every step of the
MPI document to produce high quality products but later deviate
from the MPI instructions and produce products with defects or
other problems. In another scenario, an assembler may follow his
own assembly sequence and, as needed, flip through the MPI document
as an occasional reference. Products assembled in this latter
approach may be of consistent but overall lower quality if the
approach taken by the assembler consistently skips steps or takes
unacceptable shortcuts.
[0006] The lack of controls and accountability associated with the
MPI document also makes it difficult to track down and find the
source of a problem. This is especially true if there are many
sub-assemblies or components that makeup the overall manufactured
products. Indeed, checklists may be used in conjunction with the
MPI document to query the assembler and verify whether instructions
in the MPI document were taken. Once again, the assembler may not
answer or inaccurately answer questions in the checklist thus
circumnavigating the quality control checkpoints provided.
SUMMARY
[0007] Aspects of the disclosure provide methods, systems, and
computer program products for ensuring assemblers are properly
trained before performing assembly instructions in a computer
directed assembly system. Generally, a product designer or engineer
develops a product and then creates the assembly instructions to
assemble the product. Assemblers use these assembly instructions to
guide the manual assembly of materials, components and other parts
into the final product. In accordance with embodiments, the
assembler executes these assembly instructions on a specially
equipped computer directed assembly (CDA) workstation as described
herein to ensure the products are produced both quickly and with
the highest quality.
[0008] To ensure the assemblers are adequately trained, in
embodiments, the assembler's training history is checked before
authorizing the assembler to perform each assembly instruction.
Accordingly, one embodiment for ensuring an assembler is properly
trained includes specifying that an assembler complete a
prerequisite training sequence before performing an assembly
instruction presented through a user interface of a computer
device. In embodiments, a training history associated with the
assembler is requested from a training database that includes a set
of training sequences previously performed by the assembler. Based
on the training history and other factors, a determination is made
whether the assembler has the prerequisite training sequence
necessary to perform the assembly instruction. As necessary, the
assembler is required to then perform the prerequisite training
sequence before being authorized to perform the assembly
instruction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a high level block diagram illustrating an
exemplary development process of taking a product from conceptual
design to manufacture in accordance with some embodiments;
[0010] FIG. 2 is a schematic block diagram illustrating an
exemplary computer directed assembly workstation for building and
verifying assemblies in accordance with some embodiments;
[0011] FIG. 3 is a flow chart diagram associated with creating a
sequence of assembly operations for use on a computerized assembly
workstation in accordance with some embodiments;
[0012] FIG. 4 is yet another flow chart diagram for using
multimedia assembly data along with a sequence of assembly
operations for guiding the use of matrix trays and insertable shims
in accordance with some embodiments;
[0013] FIG. 5 is another flow chart diagram outlining an exemplary
training verification operations performed in accordance with some
embodiments prior to providing an assembler authorization to
perform an instruction associated with an assembly operation;
[0014] FIG. 6A is a schematic diagram of an exemplary computer
implemented user interface for interacting with a sequence of
assembly operations in accordance with some embodiments;
[0015] FIG. 6B is a schematic diagram of an exemplary matrix tray
with multiple insertable shims and a variety of pockets for
materials in accordance with some embodiments;
[0016] FIGS. 7A-7B are additional flowchart diagrams outlining
exemplary interactions associated with performing the assembly
operations on a computer directed assembly workstation in
accordance with some embodiments;
[0017] FIG. 8 is a schematic block diagram of an exemplary computer
device used in generating and performing computerized assembly
operations in accordance with some embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the following detailed description, for purposes of
explanation, numerous specific details are set forth to provide a
thorough understanding of the various embodiments of the
disclosure. Those of ordinary skill in the art will realize that
these various embodiments are illustrative only and are not
intended to be limiting in any way. Other embodiments will readily
suggest themselves to such skilled persons having the benefit of
this disclosure.
[0019] In addition, for clarity purposes, not all of the routine
features of the embodiments described herein are shown or
described. One of ordinary skill in the art would readily
appreciate that in the development of any such actual
implementation, numerous implementation-specific decisions may be
required to achieve specific design objectives. These design
objectives will vary from one implementation to another and from
one developer to another. Moreover, it will be appreciated that
such a development effort might be complex and time-consuming but
would nevertheless be a routine engineering undertaking for those
of ordinary skill in the art having the benefit of this
disclosure.
[0020] A computer directed assembly method and system designed in
accordance with embodiments offers many advantages and benefits,
some of these advantages include one or more of the following.
Generating the assembly operations for assembling a component may
be tailored to the address specific assembly requirements in each
particular design. If an assembly is complex with strict
tolerances, the designer or manufacturing engineer may decide to
incorporate more discrete assembly operations or steps to ensure
the assembly is put together correctly and completely. The assembly
operations may incorporate different types of multimedia content
including images, videos, text, and audio to convey the specific
steps necessary to complete an operation accurately and
efficiently.
[0021] Embodiments described herein maintain control over the
assembly process and ensure each step of the assembly is performed
in sequence. Assembly operations for a component are presented in
order and recorded as both a history of the component being
assembled and the task performed by the assembler. Recording the
assembly operations serves to create a permanent record while
encouraging the assembler to follow the assembly routine. To
confirm that a component is being assembled according to plan, some
embodiments include verification steps that record images, video,
audio, and/or other multimedia data of the component as the
component is assembled. In some embodiments, the multimedia data
creates a permanent record and a traceable sequence of events
available if the assembly record needs later review. In other
embodiments, verification steps may further include comparing a
predetermined image of a previously assembled component with an
image taken of an "in-use" component being assembled. Embodiments
may alternatively use image processing routines to perform an
immediate and direct comparison between a predetermined image of an
assembly and the in-use image of a part or other component "in-use"
and being assembled.
[0022] Ensuring each assembler is properly trained increases
productivity and reduces or eliminates errors made during assembly.
Before an assembler is authorized to assembly any component, the
assembler completes a rigorous training sequence that educates the
assembler on performing the assembly and increases their skills in
the process. Training is associated with individual assembly
instructions thus a new assembler can build skills incrementally
taking one prerequisite training sequence at a time. Even after the
assembler is trained on assembling several components, the computer
directed assemble workstation and software continues to check their
training history to make sure their skills are updated. After a
period of time, even a trained assembler may be required by the
computer directed workstation to take refresher courses on certain
assembly instructions to recertify their skill level in the
system.
