GB2352692A

GB2352692A - An assembly line system

Info

Publication number: GB2352692A
Application number: GB0017037A
Authority: GB
Inventors: Marc Aston
Original assignee: Honda Canada Inc
Current assignee: Honda Canada Inc
Priority date: 1999-08-03
Filing date: 2000-07-11
Publication date: 2001-02-07
Anticipated expiration: 2020-07-11
Also published as: JP2001129730A; GB2352692B; CA2280414C; GB0017037D0; CA2280414A1

Abstract

An apparatus for assembling comprises: a plurality of assembly lines 1 each having a plurality of assembly stages 12,22,32,42 each having their own inspection and repair stages 14,24,34,44; and a communications network linking the plurality of assembly/inspection/repair stages throughout the plurality of assembly lines. Each of the inspection stages may have a data entry and computer display system so that it is possible to enter and view defects detected and repairs carried out at each of the inspection/repair stages throughout the plurality of assembly lines. The ability to view this information at the various inspection/repair stages along the assembly lines, and at other production related departments of the assembly lines, is intended to allow counter measures to defects detected to be produced and the impact of defects on the remainder of the other assembly lines to be reduced. There is also disclosed a method of manufacturing, a method of assembly, a system for tracking an assembly, an assembly line, a method of operating an assembly line, and a computer software media for controlling a processor all concerned with such an apparatus.

Description

2352692 ZONE INSPECTION MANUFACTURING LINE

FIELD OF THE INVENTION

The present invention is directed to an improved automobile manufacturing line wherein the manufacturing line is divided into functional zones with inspection and repair being performed at each zone, and to related methods.

BACKGROUND TO THE INVENTION

A conventional automobile manufacturing line, such as that disclosed in Japanese laid open publication no. 4-250958, has an inspection department, wherein static and dynamic functional inspections are performed, at the end of, and after, a plurality of assembly lines and processes. In the case of a problem or defect, the defective vehicle is sent to a repair department for processing, which, again, is at the end of the plurality of assembly lines. The repair department then performs the necessary repairs. The vehicle, upon completion of any necessary repairs, is then complete.

In recent years, the inspection and repair processes of these automobile manufacturing lines have been equipped with computers for data input and display.

The assembly line worker, known within Honda as an associate, in charge of the inspection process enters the problem items in the computer. The problem items, or defects, are then displayed in the repair department. Repairs conducted on any defective vehicles correspond to and are based on the problem items displayed by the computer.

2 In the conventional assembly described above, static and dynamic functional inspection of a vehicle is performed in a Vehicle Quality department which is located at the terminus of the assembly process. All of the defects and problems that occur 5 during the entire assembly process are repaired in the repair department of the Vehicle Quality department. When a large number of problems are identified, such as defects i'dentif 1 ied during an exterior inspection which may be the result of a defect caused early in the assembly process, the repair department, which has the responsibility for repairing the identified defects, may be overwhelmed. Moreover, isolating the cause of problems identified in the Vehicle Quality depaitment becomes difficult as the vehicle quality is only assessed as a final process in its overall assembly. Further, the data corresponding to these problems and their solutions, which is, conventionally, transmitted from the repair department to other production departments, becomes excessively large.

Accordingly, it is desired to provide a method of manufacturing an automobile which addresses these shortcomings.

SUMMARY OF THE INVENTION 20

An improved assembly line process is achieved by dividing the assembly line into a plurality of zones by static function (interior, appearance, etc.). Each functional zone is responsible for a static functional inspection and the repairs of identified defects. Static functional inspections assess non-operational characteristics of an assembly.

Thus, by assessing and repairing static functional defects, the static functional quality of a vehicle is improved at each functional zone. Moreover, the production efficiency is improved and the quality of the entire assembly line is stabilized at an early stage of assembly since these vehicles are inspected and repaired early in the manufacturing 5 process.

A first aspect of the present invention is directed to an automobile assembly line wherein a plurality of assembly lines following the course of the line are divided into a plurality of furictional zones. At the end of each furictional zone is an inspection/repair process that is responsible for static functional inspection and light repairs of defects of any vehicle entering the inspection/repair process of the functional zone. A functional zone's inspection/repair process is equipped with a data entry and display system so that all defects identified in that particular zone can be entered into the data entry system together with any problem items or defects that could not be repaired. The main characteristic of this data entry and display system is that it is not only configured to display all of the identified and/or repaired defects of a particular zone but the data entry and display system is also connected to the data entry and display systems of other production-related departments.

The assembly line may be designed so that there is an inspection process for each functional zone and each individual functional zone has its own inspection area and can perform some of its own repairs.

4 Further, the repair process of each functional zone may be able to perform many of the repairs that typically develop in that functional zone. Moreover, the repair area may also attempt to remedy those defects entered into the data input and display system in the inspection processes of other functional zones. Each repair process also may determine if the capability to remedy an identified defect is available at that repair process. If the remedial capability exists, a repair is made. Each functional zone may also display a countermeasure to prevent further defects. If possible the countermeasure to address the suspected cause of the defects may be implemented on the assembly line.

As a result, it is possible to implement countermeasures for the problem items or defects identified and pertaining to the assembly process of a particular functional zone.

Further, there may be provided, through the data entry and display system, the capability to enter and provide to the production-related departments, a wealth of data. This data may include, for example, the capabilities of a particular functional zone's repair area and the problem items or defects that can be repaired in that particular functional zone, cause of a defect, a summary of the repairs performed and the time 20 required to repair a defect.

In case of problem items or defects that are not possible to repair in a particular functional zone, data on the problem item or defect may be transmitted into the data entry and display system which can then be provided to other production- related departments, such as, for example, repair departments.

All the problem items that can be repaired in a particular functional zone are repaired and countermeasured. That is, an attempt to address the suspected cause of the defects is implemented. But, problem items or defects that cannot be repaired in a particular zone are repaired in a repair department located at the end of the entire assembly line. The countermeasure to address the cause of the defect is then transmitted or fed back to the particular functional zone which caused the defect. In this way, the cause of the problem that could not be repaired in a particular functional zone may be addressed so that further defects from this cause are reduced promptly. Even during the period of production start-up, the assembly as well as the quality of static functionality can be improved and stabilized by the operation of the functional zones.

A further aspect of the present invention is directed to an automobile assembly line that may improve and may guarantee the repair of all identified problems. Problem items or defects that cannot be repaired at a particular zone inspection process are repaired at a complex quality assurance zone. As a result, all the identified problems that are not repaired at each functional zone can be completely repaired.

According to one further aspect of the invention, there is provided an apparatus for assembling comprising: a plurality of assembly lines each manufacturing an assembly; each of said plurality of assembly lines comprising: a plurality of functional 6 zones; and each of said functional zones having: a zone for assembly; an inspection area for identification of defects; and a repair area for repairing identified defects; and a communications network providing communication amongst said plurality of functional zones of said plurality of assembly lines.

According to another aspect of the invention, there is provided a method of manufacturing comprising: manufacturing a sub-assembly at each of a plurality of sub-assembly lines; manufacturing an assembly incorporating each of said subassemblies at a primary assembly line; at each of said plurality of sub-assembly lines:

inspecting said sub-assembly for defects at each of a plurality of functional zones spaced along said each sub-assembly line; where possible, repairing, at said each ftinctional zone, defects identified during said inspecting of a given sub-assembly at said each farictional zone and defects identified during said inspecting of said given sub-assembly at functional zones upstream of said each functional zone; and transmitting for use by other sub-assembly lines of said plurality of sub- assembly lines data related to defects identified and defects repaired at said each of said functional zones.

According to another aspect of the invention, there is provided a method of assembly, comprising: at a first functional zone on a first assembly line in communication with a second assembly line: assembling a first assembly; inspecting said first assembly for defects; communicating results of said inspecting of said first assembly to said second assembly line; where possible, repairing at least some of said first ftirictional zone defects; and communicating results of said repairs to said second 7 assembly line; at a second functional zone on a second assembly line: receiving said results of said inspecting and said repairing communicated from said first assembly line; and assembling a second assembly responsive to said inspecting and repairing results received.