[0023] FIG. 1 is a high level block diagram illustrating an
exemplary development process for a manufactured product from
conceptual design to manufacture in accordance with some
embodiments. This development process illustrated in FIG. 1
provides one exemplary developmental process where the computer
directed assembly processing designed in accordance with some
embodiments can be used. Other development processes may also be
used in other embodiments as well. For example, these other
development processes may include greater or fewer steps than
illustrated in FIG. 1 or may combine several of the steps in FIG. 1
together or may expand certain steps in FIG. 1 into additional
substeps.
[0024] Referring to FIG. 1, the development process for a product
generally starts with a conceptual design and prototype 102. In the
earliest stage of product development, a person or team of people
have an idea and decide if the idea can be turned into a product.
Next, sketches of the product are either drawn by hand or using
computer aided design (CAD) or similar tools. The design may be
tested using simulation tools to quickly determine if the product
will produce a desired result under one or a variety of "what if"
scenarios. If the conceptual design and testing is viable, an
actual prototype of the product may be put together using readily
available components and manual assembly techniques. Since only one
or several prototypes of a product are made, cost and volume
production considerations are not generally the highest
concern.
[0025] During product design 104, the prototype of a product may
change to accommodate both design and production or requirements.
Some design requirements affecting product design 104 may include
aesthetic changes in the shape of the product, a reduced form
factor to make the product fit into a smaller or thinner package
for production. As part of product design 104, availability and
costs for components and materials, as well as the total costs
associated with assembling and shipping the finished product should
also be considered. In some embodiments, manufacture engineering
106 provides feedback to product designers concerning the costs of
materials and creation of the product as proposed in product design
104. In some embodiments, manufacture engineering 106 works
iteratively with product design 104 refining the details and
influencing the direction of the final product to be produced from
product design 104. For example, people involved with manufacturing
engineering 106 may find that the materials specified to create the
components for the product are too expensive or the logistics
associated with acquiring the materials for the product will not
meet the projected demand.
[0026] Computer directed assembly (CDA) engineering 108, in
accordance with some embodiments, incorporates numerous innovative
manufacturing methods and systems in the manufacture of products
while meeting and meet numerous constraints. In some embodiments,
CDA engineering 108 includes multiple disciplines from industrial
engineering, human factors, computer science, tooling and other
areas to improve light-assembly of products with increased
efficiencies, including an assembly instruction sequence 116, tool
usage control 118, material usage 120, assembly verification 122,
and assembler training and verification 114.
[0027] In some embodiments, CDA engineering 108 creates an assembly
instruction sequence 116 tailored to the specific assembly of each
product. The assembly instruction sequence 116 ensures each product
is assembled properly by providing an assembler a step-by-step
sequence of tasks to perform. To make sure the assembler
understands how to perform each assembly instruction, the computer
directed assembly workstation 124 processing the assembly
instruction sequence 116 may present one or more types of
multimedia data including text, images, video, and audio. For
example, a user interface running on the computer directed assembly
workstation 124 may present text statements describing the task to
be performed while corresponding images or videos may illustrate
the task previously performed by a trained assembler.
[0028] In the area of material usage 120, CDA engineering 108
specifies the location of materials in one or more pockets within a
matrix tray. Pockets of each matrix tray are filled in advance with
the specific materials to be used later by the assembler during the
assembly process. Specific predetermined images of the matrix tray
and the location of materials in each pocket of the tray are
specifically referenced by steps in assembly instruction sequence
116. This approach reduces wasted materials as all the materials in
the trays should be used as specified in assembly instruction
sequence 116. Leftover materials or missing materials generally may
mean that the assembly was not performed correctly or certain
materials were misplaced or lost.
[0029] CDA engineering 108 also includes tool usage and control 118
to make sure the proper tools are used and the assembly is
completed according to specified tolerances. Tool usage control 118
incorporated in assembly instruction sequence 116 selects tools for
the assembler, and the use of the tool and torque to apply upon a
fastener may also be described and/or illustrated through computer
directed assembly workstation 124. In accordance with some
embodiments, computer directed assembly workstation 124 may also
use tool usage control 118 combined with sensors embedded in the
tools as a basis for determining if the tools need to be replaced
or recalibrated. Power tools not replaced or calibrated as
specified in tool usage control 118 cannot be used for further
assembly tasks on computer directed assembly workstation 124.
[0030] Assembly training and verification 114 is another novel
component of CDA engineering 108 in accordance with some
embodiments. As new products and corresponding assembly methods are
created, assemblers must make sure they are trained and capable of
performing the assembly tasks both efficiently and accurately. CDA
engineering 108 incorporates assembly training and verification 114
as part of a database associating each assembler's skills with
specific assembly tasks used to manufacture certain products. A
manufacture engineer uses assembly training and verification 114
within CDA engineering 108 to define a prerequisite training for
each step in the assembly training sequence 116. The prerequisite
training is required before an assembler is allowed to perform one
or several tasks in the assembly of the product. In accordance with
assembly instruction sequence 116, an assembler lacking proper
training indicated by database records in ERP systems 112 are
deemed to lack the proper training and skill and cannot continue
with an assembly.
[0031] As a further control on quality, assembly verification 122
checks on the accuracy of tasks performed from assembly instruction
sequence 116 in accordance with some embodiments. The manufacture
engineer may incorporate assembly verification 122 through CDA
engineering 108 for some or all tasks performed by the assembler;
more verification generally improves the quality but may increase
the time to assemble a product. In some embodiments, assembly
verification 122 executes software instructions on the computer
directed assembly workstation 124 instructing the assembler to
identify where a material has been attached to a product or
component and then take a photo or video of the result. Generally
assembly verification 122 encourages an assembler to work more
accurately as videos, images, and/or other records of assembling
the product are kept as a permanent record of the assembler's work
history and stored in ERP systems 112 or elsewhere.
[0032] Once a product has been assembled into a manufactured
product 126, manufactured product 126 is delivered to customers 128
through normal delivery and shipping channels. In accordance with
some embodiments, ERP systems 112 are enhanced with additional
details on the assembly of each product through methods and systems
associated with CDA engineering 108. In some embodiments, records
and billing associated with supply chain 130 are updated to reflect
the materials used in the manufacture of a product. Specific
materials taken from the supply chain 130 may also be identified,
including details such as serial numbers and data of manufacture,
and stored as part of the assembly records in ERP systems 112.
Accordingly, ERP systems 112 and other databases enhanced in
accordance with the various embodiments are of particular value to
industries requiring high quality products with detailed records
and traceability to specific materials and their assembly into
products. For example, detailed information tracking materials and
their assembly is useful in medical, military, space, aeronautical,
and other industries using products that impact health and/or
safety.
[0033] Referring to FIG. 2, a schematic block diagram illustrates
an exemplary computer directed assembly workstation 124 for
building and verifying assemblies in accordance with some
embodiments. Computer directed assembly workstation 124 is the same
as referenced in FIG. 1 except FIG. 2 provides additional details
of one configuration consistent with one embodiment. Accordingly,
in some embodiments workstation 124 includes a workbench 202, an
in-use component 204 being assembled into a product, a computer
device 206, a wand 208, a keyboard 210, a scanner device 212, a
display device 214, a first camera 216, a second camera 218, a
headset 234, a third camera 232, a matrix tray 220 for holding
materials, a network 222 such as the Internet or an intranet, and a
network accessible server 224 with databases 226 including ERP
databases. Computer directed assembly (CDA) software (not shown) in
accordance with embodiments executes, on computer device 206
orchestrating the interaction between the assembler and the
aforementioned peripherals while assembling in-use component 204
into a product. While some embodiments as illustrated in FIG. 2 use
wired connections between computer device 206 and peripherals such
as wand 208, keyboard 210, scanner device 212, display device 214,
first camera 216, and second camera 218, third camera 232, headset
234 other embodiments may use wireless connections between one or
more of these aforementioned peripherals and computer device 206 as
they can be positioned more easily around workbench 202 and less
likely to interfere with the overall working area used for
assembly.
[0034] Workbench 202 provides a surface or area that an assembler
228 uses when performing assembly related tasks in conjunction with
in-use component 204. In some embodiments, assembler 228 may place
in-use component 204 directly upon workbench 202 especially if the
in-use component is relatively small, lightweight, or both. In
alternative embodiments, assembler 228 may place in-use component
204 next to or adjacent to workbench 202 especially if the in-use
component being worked upon or final product is larger, oversized,
and/or too heavy for the workbench 202.
[0035] Assembler 228 may use a number of different tools or data
gathering peripherals connected to computer device 206 when
operating a workstation 124 in accordance with some embodiments. In
one embodiment, assembler 228 may move wand 208 over one or more
areas of in-use component 204 to identify the area of the component
being assembled or receiving various materials. In some
embodiments, wand 208 may be approximately 1/2 inch in diameter and
12 to 14 inches in length and have an identifiable colored tip.
Wand 208 may be equipped with different colored light emitting
diodes (LEDs) and operatively coupled to receive signals and power
from computer device 206 that drive the brightness and colors
emitted from the LEDs. Further embodiments of wand 208 with LEDs
may be battery powered with rechargeable batteries and wirelessly
controlled from computer device 206 using Bluetooth, WiFi, or other
suitable technology. Alternatively, the color of the tip of wand
208 may be painted, dyed, or set using different colored caps and
function without power or control signals and thus not required to
be connected with computer device 206.
[0036] As assembler 228 moves wand 208, CDA software may cause
first camera 216 and second camera 218 to take one or more images
or videos of the position of wand 208 relative to in-use component
204. First camera 216 and second camera 218 are positioned to
capture images along different axes of the plane of workbench 202
however additional cameras may take overhead images looking down on
workbench or from other perspectives of workbench 202. Third camera
232 may be a handheld, lightweight, wired or wireless device that
assembler 228 can position as needed to take images of in-use
component 204 being worked upon. These cameras may be industrial or
consumer grade cameras with motorized lens having motorized zoom
and motorized iris components in their lens and controlled through
a lens controller (not shown) driving by computer device 206.
Taking images from cameras at multiple view points gives a better
understanding of how the assembly took place. This is useful to
later verify whether an assembly was done correctly or incorrectly.
In some embodiments, assembler 228 positions wand 208 in response
to one or more assembly instructions from CDA software on
workstation 124 requesting the assembler to identify a recent task
or operation performed. Computer device 206 receives images and
videos from first camera 216 and/or second camera 218 creating a
permanent visual record of the assembly performed near the user
specified portion of in-use component 204 indicated with the tip of
wand 208.
[0037] CDA software further includes a user interface presented on
display device 214 and capable, among its numerous features, of
showing images and videos taken with first camera 216 and/or second
camera 218 to the assembler 228. Depending on the color scheme of
in-use component 204, assembly instructions may specify that the
tip of wand 208 be set to a contrasting color to aid in processing
images taken with first camera 216 and/or second camera 218. If
wand 208 has LED lights, assembly instructions executed on computer
device 206 may automatically change the lights on the wand's tip to
a predetermined color that provides greater contrast against the
color scheme of in-use component 204. For example, if in-use
component 204 is a printer circuit board with a predominantly green
color scheme, some embodiments may change the LED lights of wand
208 to a red or yellow color to make wand 208 more identifiable.
Alternative embodiments of wand 208 may work without LEDs and
electronics, instead of lights the assembler 228 may be instructed
to place different colored caps over the tip of wand 208 to better
identify the wand position relative to in-use component 204.
[0038] In some embodiments, assembler 228 may use a keyboard 210 to
send text data and communicate with computer device 206,
embodiments of the CDA software records these communications along
with other information used during the assembly. Text data received
on computer device 206 from keyboard 210 may confirm data or
respond to questions posed from one or more assembly instructions
during assembly of a product. Alternatively, keyboard 210 can be
used by assembler 228 to control the overall operation of
workstation 124 including pausing, starting, or stopping the
assembly operations driven by assembly instructions executed on
workstation 124. In some embodiments, barcode scanner 212
operatively coupled to computer device 206 is used by assembler 228
for scanning bar codes, this is useful for specifically identifying
materials, components, and other products used during the assembly
operations.
[0039] In some embodiments, materials, pieces, or components used
by assembler 228 during assembly are placed in one or more matrix
trays 220. Each matrix tray 220 can be customized and transformed
to hold a different quantity of materials depending on the number
of shim inserts and the shape and number of the pockets within each
of the shim inserts. The exact number and type of shim inserts
inserted in matrix tray 220 depend on the materials being used
during assembly and how the assembly instructions are setup. In
some embodiments, assembly instructions specify the numerosity and
arrangement of these shims in each matrix tray. During assembly,
the instructions identify the matrix tray as well as the particular
pocket within the matrix tray that should hold a particular
material. Referring to FIG. 2, an exemplary matrix tray 220 may
receive up to four shim inserts with pockets ranging from one to
eight pockets for each shim. Materials are loaded into matrix trays
220 in advance with the specific materials required for assembling
a component and product. Alternate embodiments may include matrix
trays, for example, larger than matrix tray 220, capable of
receiving a greater number of shim inserts with a greater number of
pockets and a range of different sizes. Matrix tray 220 and
insertable shims in FIG. 2 may be identified by assembler 228
during assembly using scanner 212 to scan and "read" a bar code
affixed to or associated with matrix tray 220 and/or corresponding
shims.