According to another aspect of the invention, there is provided a method of assembly, comprising: at a first functional zone on a first assembly line: assembling at an assembly zone a first assembly; inspecting at an inspection zone said first assembly for a first set of defects; and at a repair zone, where possible, repairing at least some of said first set of defects; at a second functional zone on a second assembly line: assembling at an assembly zone a second assembly incorporating said first assembly; inspecting at an inspection station said second assembly for a second set of defects; and at a repair zone, where possible, repairing at least some of said first set of defects and said second set of defects; and communicating said defects identified and said repairs performed at said first functional zone to said second fimetional zone and said defects identified and said repairs performed at said second functional zone to said first functional zone.

According to another aspect of the invention, there is provided a system for tracking an assembly comprising: a receiver for receiving signals from a plurality of assembly lines; each of said assembly lines comprising: a plurality of functional zones; and each of said functional zones having: a zone for assembly; an inspection area for identification of defects; and a repair area for repairing identified defects; and said signals containing information corresponding to defects identified at said 8 inspection area and repairs performed at said repair area of each of said plurality of functional zones of each of said plurality of assembly lines; a transmitter for transmitting signals to said plurality of functional zones of said plurality of assembly lines, said transmitted signals containing information relating to said infon-nation 5 received by said receiver.

According to another aspect of the invention, there is provided an assembly line comprising: a plurality of functional zones, each functional zone having, in downstream order, an assembly area, an inspection area for identifying defects, and a repair area for repairing defects; a communication terminal associated with each said assembly station, inspection station, and repair station; a communication network interconnecting each said communication terminal and having a remote network connection to another assembly line; memory associated with said communication network for storing build sheet data and assembly sheet data for each said functional zone; at least one processor associated with said communication network for modifying said assembly sheet data based on input from communication terminals and input received over said remote network connection.

According to another aspect of the invention, there is provided a method of operating an assembly line, comprising: at each of a plurality of functional zones: at an assembly area, receiving current assembly sheet and build sheet data from a communication network and assembling in accordance with said data; at an inspection area, inspecting an assembly output from said assembly area for defects and outputting defect data to said network; at a repair area, receiving defect data from said 9 communication network, repairing said assembly based on said defect data, and outputting repair data to said cornmunication network; receiving countermeasure data from another network associated with another assembly line; developing countermeasure data based on said repair data; modifying at least one of said assembly 5 sheet data and said build sheet data based on said countermeasure data.

According to another aspect of the invention, there is provided a method for operating assembly lines, comprising: providing, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receiving from an inspection area of each of said plurality of ftinctional zones, data relating to identified defects; receiving from a repair area of each of said plurality of functional zones, repair data; sending to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; developing countermeasures based on received defect data and repair data; and revising assembly sheet and build sheet data based on said developing.

According to another aspect of the invention, there is provided a computer software media, which when loaded into a process adapts said processor to: provide, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receive from an inspection area of each of said plurality of functional zones, data relating to identified defects; receive from a repair area of each of said plurality of functional zones, repair data; send to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; develop countermeasures based on received defect data and repair data; and revise assembly 5 sheet and build sheet data based on developed countermeasures.

BRIEF DESCRIPTION OF THE DRAWINGS

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures wherein:

Figure I illustrates the basic structure of a first automobile assembly line embodying the invention.

Figure 2 illustrates, schematically, a first portion of a functional zone of the automobile assembly line of Figure 1.

Figure 3 illustrates, schematically, a second portion of the functional zone of Figure 2 and a computer network of the automobile assembly line of Figure 1.

Figure 4 illustrates another portion of the automobile assembly line of Figure 1.

I I Figure 5 illustrates the basic structure of a second automobile assembly line embodying the invention.

Figure 6 illustrates, schematically, a second portion of the automobile assembly line of Figure 5.

Figure 7 is a flow diagram of the embodiment of Figure 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referencing Figure 1, automobile assembly line 1 is divided into an assembly area 2 and complex quality assurance zone 3.

Assembly area 2 comprises a plurality of functional zones that follow the course of automobile assembly line 1. As illustrated, for exemplary purposes only, assembly area 2 is divided into functional zone A 10, functional zone B 20, functional zone C 30 and functional zone D 40. The processes and assembly that are performed in a particular functional zone are dependent upon a wide variety of factors including, for example, the speed of the assembly line, the overall design of the vehicle, the formation of a conventional portion of a vehicle (such a front engine room component, passenger cell, truck bed, etc.), as well as many others.

Each functional zone, A 10, B 20, C 30 and D 40, comprises a functional assembly zone (12, 22, 32 and 42, respectively), wherein a plurality of assembly processes are performed, and thereafter, an inspection/repair zone (14, 24, 34 and 44, respectively), wherein the functional zone performs its own static functional inspection 12 and repairs. In this manner each functional zone inspects the partially constructed vehicle for defects and problem items relating to such areas as, for example, the outer appearance and exterior and interior static function related items. In the exemplary embodiment all dynamic function related items are excluded from the functional inspection zones. As will be obvious to those skilled in the art, static functional inspection assesses non-operational characteristics of an assembly. For example, the tolerances of welds, the inclusion of the requisite parts, etc. In contrast, functional inspection assesses the operation of an assembly. For instance, the operation and interoperation of the transmission and the engine, the operation of electric window lifts, etc.

As illustrated, assembly area 2 comprises functional zone A 10, functional zone B 20, functional zone C 30 and functional zone D 40. Functional zone A 10, like functional zones B - D (20, 30 and 40, respectively), comprises a functional assembly zone A 12 and an inspection/repair zone A 14. Functional assembly zone A 12 performs various assembly processes, such as, for example, the welding of front engine room or bay component, similar to a conventional assembly line. However, unlike a conventional assembly line, functional zone A 10 incorporates, downstream of functional assembly zone A 12, inspection/repair zone A 14. 20 Inspection/repair zone A 14 performs a static inspection of the partially completed vehicle upon the vehicle's departure from functional assembly zone A 12. During the inspection of the partially completed vehicle, defects and other problem items may be identified. Hereafter, defects and problem items are used interchangeably to designate any portion of a vehicle that is outside the quality specification tolerances. The inspection of the vehicle may include the performance of a pre-determined set of routines or methods, such as for example, a visual or touch inspection of the partially completed vehicle that may, for example, check the tightening of various fasteners, the connection of wire assemblies, body defects or deforms, etc. Moreover, inspection/repair zone 14 also has repair capabilities in which, if possible, defects or problem areas identified previously are repaired. These repair capabilities are configured so as to be able to complete certain repairs without stoppage of assembly line 1. As will be obvious to a person skilled in the art, an automobile assembly line configured in accordance with this invention will improve production efficiency by the identification and repair of defects and other problem items in-line and as close to the location of the cause of those defects as possible.

Moreover, incorporating inspection/repair zone A 14 within functional zone A 10 improves the static quality of a partially assembled vehicle prior to the vehicle reaching complex quality assurance zone 3.

Similar to functional zone A 10, functional zone B 20 is comprised of functional assembly zone B 22 and inspection repair zone B 24. Similarly, functional zone C 30 is comprised of functional assembly zone C 32 and inspection/repair zone 34 and functional zone D 40 is comprised of functional assembly zone D 42 and inspection/repair zone 44. Functional assembly zones B 22, C 32 and D 42 perform conventional assembly processes.

14 With the assistance of a computer system 300 (Figure 3) equipped for data input and display, information pertaining to defects or problem items; repairs performed; and repairs not performed are input into the computer system 300 and the data is transmitted to and displayed on computer workstation located in complex quality assurance zone 3. As will be described later in greater detail, complex quality assurance zone 3 is comprised of complex quality inspection process area 3)a and dress up process area 4, as well as other production related departments.

As described heretofore, static functional inspection of a partially completed vehicle, including, for example, inspection of the exterior, interior, connections, and others, is performed at each of the functional zones of automobile assembly line I based on inspection specifications. As a result of the data input, complex quality assurance zone 3 is informed, by the display of data on a computer workstation forming part of computer system 300, of defects or problem items that could not be repaired upstream of complex quality assurance zone 3. Complex quality assurance zone 3 also performs an overall complex quality inspection of the vehicle and the inspection results are then entered in a final inspection card - a paper record which has data corresponding to a particular vehicle's assembly. Further, complex quality data is input into the computer workstation of the computer system 300, described in detail below, located at complex quality assurance zone 3.

In case of any problem items identified as a result of the inspection at complex quality inspection process 3a, data corresponding to these identified defects is input into computer system 300 and transmitted to and displayed at dress up process 4.

Finally, data from the final inspection card is input into a computer station of computer system 300 located in complex quality assurance zone 3. This data is then transmitted and is available for display at other computer workstations of the computer 5 system which are located in other production related departments.

Defects or problem items that could not be repaired at inspection/repair zones A 14, B 24, C 34 or D 44, together with those items identified at complex quality assurance inspection process area 3a are then repaired at dress up process 4.

Briefly referencing Figure 4 along with Figure 1, as will be described later, dress up process 4 comprises an in-line repair process 6 and a line side repair process 7 for any problem items that could not be repaired in functional zones A 10, B 20, C 3 0 and D 40 (see Figure 4).

In the same way that complex quality inspection area 3a is equipped with a computer workstation for the input and display of data from computer system 300, dress up process 4 is also equipped with a computer for data input wherein repair details of items repaired in-line, as well as repair contents of items repaired out-of-line, and in side line process 7, are entered. This data is then displayed on computer screens or data outputs in other production-related departments that are equipped with access to computer system 300.

16 Figure 2 illustrates, an exemplary structure of a functional zone A 10 of automobile assembly line 1. Moreover, functional zone A 10 is exemplary of the possible structure of other functional zones, such as functional zone B 20, functional zone C 30 and functional zone D 40.

As illustrated, functional zone A 10, is comprised in part of a plurality of assembly processes A, B,...,N, 202A, 202B,..., 202N, respectively, and zone inspection process 14. Assembly processes 202A - 202N install parts and perforin some assembly of the partially completed vehicle. As illustrated in the exemplary embodiment, assembly process A 202A may install a nozzle, an ABS modulator, an insulator, a filler pipe and an interior cord set. Similarly, assembly process N 202N of functional zone A 10 may install the starter cable, the hom and a slide door stopper.

Further, a high degree of quality during the assembly and processing of a partially completed vehicle in assembly processes 202A - 202N is enhanced with the assistance of set methods on assembly and processing, including the use of, for example, mechanical jigs, so that defects or problem items such as foreign substances, contaminants, bending or twisting of components, insufficient torque, etc., are reduced.

As illustrated, zone inspection process 14, responsible for the inspection and repair of, for example, interior parts, is passed a partially completed vehicle, which arrives upon completion of assembly processes 202A - 202N. Inspection process 14A is responsible for the inspection of the partially completed vehicle. Following 17 inspection process 14A, and forming part of inspection/repair zone A 14, is repair process 14B, which is responsible for performing in-line repairs to the partially completed vehicle. The main objective of inspection/repair zone A 14 is to identify and repair any problem items or defects and ensure a high level of quality of a partially 5 completed vehicle exiting the functional zone, in this case functional zone A 10.

Based on a variety of possible inspection methods which may include such as, for example, visual, measured or gauged inspection, touch and check sheet inspections, all of which may be performed manually, automatically or by a combination of the two, an inspection of the partially completed vehicle is performed on, for example, the outer appearance, fit and finish, and parts assembly. This inspection is designed to identify any out of specification static quality items relating to, for example, a vehicle's outer appearance, deforms, -float, wrong assembly and others.

Repair process 14B then performs repairs to problem items identified previously, including those identified during the inspection performed by inspection process 14A. In repair process 14B, it is determined whether repairs to particular problem items may be performed by repair process 14B based on its capabilities. It is also determined whether, based on a variety of factors, including, for example, line speed, a necessary repair to an identified problem can be completed in- line and within a specified time period. This time period may, for example, be a set number of minutes or seconds. It is desirable that problem items that may affect the process of the next functional zone be repaired prior to the partially completed vehicle entering the next functional zone.

18 Inspection process 14A and repair process 14B are equipped with computer stations for the input of data into computer system 300 (Figure 3). Therefore, problems identified in inspection process 14A are entered into computer system 300.

This entry may be performed automatically, manually or through a combination of the two methods. Repair process 14B performs repairs based on the data displayed by computer system 300. Further, data is entered into computer system 300 that corresponds to items left partially unrepaired. All of this data is then available for display on computer screens of computer stations connected to computer system 300.

These computer stations are, as described later, available in ftinctional zone 10 and in other production related departments.

Figure 3) explains the zone inspection process and outline of computer system 300, which, as illustrated, incorporates a computer Local Area Network (LAN). Only a portion of the LAN of computer system 300 is illustrated, for purposes of ease of understanding and removal of repetitive portions. Computer system 300 incorporates a plurality of computer stations 3 10 and a host computer 302 connected to a backbone 304. In communication with host computer 302 is computer software medium 305.

Computer software medium 305, which contains instructions and data for host computer 302, is readable by host computer 302. Computer software medium 305 may contain, for example, database software, computer applications, computer data, network software, data corresponding to the layout of automobile assembly line I (Figure 1), or the like.

19 While computer software medium 305 is illustrated as a computer diskette, it could equally be a tape, memory chip, or other removable or non- removable computer readable medium. Furthermore, the software medium may be a remote medium, such as a memory of a remote computer, and be downloaded over a suitable link such as 5 over an network, internet, intranet, dedicated data link, or the like.

As described above, each fimctional zone, that is, ftmctional zones A 10, B 20, C 30 and D 40 (Figure 1), has a plurality of workstations capable of data entry and data display. Specifically, and as illustrated in greater detail in Figure 3, the inspection/repair zones of each ftmctional zone (as illustrated inspection/repair zone 14 of ftmctional zone A 10) has a computer workstation 3 10 in each of the inspection and repairs processes (here, inspection process 14A and repair process 14B). The various assembly processes (such as assembly process A-N, 202A - 202N, shown in Figure 2) may also have computer workstations proximally located thereto).

The computer workstation in the inspection process 14A comprises an input device, such as bar code scanner 330, and a data display device, such as touch panel display 332, which, in this case, is capable of both the display of data and the entry of data into computer system 300.

The computer workstation in the repair process 14B also comprises an input device, such as bar code scanner 340, and a data display device, such as touch panel display 342, which, in this case, is capable of both the display of data and the entry of data in computer system 300.

Figure 3 also illustrates the various processes that are performed in inspection/repair zone 14. As illustrated, inspection process 14A determines a particular vehicle identity through the use of, for example, bar code scanner 330 which reads a vehicle's vehicle identification number (VIN). In response to the reading of the VIN, an "assembly specification sheet" is retrieved from the memory of host computer 302 and transmitted and displayed on touch panel display 332 of the computer workstation located in inspection process 14A. Based on the specification sheet retrieved and displayed on touch screen 332, an inspection routine is performed on the partially assembled vehicle located within inspection process 14A.

Inspection results and the problem items identified during the inspection routine are then entered into workstation 310 of inspection process 14A, via touch screen 332, and form part of the data available on computer system 300. The data so entered is then fed back and available for display at all of the production-related departments.

In repair process 14B, the "assembly specification sheet" is retrieved in the manner described in reference to inspection process 14A. Moreover, the action of bar code scanning the partially assembled vehicle's VIN also provides repair process 14B with data corresponding to the problem items and defects identified so far, including those problem items identified by and entered into computer system 300 during inspection process 14A through use of touch screen 332. Based on the defects and problem items displayed on display 342, a determination is made as to whether to 21 perform the necessary repairs. For defects or problem items that are possible to repair, based on a variety of factors including, for example, time available, the capabilities of the repair process 14B and others, repairs are commenced and completed based on the repair standards and routines. Data, corresponding to both the problem items repaired and those not repaired, is entered, through use of touch screen 342, into computer system 300. This data is then available for display on the computer workstations 310 in the particular functional zone, in this instance functional zone A 10, and those of all the other computer workstations 3 10 in the other production related departments.

By having an inspection and repair process at the end of each functional zone, the quality of partially completed vehicles exiting each functional zone is improved. Moreover, data and information regarding defects and problem items not repaired can be provided to the required departments such as, for example, complex quality inspection process 3a and dress up process 4. 15 Further, defects and problem items of a particular functional zone can be repaired and this repair data is then fed back to the assembly process of that particular zone and, as a result, repair information is immediately available to the whole of automobile assembly line 1 and may be used to implement countermeasures to prevent 20 further problem items or defects.