[0040] One or several power tools connected to computer device 206
may be used by assembler 228 to assemble a product. In some
embodiments, a power tool such as a screw gun 230 provides
operational information to computer device 206 through sensors
measuring torque, operating time, and other data relevant to the
particular power tool. Computer device 206 compares the data
received from the power tool with the data specified in the various
assembly instructions for the product. For example, an assembly
instruction may specify that screw gun 230 apply a specific amount
of torque to a fastener attached to a component. If computer device
206 detects the torque level is incorrect, in some embodiments,
computer device 206 prevents or stops assembler 228 from continuing
until the torque level is corrected and the proper torque applied.
Moreover, in some embodiments, a power tool may require servicing
or recalibration if the operating time of a tool such as screw gun
230 has exceeded a predetermined time or operating interval
threshold.
[0041] Some embodiments store all the assembly information remotely
over network 222 using a network accessible server 224 and
databases 226. In the example illustrated in FIG. 2, databases 226
includes at least an ERP database 226a, an assembly sequence
database 226b, an assembler train/certify database 226c, and an
assembly record database 226d. ERP database 226a includes resource
related data for all different aspects of manufacturing and product
assembly. For example, the data in ERP database 226a may be used in
some embodiments to determine if sufficient materials are available
to complete a required number of assemblies.
[0042] In addition to materials, ERP database 226a has additional
resource information on trained assemblers qualified and ready to
assemble specified materials into products. This additional
resource information in ERP database 226a may be cross-referenced
by those assemblers in assembler train/certify database 226c who
have been trained to perform the assembly of certain products. In
some embodiments, assemblers may be initially qualified to assemble
certain products but over time may eventually need to be
recertified and/or retrained. The time interval allowed between
retraining may be shorter if the particular assembly sequence is
complex and more critical, while a longer time interval between
retraining may be allowed if the assembly sequence covers
operations considered more routine and less critical to the overall
assembly.
[0043] If assembler 228 is trained, assembly sequence database 226b
provides the sequence of assembly instructions to be followed when
assembling a product. The workstation 124 presents instructions for
assembling a product using a variety of multimedia data displayed
through a user interface on display device 214 and audio through
audio speakers (not illustrated in FIG. 2). Likewise, the results
of these assemblies are also recorded using a variety of multimedia
and then stored in assembly record database 226d for future
reference and potential auditing.
[0044] Referring to FIG. 3, a flowchart diagram illustrates the
operations associated with generating a sequence of assembly
operations to be processed by a computer directed assembly
workstation. Initially, in some embodiments, a sequence of assembly
operations is identified for combining materials into a component
of the manufactured product (302). In some embodiments, a
manufacture engineer or product designer also creates the sequence
of assembly instructions during the design and development of the
product. Over time, the sequence of assembly operations may be
modified and refined to improve the product quality and reduce
associated assembly time.
[0045] Each operation may further specify a predetermined pocket in
a matrix tray for holding a material to be used when an assembler
performs the sequence of assembly operations (304). In some
embodiments, the matrix tray is adapted to receive insertable shims
with different pocket sizes for holding various size materials.
Different shims may be inserted into the tray to accommodate the
assembly of different materials as used in the creation of various
products. Generally, the person creating the assembly operations
also specifies the configuration of the matrix tray including the
number of insertable shims and associated pockets. Pockets in the
shims are arranged in a row and a column "matrix" configuration,
and a specific pocket may be used by referencing a row and column
location on the overall matrix tray in accordance with some
embodiments. For example, one matrix tray may be configured to
receive four 2.times.2 shims each having 4 individual pockets, the
16 pockets in this embodiment would be addressed according to (X,Y)
coordinates corresponding to the rows and columns of a 2.times.8
matrix. Materials placed in the predetermined pocket of a given
matrix are generally taken from a Bill of Materials (BOM) stored in
an enterprise database system, such as an ERP system, that manages
inventory as products are manufactured. In some embodiments,
materials in each pocket are consumed or used by at least one
assembly operation performed from the sequence of assembly
operations. Since an exact amount of parts for an assembly should
be placed in the matrix tray, left over parts in the matrix tray
after assembly indicates that the product has likely been assembled
incorrectly.
[0046] Next, in some embodiments, multimedia assembly data and
related assembly instructions are generated for presentation
through a user interface of a computer device (306). Multimedia
assembly data may include a variety of images, video, text, and
audio related to the materials, components, and final product being
assembled and produced. Some embodiments of multimedia assembly
data may include photos of specific fasteners or group of fasteners
in the pocket of a matrix tray along with videos of the fasteners
being inserted into a component of a product. Other embodiments of
the multimedia assembly data may include images of wire materials
held in a matrix tray along with additional images of the wires
attached to an insertion point in the component of a product. In
addition to images and videos, some embodiments of multimedia
assembly data may further include displaying text on the user
interface of the computer that the assembler can read and follow.
Computer directed assembly operations delivered through a
combination of text instructions, videos and images serve as a
powerful guide for assemblers combining materials into a component
and product in accordance with some embodiments.
[0047] In some embodiments, the assembly instructions may determine
whether an assembly instruction requests a tool to combine
materials with the component or product being assembled (308). If
an assembly instruction does not request the use of a tool
(308-No), the assembler may attach materials to a component
directly with their hands. This might be preferred if
hand-tightening a fastener or other material is preferred.
Alternatively, the assembly instruction may request using a tool
(308-Yes) if the tool would aide in performing the assembly quickly
and with a higher degree of accuracy and quality. For example, a
power screwdriver designed in accordance with some embodiments
having a built-in torque sensor is useful if an assembly
instruction requires attaching multiple fasteners to a component at
a predetermined torque. Manual tools such as screwdrivers and
wrenches may also be used if sensors, such as the torque sensor,
are not required or a fastener need not be attached as precisely as
a power tool with sensors is capable.