Further, based on the repair data fed back from dress up process 4, repair information is transmitted back to the assembly process, for example processes 202A - 202N, of a particular functional zone and, as a result, it is possible to improve the 22 quality of a particular ftmctional zone as the time delay between introducing a defector problem item-creating error is reduced. Therefore, the causes of the defects and problem items are easier to determine and the time to respond to these causes is also reduced.

Figure 4 explains the structure of an exemplary dress up process 4. As illustrated, dress up process 4 comprises in-line repair process 6 and line side repair process 7. Defect and problem item data entered into computer system 300 in each of the functional zones, A 10, B 20, C 30 and D 40, is displayed on a computer display of a computer workstation located in in-line repair process 6. This information may be retrieved by a manner similar to that in inspection process 14A and repair process 14B. That is, the information relating to a particular vehicle may be retrieved from host computer 302 by scanning the vehicle's VIN through use of a bar code scanner. Based on the defect and problem item data retrieved, repairs that are able to be completed in-line are performed by in-line process 6. After the completion of in-line process 6, the static quality of a vehicle, with the exception of those items that are not capable of being repaired inline, is guaranteed to be within the static function specifications (an "in-spec" vehicle). An "in-spec" vehicle is then conveyed to the dynamic function inspection process 10, which is the next process set in the assembly line.

Defects and problem item data from each of the inspection processes of each of the functional zones, A 10, B 20, C 30 and D 40, is also displayed, in a manner described above, on the display screen the computer workstation located within side 23 repair process 7. Based on the problem item data, problems that could not be repaired in-line, by the plurality of repair processes in inspection/repair zone A 14, inspection/repair zone B 24, inspection/repair zone C 34 and inspection/repair zone D 44 and in-line process 6 (for example, repairs that require more time and are not suited to in-line repair) are repaired completely in line side repair process 7. Vehicles repaired in line side repair process are then transported to dynamic function inspection process. Vehicles transported to dynamic function inspection process are guaranteed to be "in-spec" with respect to the static functional specifications.

Upon completion of the dynamic function inspection process 10 (which may include repairs to remedy any dynamic functional defect) the dynamic functional quality of a vehicle is guaranteed to be "in-spec".

As was the case in the other zones described heretofore, both in-line repair process 6 and line side process 7 are equipped with an data entry system in computer system 300 for the input of data which corresponds to the repairs completed. This repair data is then available for access or display at the other production related departments which include functional zones A 10, B 20, C 3 0 and D 40.

As is obvious to a person skilled in the art, in dress up process 4, which comprises in-line repair process 6 and line side repair process 7, all identified defects and problem items that were not repaired in functional zones A 10, B 20, C 30 and D 40, are repaired with the result that quality of static functionality of a vehicle is guaranteed.

24 Further, since repair data of each functional zone and repair data from complex quality assurance zone 3 and dress up process 4 is fed back to the rest of automobile assembly line 1, defects and problem items are reflected on assembly line 1 immediately upon identification and immediately upon repair. As a result, countermeasures can be undertaken thereby stabilizing the quality of a vehicle soon after production start up.

A second embodiment of the invention is illustrated in Figure 5. Figure 5 illustrates an automotive assembly process 500 having a plurality of assembly lines, namely primary assembly line 510, engine/front suspension assembly line 520, door assembly line 530, instrument panel assembly line 540, and rear suspension assembly line 550: (collectively sub-assembly lines 560. The sub-assembly lines 560 can each operate in a manner similar to that of automobile assembly line I (Figure 1).

While the plurality of assembly lines (510, 520, 530 and 540) are illustrated as being proximate to one another and within the same plant, as those skilled the art are aware, it is common in the automotive industry to have subassemblies produced at different sites from the final assembly of the vehicle. The embodiment illustrated in Figure 5 is viable where the various subassemblies produced by engine/front suspension assembly line 520, door assembly line 530 and instrument panel assembly line 540 and rear suspension assembly line 550 are produced at different physical sites. In such a case, data corresponding to defects, repairs performed and repairs required to be performed is shared amongst the various sub-assembly sites by way of a Wide Area Network (WAN), Virtual Private Network (VPN) or the like. Moreover, the subassemblies need not be produced by a single entity, such as Honda, but could be produced by number of entities in cooperation.

As described above, in conjunction with the first embodiment, each of the sub assembly lines, namely engine/front suspension assembly line 520, door assembly line 530, instrument panel assembly line 540 and rear suspension assembly line 550, will each be divided into functional zones 570 with each functional zone comprising a functional assembly zone 582 and an inspection/repair zone 584. As described heretofore, the functional assembly zones of sub-assembly lines 560 will carry out the conventional processes to assemble a portion of a vehicle, for instance, an engine/front suspension assembly, a door assembly, an instrument panel or a rear suspension assembly. Depending on the nature of the sub-assembly, it may be preferable not to include a complex quality assurance zone 572, similar to complex quality assurance zone 3, as the added benefits provided by an complex quality assurance zone at the end of the sub-assembly line may not be sufficient to warrant the inclusion of an additional complex quality assurance zone. Moreover, the sub-assembly, once installed on the vehicle, will be inspected, and if necessary, repaired in the complex quality assurance zone 572 which is a part of primary assembly line 5 10. However, in some instances, it may be preferable for the sub-assembly line to include all of the finictionality of automobile assembly line 1 (Figure 1). That is, (as illustrated for door sub-assembly line 530) the sub-assembly line may comprise a plurality of ftinctional zones 570, a complex quality assurance zone 572 and a dynamic functional inspection process 574.

26 This may be preferable where a sub-assembly line and the primary assembly line are not physically located proximate to one another.

The sub-assembly lines 560 may be formed by grouping functional zones that are related to a distinct portion of the partially assembled vehicle and that can be assembled in parallel to other portions of the vehicle.

Regardless of the inclusion of final inspection areas (such as complex quality assurance zone 572 and dynamic function inspection processes 574), each of the sub- assembly lines 560 is functionally divided into functional zones 570 with each function zone comprised of a functional assembly zone 582 and an inspection/repair zone 584. Moreover, each functional zone 570, and therefore each of the assembly, inspection and repair processes therein, are in communication with each other through a communications system, such as computer system 600 (Figure 6).

In the exemplary embodiment of Figure 5, sub-assembly lines 520, 540 and 550, shown in dotted outline, are physically located at sites removed from primary assembly line 5 10 and door assembly line 530. That is, instrument panel sub-assembly line 540 is located at a different physical location (i.e., not in the same plant) from that of primary assembly line 510. Similarly, engine/front suspension assembly line 520 is also located at a site different from that of primary assembly line 5 10 and, possibly, at a different location from instrument panel sub-assembly line 540. Further, rear suspension sub-assembly line 550 is also located a site different from that of primary assembly line 510, and may different from that of engine/front suspension sub- 27 assembly line 520 and/or rear suspension sub-assembly line 550. There may be many reasons for locating the sub-assembly lines at a different plant (or plants) from that of main assembly line including, but not limited to: the cost of providing an engine foundry at the primary assembly line site; local expertise in manufacturing a particular product; local environmental concerns for producing a particular product; labour costs; and the like.

The sub-assemblies manufactured at these off-site sub-assembly lines (i.e. , subassembly lines 520, 540 and 550) will be shipped to the location of primary assembly line 5 10 where the sub-assemblies will be installed into a vehicle.

The sub-assemblies produced at the off-site sub-assembly lines 520, 540 and 550 are, as described above, inspected during manufacture and, if defects are identified, repaired prior to transport to primary assembly line 510. However, as is known in the industry, the sub-assemblies produced may not arrive defect-free due to damage caused during transport. Moreover, it may be the case where, when the subassembly is viewed in isolation (i.e., without reference to the remainder of the vehicle), the sub-assembly is considered to be free of defects. However, due to the complexity of large scale integrated products, such as, for example, an automobile, defects are identified when the sub-assembly is to be installed into the final assembly, such as the automobile. These defects may be, for example, misalignment of parts (such as fastening devices, such as, bolt holes), interference of the sub- assembly with other parts of the main assembly, incorrect sub-assemblies being shipped, incorrect number of sub-assemblies being shipped, and the like. Moreover, changes in the production schedule of primary assembly line 5 10 (due to, for example, defects being identified 28 with some parts on primary assembly line 5 10) may require changes in other parts supplied to primary assembly line 510 in order to reflect the scheduling changes. For example, it may be the case that due to an identified defect, such as, for example, a parts shortage of one particular type of component (for example, a specific type of seating system may not be available, such as, for example, leather seating), causes primary assembly line 510 to be unable to manufacture a specific automobile type (such as a luxury version of a particular model type - e.g. a Honda:rm AccordTm EXR). In such an instance, the vehicle or assembly that cannot be provided to primary assembly line 5 10 may impact the parts required from sub-assembly lines 520, 540 and 550. In the above example, namely the lack of availability of leather seats, the luxury version of the automobile that was to have been produced, may have had a type of engine/front suspension sub-assembly, or instrument panel sub-assembly or rear suspension sub-assembly that was unique to that version of the model type. In such an instance, the production schedule may change to ensure that the primary automobile assembly line 5 10 is not idled. The production schedule, in such an instance, may be changed to produce more base models of the same vehicle model type (e.g., a Hondarm AccordTm DX). This change in the production schedule may necessitate a change in the sub-assemblies supplied to the primary assembly line 5 10. Further, it is not uncommon, due to modem Just In Time (JIT) production methods, for a single plant to fail to meet its production schedule due to unforeseen defects, such as, for example, delays in receipt of parts at sub-assembly lines 520, 540 or 550 from the various parts suppliers. This defect may result in the inability for the primary 'assembly line 5 10 being unable to manufacture the vehicles scheduled.

29 To address these further shortcomings and difficulties, the automotive assembly process 500 incorporates communications system 600 illustrated schematically in Figure 6 - an improvement of the computer system 300 of the first embodiment illustrated in Figures 1-4. Communications system 600 includes a plurality of local computer networks 601A, 601B, 601C and 601D (collectively computer networks 601) in communication with each other through wide area network 618.

Computer network 601A includes host computer 604, computer server 606, printers 610, computer terminals 612 and PLCs 614 in communication over network backbone 602. Similar to host computer 302 (Figure 3), server 606 is shown in communication with computer software medium 607. Computer software medium 607, which contains instructions and data for server 606, is readable by server 606.

Computer software medium 607 may contain, for example, database software, computer applications, computer data, network software (including, for example, wide area networking software), data corresponding to the layout of automotive assembly process 500 (Figure 5), or the like. While computer software medium 607 is illustrated as a computer diskette, it could equally be a tape, memory chip, or other removable or non removable computer readable medium. Furthermore, the software medium may be a remote medium, such as a memory of a remote computer, and be downloaded over a suitable link such as over an network, internet, intranet, dedicated data link, or the like.

Connected to PLCs 614 are manufacturing equipment 616 which includes, but is not limited to, readers (such as bar code readers, and the like), robots (for welding, VIN stamping, painting, dispensing sealers, surfacers, fluid fillers, engine placement, quality testing, glass placement, and the like), conveyors, vehicle carriers, torque guns, computer terminals for data input and output, repair and inspection robots, and the like. PLCs 614 are typically assigned a unique address on the network, such as an IP address or the like.

Consequently, the addition of new pieces of equipment can be easily facilitated by inserting a new PLC 614 into computer network 601A, assigning a unique identifier or address to the new PLC 614, and attaching the equipment 616 to the new PLC 614.

Bar code readers, such as a SmartEyeTm readers, are statically located at various 10 points on the primary and sub-assembly lines. Data collected from these readers, which includes the vehicle identification number (VIN) and vehicle location, is transmitted from the reader, which may be connected to a PLC 614, over network backbone 602 and stored in database 608A running on server 606. A redundant database, database 608B, is stored and hosted by host computer 604. Database 608A stores data about each particular vehicle including conventional build and assembly sheets data. (The build sheet, which is a computer record, includes instructions as to the processes that need to be performed to the assembly and the locations to which the assembly should be transported. The build sheet may be printed out and attached, either directly or indirectly, to the particular assembly or sub-assembly that is being manufactured. In contrast, the assembly sheet identifies the various parts or components that must be installed for the particular assembly or sub-assembly to which the assembly sheet is associated. Consequently, the assembly sheet identifies the parts that are to be installed and the build sheet contains the instructions as to where and what processes are to be 31 used in putting the parts identified on the assembly sheet together in order to manufacture the assembly or sub-assembly.) Database 608A will also collect enhanced data corresponding to each vel&le's progress through the manufacturing process including: identified defects, painted body storage status, vehicle lot number, repairs performed, repairs required, physical position on assembly line 500 as measured over time, identification of the carrier (e.g., a conveyor hanger, underbody carrier, or the like) upon which a vehicle is transported throughout a plant or plants (which may change over time), identification of individual components installed on the vehicle, installation instructions performed during assembly (such as, for example, the torque settings used to install lug nuts, bolts, etc.), and the like. Virtually every part, process, inspection and repair detail about the manufacturing process and the assemblies and sub-assemblies manufactured is stored in databases 608A, 608B.

In addition to the above noted data that is keyed to specific assemblies or sub- assemblies, general data corresponding to the assembly process as a whole is also stored in database 608A on server 606. This general assembly process data includes: inventory data, production schedules, tool (including robot) availability, quality results and the like. In an embodiment of the invention, database 608A is used for the collection of production data, and determines routing of assemblies or sub-assemblies throughout the manufacturing process, while database 608B is a replication of database 608A that is used for non-production related inquiries (such as those made by management and suppliers about production status) and backup purposes. Using database 608A solely for manufacturing purposes assists the system's response time to database access by limiting 32 non-production inquires and access to redundant database 608B. Database 608B may be updated every few seconds or minutes, as required. In the event that database 608A fails, production access could automatically be transferred to database 608B until such time as database 608A is operating normally. Databases 608A, 608B may be commercially available software such IBMTm Universal DatabaseTm (UDB), OracleTm database, or the like. Hereinafter, databases 608A and 608B will be referred to interchangeably and collectively as database 608.

PLCs 614, which may be those commercially available from suppliers such as Yaskawarm, NfitsubishiTM, Allen Bradleyrm, and others, enable communication from and to the various pieces of manufacturing equipment 616. Consequently, PLCs 614 enable data to be transmitted from equipment 616 over network backbone 602 to, for example, server 606, and vice versa. As a result, counter-measures to adjust the production process, such as new robotic build instructions (which may be in the form of ladder logic instructions) can be transmitted from computer server 606 to the various pieces of manufacturing equipment 616. Similarly, data on the performance of equipment 616, such as operations performed, equipment availability and the like, can be transmitted from equipment 616, through PLCs 614 over network backbone 602 to computer server 606.

Terminals 612 enable real-time input and output of data from line workers (also referred to as associates), management and other interested parties. For example, data corresponding to defects identified by an associate relating to a specific vehicle may be input into terminals 612 by use of input device, such as keyboard, touch screen, bar code 33 reader, or the like. This information would then be available to any other terminal or networked device (such as other terminals 612, plant displays, etc.) for the display of data. The data so displayed may be summarised or collated by computer server 606 in a variety of ways that are known in the art. Terminals 612 may access the data on database 608 through custom software or via commercial software such as, for example, web browsers, such as Internet Explorer:lm or NetscapeTm Navigatofrm.

Server 606 monitors and controls manufacturing network 602. Also, as indicated previously, server 606 hosts database 608A. Server 606 may be a conventional work station, such as an IBMTm RS/600OTm running ADCrm. Server 606 may also provide for data archiving and redundant capacity should there be a failure in host computer 604, and vice versa. If required, server 606 may be several individual computers providing the functionality described herein.

Host computer 604 may be a conventional mainframe or mini-computer such as, for example, an EBMTm S/390Tm.

Local manufacturing networks 601B, 601C and 601D, which may be located, for example, at the plants housing sub-assembly lines 520, 540 and 550, respectively, are configured similar to manufacturing network 601A. Manufacturing networks 601 B, 601 C and 601 D may not include local databases similar to that of databases 608 of manufacturing network 601A. Rather, manufacturing networks 601B-D may query, update and generally access database 608A by communicating over wide area network 618. In an alternative embodiment, and in an effort to reduce bandwidth requirements 34 over wide area network 618, database 608A of network 601A may be a master database, with a slave copy at each of local manufacturing networks 601 B, 601 C and 601D. In this latter embodiment, the local slave copies of database 608A would be updated and accessed by equipment and devices locally situated. The master and slave 5 databases of network 60 1 A - D would be synchronized periodically.