[0048] To guide in the use of these tools, the assembly instruction
generated also provides multimedia tool data on the user interface
(310). Multimedia tool data may include a variety of images, video,
text, and audio related to the power tools or manual tools and
their use in attaching fasteners or other materials during the
sequence of assembly operations. Some embodiments of multimedia
tool data may include displaying a schematic image or photo of a
tool along with a text description of the tool on the user
interface. The text description of the tool may also describe how
the tool should be used to attach a fastener or material or which
torque setting should be used when tightening the fastener. If the
assembler needs even more detailed guidance on using a tool,
predetermined audio describing the use of the tool may accompany
the images, videos, and other multimedia tool data displayed on the
user interface.
[0049] Next, the assembly instruction in accordance with some
embodiments guides an assembler to perform the assembly operation
that combines a material with a component used in creating a
product (312). In accordance with some embodiments, the assembly
instruction guides the assembler to perform one assembly operation
from a sequence of assembly operations for assembling a product.
For example, one assembly instruction may instruct an assembler to
attach multiple fasteners, such as several metal screws, from a
first component to a second component of a product. In this
example, the assembly instruction is used to complete the assembly
operation associated with attaching the first and second components
together as one unit within the final product.
[0050] Next, the assembly instruction in some embodiments may
optionally include a verification operation to ensure materials and
components are properly combined together during the assembly
(314). An assembly instruction may further request verification
that materials and components have been assembled together
correctly (314-Yes). In some embodiments, the verification
operation records multimedia verification data associated with a
material as it is combined with an in-use component of the finally
assembled product (316). As previously described, the in-use
component is the portion of the product currently being worked on
by the assembler. For example, one verification method includes
recording images or video of the in-use component being assembled
or worked upon by the assembler and then storing the results in an
assembly database for later review and/or analysis. In an alternate
approach to verification, the assembler places a wand having a
colored tip or end near the portion of the in-use component being
assembled as an image or video of the area is recorded by a camera
associated with the workstation. In some embodiments, the area near
the tip of the wand is further analyzed to determine if the
assembler installed the materials in the correct area or portion of
the in-use component. In yet another embodiment, computerized
comparisons are performed of the images or videos of the in-use
component being assembled with predetermined images, videos, and/or
other multimedia data associated with a previously assembled
component and materials.
[0051] Alternatively, in some embodiments, the assembly instruction
does not include a verification operation and no verification
operation is performed (314-No). When this occurs, (i.e., no
verification operation is performed), the next assembly instruction
in a sequence of assembly instructions is performed (304) and many
of the above sequence of steps in the flowchart of FIG. 3 are
repeated.
[0052] FIG. 4 provides a flowchart diagram of the operations for
specifying matrix trays and selectable inserts used with multimedia
assembly data in some embodiments. To accommodate different
materials during the assembly, the product designer or manufacture
engineer specifies a particular matrix tray design and the
materials that should go in the pockets of the matrix tray (402).
In some embodiments, the matrix tray is a combination of one or
more interchangeable shim inserts tailored to the particular
assembly being performed. Each interchangeable shim insert has one
or more pockets arranged in rows and columns for holding different
size and quantities of materials to be used during the sequence of
assembly operations.
[0053] Generating the multimedia assembly data begins by creating
an image of the matrix tray holding the materials to be used by the
assembler performing the sequence of assembly operations (404). In
some embodiments, some of the pockets in the matrix tray hold
materials while other pockets in the matrix tray are intentionally
left empty. Next, the assembly instruction configures the user
interface of the computer device to display the image of the matrix
tray having materials stored in the various pockets (406). By
displaying an image of the matrix tray and materials, the assembler
can more readily locate the materials and perform the sequence of
assembly operations. In some embodiments, highlighting a portion of
the image of the matrix tray near the predetermined pocket
containing the material also serves to assist in locating materials
during the assembly process. For example, the portion of the image
may be highlighted by further displaying a geometric shape, such as
a square or circle, around the area of interest in the image of the
matrix tray. Assembly instructions in some embodiments may also be
configured to send a request through the user interface of the
computer device asking the assembler to provide an indication of a
pocket on an in-use matrix tray holding the material the assembler
intends to use in conjunction with performing the at least one
assembly operation. The in-use matrix tray is the tray the
assembler is using for the current one or more assembly operations.
For example, the assembler may use a wand with a colored tip and
move the tip of the wand over the area of the in-use matrix tray
where the materials to be used for the assembly are located.
[0054] In some embodiments, the assembly instruction may then
instruct a camera associated with the assembler's workstation to
acquire at least one image of the in-use matrix tray (408). The
image taken of the in-use matrix tray in some embodiments should
also include the indication from the assembler of the pocket on the
in-use matrix tray holding the material to be used with the
assembly operation. Image processing may be used in further
embodiments to determine how much materials from the portion of the
matrix tray have been used by the assembler and whether more
materials are left. If the materials in the matrix tray are
determined not to match the expected amounts, a warning may be
displayed on the user interface of the workstation indicating that
some type of error has occurred. Once the image has been processed,
in some embodiments, the image of the in-use matrix tray is stored
in an assembly record database creating a traceable record of the
materials used in performing the assembly operation (410).
[0055] FIG. 5 is another flow chart diagram outlining the training
verification operations performed in accordance with some
embodiments prior to providing an assembler authorization to
perform an assembly operation. Training verification operations may
be performed in addition to the operations associated with
generating multimedia assembly data and assembly instructions in
FIG. 3 at 306. Preferably, the training verification operations in
FIG. 5 ensures that each person assembling a product (also referred
to as an "assembler") has been properly trained and that products
will be assembled properly with the highest quality and zero
defects. Accordingly, an assembly instruction may specify a
prerequisite training sequence to be completed by each assembler
before performing the instruction presented through the user
interface a workstation or computer device (502). In some
embodiments, the prerequisite training sequence is the identical
sequence of actions for the particular assembly instruction and
assembly operation. For example, if the assembly instruction is to
install five (5) standoff screws in a printed circuit board then
the prerequisite training sequence may be to perform the identical
task of installing five (5) standoff screws in a printed circuit
board with a power tool. Alternatively, similar tasks of installing
three (3) or more standoff screws in a printed circuit board may
also satisfy the prerequisite training sequence for the assembly
instruction.