It should be noted that in addition to manufacturing networks 601A-D of communications system 600, communications system 600 may also include computer terminals for the input and/or output of data at suppliers, shippers, dealers, and other parties involved in the manufacture, sale and maintenance of vehicles (or parts thereof) produced by primary assembly line 5 10 (which are not shown in Figure 6).

Moreover, while each server 606 of networks 60 1 A-D may provide for control and maintenance for its respective network backbone 602, server 606 of network 601 A may additionally provide centralized control of wide area network 618.

Printers 610 may be distributed throughout the manufacturing plant and may provide for the printing of- ID Cards; tracking sheets; assembly sheets for the body, fi=e, instrument panel, engine, knuckles, and inspections cards; and inventory print- outs, and the like.

In operation, each assembly (such as, for example, an automobile) or subassembly (such as, for example, a rear-engine suspension) is assigned a unique identifier such as Vehicle Identification Number (VIN) in the former case or some other unique 33 5 identifier in the latter case. These unique identifiers are created as a first step in the manufacture of the assembly, or sub-assembly as the case may be. These identifiers are then stored in database 608A and used to track the assembly (or sub-assembly) throughout the entire manufacturing process. Moreover, each assembly (or sub- assembly) to be produced will be associated with a build sheet and an assembly sheet, as described above. Referencing Figure 7, along with Figures 5 and 6, in operation,

information detailing the vehicles that need to be manufactured (based on customer orders) will be used to establish a production schedule. This production schedule may be determined by inputting into a computer (such as server 606 and database 608A of network 601 A) the orders. The computer may then determine the parts required to build the vehicles ordered, determine parts availability for these vehicles (based on inventory records stored on database 608A), order more parts (if required), etc. The vehicles to be manufactured will then be broken down into sub-assemblies, each of the subassemblies being further broken down into further sub-assemblies and/or individual components (such as bolts, belts, fluids, etc.) which are required (i.e., the build and assembly sheets for each vehicle will be generated). Based on this information stored in computer database 608A, a production schedule is then established. The production schedule may also group like vehicles (that is, those vehicles that have similar assembly and build sheets) into groups or lots. Each of the vehicles in the production schedule will be assigned a unique identifier (such as, for example, a VIN) and a lot number. Each vehicle that is a member of the same lot of vehicles will be assigned the same lot number. Again, this information is stored in a database 608A (S702). The 36 production schedule will then be broadcast to all of the locations required for the manufacture of the vehicles necessary to satisfy the customer orders (S704).

Once the production schedule is broadcast to the various plants and suppliers including the plants housing sub-assembly lines 520, 540 and 550, production will commence on the manufacture of the various sub-assemblies with unique identifiers for each of these sub-assemblies being generated, assigned to the sub- assemblies, and associated with a vehicle's unique identifier (such as, for example, a VIN) in database 208. (S706). These unique identifiers will be stored in database 608A of network 601A.

Focussing on engine/front suspension (EFR) sub-assembly line 520, for exemplary purposes only, appropriate build and assembly sheets previously generated will be associated with each unique EFR sub-assembly (S708). It should be noted that the build and assembly sheets for each sub-assembly is simply a portion of the build and assembly sheets for the entire vehicle. Each sub-assembly will pass through the plurality of fimctional zones 570 (five, as illustrated) that comprise EFR sub-assembly line 520. In the functional assembly zone 582 of each functional zone 570, parts will be applied and processes performed in accordance with the build and assembly sheets (S710). The build and assembly sheets stored in database 608A are accessed by the associates and/or robotic equipment by querying database 608A. The query may be requested by PLCs 614, in conjunction with robotic equipment 616, and/or by computer terminals 612, both being connected to network backbone 602. The query, based on a sub-assembly's unique identifier, will be transmitted over network 37 backbone 602. The query will be transmitted to server 606 of local network 601B where it will be formatted for transmittal and transmitted over wide area network 618 to server 606 of master network 601A. In response to the query transmitted, database 608A will return to the requesting party (the computer terminal 612 or PLC 614 of slave network 601B over wide area network 618) a response such as, for example, the build and assembly sheets. Based on the operations performed and parts installed at functional assembly zone 582, database 608A will be updated by the transmission of this data over backbone 602 by PLCs 614, in conjunction with robotic equipment 616, and/or by computer terminals 612. This data may include identifiers for the parts installed, torque settings applied to various fasteners, welds performed, etc. (S712).

Upon exiting the functional assembly zone 582, the sub-assembly will be transported to, and identified (by a SmartEyeTm reader, for example) at, the inspection/repair zone 584 of the functional zone 570 (S714). A variety of functional inspections will then be performed, including, for example, determining if all parts required have been installed, if the correct parts have been installed, etc. (S716). The identity of the sub-assembly, and the inspections completed and the results obtained from those inspections are then transmitted to database 608A, which is updated accordingly (S718). The sub-assembly is then transferred to the repair portion of the inspection/repair zone 584. The identity of the sub-assembly is determined again (by a SmartEyeTm reader, for example) and a query for the complete inspection results of the sub-assembly is transmitted to database 608A (S720). The complete inspection results will include all outstanding defects identified in the current functional zone 570 as well as those defects identified and not repaired upstream. Based on the inspection results, 38 the time available and the repair capabilities at the present repair area 584, some repairs may be carried out and some defects rectified (S722). The defects rectified will be transmitted to database 608A so that it may be updated (S724). The EFR sub assemb ly is then transferred to the remaining functional zones 720 of EFR sub assembly 520 (S726) where operations S71 O-S724 will be perfon-ned.

Upon completion of the manufacture of the EFR sub-assembly, the sub assembly is packaged and shipped to primary assembly line 510 (S728). Included in the shipping of the EFR sub-assembly is the updating of database 608A with the required shipping information (e.g., number of sub-assemblies shipped, date of shipment, identity of the sub-assemblies, identity of shipper, way bill (or shipping) number, etc.). Upon arrival at primary assembly line 510, the sub- assemblies are transferred to line side proximate to the functional zone 570 that installs the EFR sub assembly to the vehicle on primary assembly line 5 10 - shown by dotted arrows in Figure 5 (S730). The EFR sub-assembly is then installed at this functional zone 570 (S732). If defects are identified at the inspection/repair zone 584 of the fimctional zone 570 installing the EFR sub-assembly or any other downstream functional zone 570 (S734), these defects are recorded in database 608A (S736). Moreover, the identified defect (including the defect type, the identity of the sub- assembly and, possibly, a countermeasure) is broadcast to manufacturing network 601B the local network of EFR sub-assembly line 520. The defect message is broadcast by issuing a message from server 606 of master network 601A, which transmits the message over wide area network 618 to sever 606 of slave network 601B. Slave network 601B may then transmit the defect to all or some of terminals 612 of slave network 60 1 B located 39 throughout the plant. As a result of this broadcast message, countermeasures to rectify the cause of the defect may be implemented on EFR sub-assembly line 520.

As mentioned above, the defect in the sub-assembly identified on primary assembly line 5 10 may be, for example, delayed parts, missing components, parts not fitting properly, incorrect parts shipped, etc.

In the case of parts shortages or production schedule changes (which may be caused, for example, by other parts shortages, quality problems, or the like), a change to the production schedule may be broadcast to the sub-assembly lines affected, such as, for example, EFR sub-assembly line 520. If, for example, a shipment of upgraded rear suspensions is delayed in arriving at primary assembly line 5 10 from rear suspension assembly line 550 due to a supplier problem, this delay will have been transmitted to database 608A of master network 601 A over wide area network 618.

As a result of this delay, a message (such as a revised production schedule) may be broadcast to EFR sub-assembly line 520 requiring that production of upgraded EFR sub-assemblies (which would have been installed on vehicles having the upgraded rear suspension assembly) be placed on hold and production of base model EFR subassemblies be increased or ramped up. Alternatively, the build and assembly sheets for each of the unique identifiers being produced on the EFR sub-assembly line may be altered to include reference to only those components and operations necessary to manufacture base model EFR sub-assemblies. For example, the upgraded/luxury EFR suspension sub-assembly may differ only slightly from the base model EFR subassembly. For example, the upgrade EFR sub-assembly may have higher performance springs and shocks (or dampers), as compared to that of the base model EFR subassembly. In such an instance, it may only be necessary to alter the assembly sheet substituting (in the database records of database 608A) the higher performance springs and shocks with base model springs and shocks. As a result of the electronic substitution in database 608A, when the sub-assemblies which have had their assembly sheets modified reach the functional zone 570 where the shocks and springs are installed, the assembly sheet accessed at this functional zone will include instructions to install the base model shocks and springs thereby effecting the change desired.

As will now be apparent, corrective counter-measures and real-time alterations in build and assembly sheets (instructions) can be made based on problems or defects identified in other portions of the assembly process. In either case, overall throughput of assembly line 500 is improved as the impact of identified defects is reduced.

As a result of communications system 600 incorporating wide area network 618 and database 608A of master network 601A, the impact of defects that are identified in one portion of the assembly process may be reduced. Moreover, defects identified that may have an impact on other portions of the assembly line (including sub-assembly lines) can be remedied and/or countermeasures can be taken to reduce 20 the impact on the overall production process.

While the embodiment disclosed with reference to Figures 5, 6 and 7 discloses a plurality of sub-assembly lines feeding a primary assembly line, the invention may be applied to a plurality of sub-assembly lines that manufacture sub-assemblies which 41 are not integrated on a primary assembly line. For example, a sub- assembly line at a first location may produce a first sub-assembly (such as, for example an automobile engine) for shipment to another location. Similarly, a second sub-assembly line, which may be at a second location, may produce a second sub-assembly (such as, for example, a rear suspension), also for shipment. Nevertheless, the first sub-assembly line, which will be communication with the second subassembly line, may react to defects (such as, for example, delayed shipment of sub-assemblies) identified in the second sub-assembly line, and vice versa.

While the above embodiments have been described in conjunction with a computer system for entering and retrieving data corresponding to a vehicle, defects identified, and repairs carried out, the assembly line aforementioned could be implemented using a paper-based system.

While more than one embodiment of this invention has been illustrated in the accompanying drawings and described above, it will be evident to those skilled in the art that changes and modifications may be made therein without departing from the essence of this invention.

42

Claims

1. An apparatus for assembling comprising:

a plurality of assembly lines each manufacturing an assembly; each of said plurality of assembly lines comprising:

a plurality of flinctional zones; and each of said functional zones having:

a zone for assembly; an inspection area for identification of defects; and a repair area for repairing identified defects; and a communications network providing communication amongst said plurality of functional zones of said plurality of assembly lines.

2. The apparatus of claim I wherein said assembly lines are physically located at a plurality of separate manufacturing sites remote from one another.

3. The apparatus of claim 2 wherein said plurality of assembly lines comprises a primary assembly line and at least one sub-assembly line.

4. The apparatus of claim 3 wherein said primary assembly line further comprises a final quality assurance area.

43 5. The apparatus of claim 4 wherein each said inspection area is arranged to identify static defects.

6. The apparatus of claim 5 wherein said final quality assurance area is arranged to provide at least dynamic functional inspection.

7. The apparatus of claim 3 wherein said communications network comprises a computer network associated with each of said plurality of assembly lines, and a wide area network such that each of said computer networks is in communication with each other of said computer networks.

8. The apparatus of claim 7 wherein said communications network includes a memory storing data representing defects identified and defects repaired for each assembly produced by said plurality of assembly lines.

9. The apparatus of claim 3, wherein said assembly lines are arranged to run continuously such that said inspection area and said repair area of each of said functional zones operate to identify said defects and repair defects in- line and without stoppage of any of said plurality of assembly lines.

10. The apparatus of claim 9 wherein at least a given one of said at least one sub assembly line is adapted to alter production of a sub-assembly manufactured by said given sub-assembly line responsive to countermeasures developed to respond to defects identified on another one of said plurality of assembly lines.

44 11. The apparatus of claim 9 wherein at least a given one of said at least one subassembly line is adapted to alter production of a subassembly manufactured by said given sub-assembly line responsive to defects identified on another one of 5 said plurality of assembly lines.

12. The assembly line of claim 10 wherein said given sub-assembly line ftirther comprises:

a communications device connected to said wide area network for receiving data corresponding to defects identified; said communications device in communication with said zone for assembly of at least one of said plurality of functional zones and for transmitting instructions responsive to said data received for the manufacture of said sub-assembly manufactured by said given sub assembly line; and said zone for assembly of said at least one of said plurality of functional zones for altering the manufacture of said sub-assembly responsive to instructions received.

13.A method of manufacturing comprising:

manufacturing a sub-assembly at each of a plurality of sub assembly lines; manufacturing an assembly incorporating each of said sub assemblies at a primary assembly line; at each of said plurality of sub-assembly lines:

inspecting said sub-assembly for defects at each of a plurality of functional zones spaced along said each sub-assembly line; where possible, repairing, at said each functional zone, defects identified during said inspecting of a given sub-assembly at said each functional zone and defects identified during said inspecting of said given sub assembly at functional zones upstream of said each functional zone; and transmitting for use by other sub-assembly lines of said plurality of sub-assembly lines data related to defects identified and defects repaired at said each of said functional zones.

46 14. The method of claim 13 further comprising, at each of said plurality of subassembly lines, where possible, developing a countermeasure from defects identified and defects repaired and wherein said transmitted data related to defects identified and defects repaired comprises data for implementing said 5 countermeasure and wherein said manufacturing a sub- assembly comprises:

obtaining instructions to manufacture said sub-assembly from a database; constructing said sub-assembly from said instructions obtained; and modifying said instructions based on said countermeasure data.

15. The method of claim 14 ftu-ther comprising, where possible, developing countermeasure data from said transmitted data related to defects identified and defects repaired and wherein said manufacturing a sub-assembly comprises:

47 16. The method of manufacturing of claim 14 wherein said inspecting and repairing are performed without stoppage of said plurality of subassembly lines.

17.The method of manufacturing of claim 16 further comprising inspecting and repairing, downstream of said plurality of functional zones, any defects in sub assemblies not repaired in said plurality of ftmetional zones.

18. The method of manufacturing of claim 17 wherein said repairing at said functional zones is performed on static defects identified.

19. A method of assembly, comprising:

at a first functional zone on a first assembly line in communication with a second assembly line:

assembling a first assembly; inspecting said first assembly for defects; communicating results of said inspecting of said first assembly to said second assembly line; where possible, repairing at least some of said first functional zone defects; and 48 communicating results of said repairs to said second assembly line; at a second functional zone on a second assembly line:

receiving said results of said inspecting and said repairing communicated from said first assembly line; and assembling a second assembly responsive to said inspecting and repairing results received.

The method of assembly of claim 19 further comprising assembling a composite assembly including said first assembly and said second assembly.

21. The method of claim 20 wherein said second assembly line further comprises:

inspecting said second assembly for defects; communicating results of said inspecting of said second assembly to said first assembly line; where possible, repairing at least some of said second functional zone defects; and 49 communicating results of said repairing of said second functional zone assembly to said first assembly line.

22. The method of claim 21 said first assembly line further comprises: 5 a third functional zone downstream of said first functional zone receiving said results of said inspecting and said repairing from said first functional zone; further assembling said first assembly at said third functional zone; further inspecting said first assembly at said third functional zone; 15 where possible, repairing at least some defects of said first assembly identified during at least one of said inspecting at said first functional zone and said further inspecting at said third functional zone; and 20 communicating said results of said inspecting and said repairs conducted at said third functional zone to said first and said second functional zones.

23. The method of claim 22 further comprising: communicating from said second functional zone to said first functional zone a countermeasure to avoid a defect at said first functional zone; and 5 implementing said countermeasure during said assembling at said first functional zone.

24. The method of claim 23 wherein said inspecting and said repairing at each said functional zone is performed without stoppage of said assembly lines.

25. The method of claim 24 further comprising:

during said assembly of said composite assembly, repairing any remaining defects in said first and second functional zone assemblies identified during inspecting at said first functional zone, said second functional zone and said third functional zones, off-line, if necessary.