[0056] Next, the assembly instruction may then request a training
history associated with an assembler from a training database that
includes a set of training sequences performed by the assembler
(504). Embodiments of the present invention keep a detailed history
of the various skills amassed by each assembler in a training
database. Some skills in the training database may be acquired when
the assembler performs a training exercise while other skills in
the training database may result when the assembler performs other
assemblies and task. In some embodiments, each assembly instruction
may check the training database to determine whether the assembler
is trained to perform the particular instruction or task.
[0057] A determination is then made whether the training history
associated with the assembler includes the specified prerequisite
training sequence (506). For example, the training history for the
assembler may already include a task of installing five (5)
standoff screws in a printed circuit board with a power tool.
Accordingly, in the event the assembler already meets the specified
prerequisite training sequence (506-Yes), some embodiments will
then authorize the assembler to perform the instruction displayed
on the user interface and guide the assembler to combine the
materials from a pocket in a matrix tray with the component (510).
Alternatively, the assembler may be required to perform a
prerequisite training sequence when the determination indicates
that the assembler has not been trained with the prerequisite
training sequence (506-No). Some embodiments may consider the
assembler to also need training if the prerequisite training
sequence is in the assemblers training history yet is older than a
predetermined time interval. When the prerequisite training
sequence was performed too far in the past, there is a possibility
that the assembler may make an error or mistake performing the
assembly instruction. For example, a particularly difficult
assembly instruction or one that is critical to the overall product
being produced may require the assembler to perform the
prerequisite training sequence every several months. If any of
these situations occur, the assembler must first perform the
prerequisite training sequence before proceeding with the assembly
instruction and further operations to assemble the product (508).
Once the assembler performs the prerequisite training sequence,
embodiments will then authorize the assembler to perform the
instruction displayed on the user interface (510). In some
embodiments, the assembly instruction may further guide the
assembler to combine materials from a pocket of a matrix tray with
a component using a tool or using the assembler's hands.
[0058] FIG. 6A schematically illustrates an exemplary
computer-implemented user interface method for interacting with
assembly operations in accordance with some embodiments. Areas
displayed on the user interface assist and guide an assembler
through the assembly operations to create a manufactured product.
These areas include assembly build information area 604, in-use
view area 606, text assembly instructions area 608, validation area
610, preassembled view area 612, tool area view area 614, and
inventory area 616.
[0059] Assembly build information area 604 of the user interface
details information on the product being assembled and the
assembler currently performing the assembly on the workstation. In
this example, assembly build information area 604 provides a part
number and details on the particular release and version of the
part number. In addition, the person associated with assembling the
particular product is identified as "Rob Jones". Details from
assembly build information area 604 are permanently recorded in an
assembly database along with other details associated with the
assembly of the components and this product.
[0060] In-use view area 606 is an area on the user interface that
provides an image of an item the assembler is currently working on
in conjunction with assembling the manufactured product. Some
embodiments of the in-use view area 606 display live video
recordings of the in-use item as the assembler positions the in-use
item in front of a camera on the workstation and performs a task in
accordance with one of the assembly instructions. The in-use item
may include one or any number of different items used by an
assembler during the assembly. The in-use items in some embodiments
may include a component making up a portion of the manufactured
product, a matrix tray holding various materials, or a material,
such as a fastener, to be attached to the component of the product
being assembled.
[0061] In some embodiments, live video displaying the in-use item
being assembled may highlight a portion of the image to assist the
assembler in performing an assembly instruction. For example,
in-use view area 606 in FIG. 6A displays a component 606B lying on
a workbench surface 606A ready for assembly. In this embodiment, a
geometric shape such as rectangle highlight 606C overlays the image
of component 606B and highlights where materials from a matrix tray
are to be attached. To further assist the assembler, text assembly
instructions area 608 includes a sequence of assembly instructions
for the assembly of component 606B into a product. In reference to
the area under rectangular highlight 606C, exemplary text assembly
instructions specified in assembly instruction 608A directs the
assembler to, "STACK TWO STANDOFFS TOGETHER AND THEN INSTALL INTO
CONTROLLER." Additionally, assembly instructions area 608 in FIG. 6
include a created-by-entry 608B that stores the name of the person
who created the assembly instructions--in this case, a J.
WOOLISCROFT--and an assembly instruction sequence counter 608C that
indicates the current assembly instruction is 6 out of 23
instructions.
[0062] Preassembled view area 612 is an area on the user interface
that provides an image of a preassembled item to guide the
assembler in the assembly of the manufactured product. The
preassembled item is an exemplary component assembled correctly in
advance by a skilled assembler and now can be used as a model or
example for the assembly of new items displayed in the in-use view
area 606. In the illustrated exemplary embodiment, preassembled
view area 612 includes a matrix tray 612A assembled with insertable
shim 612F having two pockets with fasteners, insertable shim 612G
having twenty pockets with fasteners, and insertable shim 612J
having twenty pockets with fasteners. As illustrated, a portion of
matrix tray 612A also has an open area 612K that is holding a strap
fastener 612H ready to be assembled into a component or
product.
[0063] Preassembled view area 612 further includes several other
selectable views in addition to tray view 612B that include detail
view 1 612C, detail view 2 612D and detail view 3 612E. In some
embodiments, a portion of the preassembled item may be highlighted
in preassembled view area 612 to help the assembler find a material
or attach a material to the proper component. In one illustrated
embodiment in FIG. 6A, matrix tray 612A has used rectangular
highlight 612I to draw the attention to the location of the
standoffs referenced in the sequence of assembly instructions 608A
in the assembly instruction view area 608 as previously described.
In general, the preassembled item may include a variety of
different items including a matrix tray assembled with materials
(such as matrix tray 612A), a product assembled with one or more
components, a component assembled with one or more materials (such
as component 612E), and materials to be attached to the at least
one in-use item the assembler is currently using (such as materials
612C). In accordance with some embodiments, the matrix tray 612A is
one preassembled item having several insertable shims and numerous
fasteners.
[0064] Tool view area 614 on user interface 600 provides an image
of a tool as specified in the sequence of assembly instructions.
The tool displayed in tool view area 614 is specified in the
assembly instructions to assist the assembler in selecting the next
tool to use in the subsequent steps in assembling the manufactured
product. For example, assembly instructions specify wand 614A as
the tool to be used by the assembler to assist in verifying that an
assembly instruction has been performed correctly. Other tools that
may be specified to appear in tool view area 614 include manual
tools and power tools as appropriate for the particular
assembly.
[0065] FIG. 6B illustrates an exemplary matrix tray and insertable
shims for holding materials in accordance with some embodiments.
Unlike conventional material trays fixed in a single configuration,
matrix tray 618 can be tailored to accommodate the size and number
of materials required for each product. Different insertable shims
allow both the size and the number of pockets in matrix tray 618 to
change to provide suitable capacity, yet keep a common form factor
for ease of handling and compatibility. Since the pockets in matrix
tray 618 are kept in predetermined rows and columns, assembly
instructions reference specific trays using a bar code of each tray
and then a row/column (e.g., (x,y) coordinates) to address specific
pockets in the tray. As an added benefit, this regular organization
enables computers executing image processing routines to more
easily recognize the pockets, and the materials kept in these
pockets.
[0066] Database applications and embodiments may also identify and
associate materials with assembly instructions as the assembly
instructions are performed by the assembler. In the illustrated
exemplary embodiment in FIG. 6B, each of the twenty (20) pockets
from insertable shim 618C or 618E may be digitally identified with
(x,y) coordinates or enumerated as pockets 0 through 19 by one or
more database programs. In some embodiments, image processing
routines may capture images of matrix tray 618 during assembly and
quickly determine if the number of fasteners or other material for
the assembly instruction are correct. To aid in further
identification and automation, some embodiments may individually
identify matrix tray 618 using a combination of one or several of a
bar code (not shown), a QR code (not shown) or passive RFID
technology attached to matrix tray 618 (not shown).
[0067] In illustration of one embodiment, a tray portion 618A of
matrix tray 618 has been separated from insertable shims 618B,
618C, and 618E making apparent the flexibility and accompanying
advantages of the design. Tray portion 618A in some embodiments has
four (4) areas labeled I, II, III, and IV adapted to receive either
an insertable shim or directly receive material. For example, since
strap fastener 618F cannot be contained within an insertable shim,
it is instead placed directly on the area of tray portion 618A
labeled III. As illustrated, insertable shims 618B, 618C, and 618E
may be replaced with different shims and inserted back onto tray
618A in different configurations as demanded by a different set of
assembly instructions and specific product being manufactured. In
some embodiments, shims may include two (2) pockets such as with
insertable shim 618B or twenty (20) pockets as exemplified by
insertable shim 618C. Other shims may contain greater than two (2)
pockets yet fewer than twenty (20) pockets (not shown) with the
exact number of pockets depending on the size and quantity of the
materials used by a particular assembly instruction or
instructions. Alternate embodiments may also include tray portions
larger than tray portion 618A as illustrated in FIG. 6B and formed
from different geometric shapes other than a rectangle or other
conventional geometries. It is also possible that a tray portion of
a matrix tray has greater than just the four (4) areas illustrated
in tray portion 618A; indeed the size of the tray portion 618A may
be larger or smaller depending on the size of materials being used
and the application.
[0068] FIGS. 7A and 7B illustrate a flowchart diagram of an
exemplary operation associated with assembling materials into a
component of a manufactured product. In some embodiments, these
flowchart operations are performed on a workstation as an assembler
performs an assembly sequence of instructions to create the
manufactured product. Initially, in some embodiments a training
history is retrieved that is associated with an assembler selected
to combine materials with a component of a manufactured product in
accordance with a sequence of assembly operations (702). The
training history may be stored in a training database that
describes the experience and/or training that an assembler has
achieved through a combination of training assemblies and
experience assembling other components together into products.
[0069] Preferably, the assembler selected to assemble the product
is already sufficiently trained and competent to perform each
instruction of the assembly sequence. To make this determination,
embodiments of the present invention check if the training history
for the assembler satisfies a prerequisite training sequence
associated with the sequence of assembly instructions (704). In one
exemplary embodiment, the prerequisite training sequence may
require the assembler to have experience or training installing a
set of four standoffs with a power screwdriver before proceeding
with the remaining instructions of the assembly sequence. This
specific experience must be acquired through training assemblies or
practice assemblies before the assembler can make a production
assembly for shipment.
[0070] If the assembler's training history does not include
sufficient experience (704-No), in certain embodiments, the
assembler is guided through a prerequisite training sequence using
training multimedia data on a user interface of a computer device
at an assembly workstation (706). In some embodiments, the
assembler is required to perform the actions associated with the
training using sample materials and a sample component. In some
embodiments, training multimedia displayed on a user interface of
the workstation includes images of the materials and components
being assembled and text assembly instructions to guide the
assembler through the training.
[0071] Once the assembler has performed the prerequisite training
sequence, in some embodiments, the training history of the
assembler is updated to include the prerequisite training sequence
and associated assembly performance details (708). In some
embodiments, the assembler's training history is updated in a
training database to include a speed and an accuracy with which the
assembly was performed. Speed and accuracy information helps
determine how quickly an assembler is likely to perform a sequence
of assembly instructions and also how many products the assembler
is capable of assembling over a period of time. This performance
related information helps determine how to establish work schedules
of people assembling certain products and meet product delivery
goals. For example, if a product delivery must take place quickly
and with high quality results and zero-defects then only people who
have a history and are capable of assembling the product meeting
these constraints will be selected to assemble the product and
fulfill the order.
[0072] If the assembler's training history does include sufficient
experience (704-Yes), in some embodiments, assembly instructions
are provided through the user interface to guide the assembler in
combining materials with the component (710). To further assist the
assembler, in some embodiments, specific materials stored in
predetermine pockets of a matrix tray are identified using a
variety of multimedia data and guidance is provided on assembling
these materials with the component.
[0073] In some embodiments, assembly instructions determine whether
a tool is used to combine materials with a component (712). If an
assembly instruction does request using a tool (712-Yes), the
assembler is presented with a variety of multimedia tool data
through the user interface. The multimedia tool data guides the
assembler in using the tool to perform a portion or all of the
sequence of assembly instructions. In some embodiments, the tool
multimedia data may be a single image of a tool, a video of the
tool, or a combination of images and video along with instructions
for using the tool to assist in performing the particular assembly
instruction or instructions. For example, if the tool's usage is
routine or typical then the multimedia tool data may only need to
identify the tool using a single image displayed on the user
interface. However, if the assembly instruction uses the tool in a
more complicated manner, the multimedia tool data may include
images and videos along with detailed instructions for using the
tool.
[0074] In some embodiments, the assembly instruction may not
request using a tool when the assembler can use their hands to
perform an assembly or other task (712-No). For example, an
assembly instruction may request that the assembler insert a wire
connector with a group of wires into a connector receiver on a
printed circuit board. Referring to FIG. 7B, some embodiments may
then determine if the assembly instructions should also be verified
using one or more verification operations (716). In the event the
assembler does not have to verify the assembly instruction
(716-No), the above described steps in FIG. 7A starting with step
702 are repeated until all the assembly instructions for the
product are completed.
[0075] Alternatively, some embodiments may indeed require a
verification operation to ensure the assembly instructions were
performed correctly (714-Yes). In some embodiments, the
verification operation records verification multimedia data
associated with combining the materials and the component (718).
Once the assembler completes the assembly instruction or
instructions, in certain embodiments, an image or video of the
in-use component being assembled is taken and stored in an assembly
record database as a permanent record of the assembled component or
product. In further embodiments, the verification operation may
also request the user to point to or identify a location of the
portion of the in-use component being assembled using a wand and
then take the images or videos as a permanent record. In another
embodiment, image processing functions are utilized on a
workstation to compare the images of the in-use component with a
predetermined multimedia assembly data showing a previously
assembled component or product known to be assembled correctly and
with a high quality.
[0076] In accordance with some embodiments, FIG. 8 is a schematic
block diagram of an exemplary computer device 800 capable of
creating and processing assembly instructions for guiding
assemblers manufacturing products. Computer device 800 includes a
memory 802, presentation device driver 804 coupled to a display
device (not shown), a processor complex 806, secondary storage 808,
network communication port 810 and I/O ports 812 coupled to a
variety of different input-output devices over an interconnect 816.
In particular, processor complex 806 may be a single processor,
multiple processors or multiple processor cores on a single die. It
is contemplated that processor complex 806 represents the one or
more computational units available in computer device 800. Further,
input-output devices coupled to I/O ports 812 may include one or
more of the following: cameras, power tools, power tools with
sensors, wands, scanners, keyboards, mice, any other peripheral
device previously described in conjunction with FIG. 2, and other
suitable devices. Network communication port 810 may further
include a WiFi, WiMAX or other connection to a network such as the
Internet. Network communication port 810 may also include wired
connections to the Internet using CAT 5/6, Fiber Channel or similar
approaches.
[0077] In the illustrative embodiment in FIG. 8, memory 802
includes storage locations that are addressable by the processor
complex 806 and adapters for storing software program code and
data. For example, memory 802 may include a form of random access
memory (RAM) that is generally cleared by a power cycle or other
reboot operation and classified as "volatile" memory. Processor
complex 806 and various adapters may, in turn, comprise processing
elements and logic circuitry configured to execute the software
code and manipulate the data stored in the memory 802. In
comparison, secondary storage 808 may be a form of non-volatile
storage for storing a copy of run-time environment 826,
applications and other data used by computer device 800.
Alternatively, secondary storage 808 may include conventional
magnetic tapes or disks, optical disks such as CD-ROM, DVD,
magneto-optical (MO) storage or any other type of non-volatile
storage devices suitable for storing large quantities of data.
These latter storage device types may be accessed locally through a
direct connection to interconnect 816 or remotely in the "cloud"
through network communication port 810 with an appropriate network
protocol.
[0078] In some embodiments, memory 802 includes assembly
instruction sequence component 818, tool usage component 820,
material usage component 822, multimedia assembly/verify component
824, assembler training and verification component 825 and run-time
module 826. Assembly instruction sequence component 818 includes
methods and systems for creating assembly sequences for combining
materials, components, and parts into products as described
previously in conjunction with FIG. 3 through FIG. 5. This assembly
instruction sequence component 818 also processes these assembly
instructions to guide and control assemblers creating products also
as previously described in conjunction with FIGS. 7A-7B. Tool usage
component 820 incorporates the creation and presentation of
multimedia tool data on a user interface to also assist in guiding
an assembler creating products. As previously described in
conjunction with FIG. 6B, material usage component 822 includes
data associated with the configuration of matrix trays, insertable
shims, and the materials stored in these for the creation of
different products. Multimedia assembly record/verify component 824
includes images, video, data, and processes for verifying the
assembly of products as also described in conjunction with at least
FIG. 2-4 and FIG. 7A-7B. Assembler training and verification
component 825 includes images, video, data, and processes for
training and verifying the skills of assemblers and is previously
described in conjunction with at least FIGS. 1-3, 5, 6A-B, and
7A-B. Lastly, memory 802 includes run-time environment 826 portions
of which typically reside in memory and are executed by the
processing elements. Run-time environment 826 may be based upon a
general-purpose operating system, such as Linux, UNIX or Windows,
the AppleOS or any other general-purpose operating system as well
as mobile or embedded operating systems based upon Android,
Blackberry, QNX, Apple iOS, and others as used in mobile phones,
mobile devices, touchpads, or touchscreen-based computer
systems.
[0079] While examples and implementations have been described, they
should not serve to limit any aspect of the present invention.
Accordingly, implementations of the invention can be implemented in
digital electronic circuitry, or in computer hardware, firmware,
software, or in combinations of them. Apparatus of the invention
can be implemented in a computer program product tangibly embodied
in a machine readable storage device for execution by a
programmable processor; and method steps of the invention can be
performed by a programmable processor executing a program of
instructions to perform functions of the invention by operating on
input data and generating output. The invention can be implemented
advantageously in one or more computer programs that are executable
on a programmable system including at least one programmable
processor coupled to receive data and instructions from, and to
transmit data and instructions to, a data storage system, at least
one input device, and at least one output device. Each computer
program can be implemented in a high level procedural or object
oriented programming language, or in assembly or machine language
if desired; and in any case, the language can be a compiled or
interpreted language. Suitable processors include, by way of
example, both general and special purpose microprocessors.
Generally, a processor will receive instructions and data from a
read only memory and/or a random access memory. Generally, a
computer will include one or more mass storage devices for storing
data files; such devices include magnetic disks, such as internal
hard disks and removable disks; magneto optical disks; and optical
disks. Storage devices suitable for tangibly embodying computer
program instructions and data include all forms of non-volatile
memory, including by way of example semiconductor memory devices,
such as EPROM, EEPROM, and flash memory devices; magnetic disks
such as internal hard disks and removable disks; magneto optical
disks; and CD ROM disks. Any of the foregoing can be supplemented
by, or incorporated in, ASICs.
[0080] While specific embodiments have been described herein for
purposes of illustration, various modifications may be made without
departing from the spirit and scope of the invention. Accordingly,
the invention is not limited to the above-described
implementations, but instead is defined by the appended claims in
light of their full scope of equivalents.
* * * * *