26. The method of claim 25 including storing defects and repairs.

27. A method of assembly, comprising:

at a first ftinctional zone on a first assembly line:

assembling at an assembly zone a first assembly; 51 inspecting at an inspection zone said first assembly for a first set of defects; and at a repair zone, where possible, repairing at least some of said first set of defects; at a second functional zone on a second assembly line:

assembling at an assembly zone a second assembly incorporating said first assembly; inspecting at an inspection station said second assembly for a second set of defects; and at a repair zone, where possible, repairing at least some of said first set of defects and said second set of defects; and communicating said defects identified and said repairs performed at said first functional zone to said second functional zone and said defects identified and said repairs performed at said second functional zone to said first functional zone.

52 28. The method of claim 27 further comprising:

developing a first countermeasure in respect of one of said first set of defects at said first functional zone inspection zone or said first functional zone repair zone; communicating said first countermeasure to said first functional zone assembly zone; and implementing said first countermeasure at said first functional zone assembly zone.

29. The method of claim 28 further comprising:

developing a second countermeasure in respect of one of said first set of defects at said second functional zone; communicating said second countermeasure to said first functional zone assembly zone; and implementing said second countermeasure at said first functional zone assembly zone.

53 30. A system for tracking an assembly comprising:

a receiver for receiving signals from a plurality of assembly lines; each of said assembly lines comprising:

a plurality of functional zones; and each of said functional zones having:

a zone for assembly; an inspection area for identification of defects; and a repair area for repairing identified defects; and said signals containing information corresponding to defects identified at said inspection area and repairs performed at said repair area of each of said plurality of functional zones of each of said plurality of assembly lines; a transmitter for transmitting signals to said plurality of functional zones of said plurality of assembly lines, said transmitted signals containing information relating to said information received by said receiver.

54 The system of claim 30 wherein said receiver and said transmitter form part of a computer network, said computer network further comprising a memory for storing said information received.

3) 2. The system of claim 31 further comprising:

for each of said functional zones:

an input device for inputting data for transmission to said receiver, said data forming part of said information received by said receiver; an output device for receiving signals transmitted by said transmitter; and said input device and said output device being in communication with said computer network.

33. The system of claim 30 ftirther comprising one or more processors for (i) developing countermeasure data from said received signals containing information corresponding to defects identified and repairs performed; and (ii) modifying assembly instructions for use by at least one said zone for assembly based on said countermeasure data.

34. An assembly line comprising:

a plurality of functional zones, each functional zone having, in downstream order, an assembly area, an inspection area for identifying defects, and a repair area for repairing defects; a communication terminal associated with each said assembly station, inspection station, and repair station; a communication network interconnecting each said communication terminal and having a remote network connection to another assembly line; memory associated with said communication network for storing build sheet data and assembly sheet data for each said functional zone; at least one processor associated with said communication network for modifying said assembly sheet data based on input from communication terminals and input received over said remote network connection.

35. The assembly line of claim 34 wherein said inspection area communication terminal inputs defect data to said conununication network, said repair area 56 communication terminal receives defect data from said communication network and inputs repair data to said communication network, and said assembly station communication terminal receives current assembly sheet data from said communication network.

36. The assembly line of claim 3) 5 including means for developing countermeasure data from said repair data and for receiving countermeasure data from said remote network connection and for modifying said assembly sheet data based on said countermeasure data.

37. A method of operating an assembly line, comprising:

at each of a plurality of functional zones:

at an assembly area, receiving current assembly sheet and build sheet data from a connnunication network and assembling in accordance with said data; at an inspection area, inspecting an assembly output from said assembly area for defects and outputting defect data to said network; at a repair area, receiving defect data from said communication network, repairing said assembly based on said 57 defect data, and outputting repair data to said communication network; receiving countermeasure data from another network associated with another assembly line; developing countermeasure data based on said repair data; modifying at least one of said assembly sheet data and said build sheet data based on said countermeasure data.

38. A method for operating assembly lines, comprising:

providing, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receiving from an inspection area of each of said plurality of functional zones, data relating to identified defects; receiving from a repair area of each of said plurality of functional zones, repair data; 58 sending to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; developing countermeasures based on received defect data and repair data; and revising assembly sheet and build sheet data based on said developing.

39. A computer software media, which when loaded into a process adapts said processor to:

provide, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receive from an inspection area of each of said plurality of functional zones, data relating to identified defects; receive from a repair area of each of said plurality of functional zones, repair data; 59 send to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; 5 develop countermeasures based on received defect data and repair data; and revise assembly sheet and build sheet data based on developed countermeasures.

Amendments to the claims have been filed as follows I An apparatus for assembling comprising:

a plurality of functional zones; and each of said functional zones having:

4. The apparatus of claim 3) wherein said primary assembly line further comprises a final quality assurance area.

(0( 5. The apparatus of claim 4 wherein each said inspection area is arranged to i'dentif y static defects.

7. The apparatus of claim 3) wherein said conununications network comprises a computer network associated with each of said plurality of assembly lines, and a wide area network such that each of said computer networks is in communication with each other of said computer networks.

11. The apparatus of claim 9 wherein at least a given one of said at least one sub assembly line is adapted to alter production of a sub-assembly manufactured by said given sub-assembly line responsive to defects identified on another one of said plurality of assembly lines.

12. The assembly line of claim 10 wherein said given sub-assembly line further comprises:

13.A method of manufacturing comprising:

3 manufacturing a sub-assembly at each of a plurality of sub assembly lines; manufacturing an assembly incorporating each of said sub assemblies at a primary assembly line; at each of said plurality of sub-assembly lines:

inspecting said sub-assembly for defects at each of a plurality of functional zones spaced along, said each sub-assembly line; where possible, repairing, at said each functional zone, defects identified during said inspecting of a given sub-assembly at said each functional zone and defects identified during said inspecting of said given sub assembly at functional zones upstream of said each functional zone; and transmitting for use by other sub-assembly lines of said plurality of sub-assembly lines data related to defects identified and defects repaired at said each of said functional zones.

14. The method of claim I') further comprising, at each of said plurality of subassembly lines, where possible, developing a countermeasure from defects identified and defects repaired and wherein said transmitted data related to defects identified and defects repaired comprises data for implementing said 5 countermeasure and wherein said manufacturing a subassembly comprises:

15. The method of claim 14 ftirther comprising, where possible, developing countermeasure data from said transmitted data related to defects identified and defects repaired and wherein said manufacturing a sub-assembly comprises:

16. The method of manufacturinc, of claim 14 wherein said inspecting and repairing are performed without stoppage of said plurality of subassembly lines.

17. The method of manufacturing of claim 16 further comprising inspecting and M C, repairing, downstream of said plurality of functional zones, any defects in sub assemblies not repaired in said plurality of functional zones.

19. A method of assembly, comprising:

assembling a first assembly; inspecting said first assembly for defects; communicating results of said inspecting of said first assembly to said second assembly line-, where possible, repairing at least some of said first functional zone defects; and b(O communicating results of said repairs to said second assembly line; at a second functional zone on a second assembly line:

20. The method of assembly of claim 19 ftirther comprising assembling a composite assembly including said first assembly and said second assembly.

21. The method of claim 20 wherein said second assembly line further comprises:

inspecting said second assembly for defects; communicating results of said inspecting of said second assembly to said first assembly line; where possible, repairing at least some of said second functional zone defects; and communicating results of said repairing, of said second functional zone assembly to said first assembly line.

22. The method of claim 21 said first assembly line further comprises:

a third functional zone downstream of said first functional zone receiving said results of said inspecting and said repairing from said first functional zone; further assembling said first assembly at said third functional zone; further inspecting said first assembly at said third functional zone; where possible, repairing at least some defects of said first assembly identified during at least one of said inspecting at said first functional zone and said further inspecting at said third functional zone; and communicating said results of said inspecting and said repairs conducted at said third functional zone to said first and said second functional zones.

23. The method of claim 22 further comprising:

cominunicating from said second functional zone to said first functional zone a countermeasure to avoid a defect at said first functional zone; and implementing said countermeasure during said assembling at said first functional zone.

24. The method of claim 23 wherein said inspecting, and said repairing at each said functional zone is performed without stoppage of said assembly lines.

25. The method of claim 24 further comprising:

during said assembly of said composite assembly, repairing any remaining defects in said first and second functional zone assemblies identified during inspecting at said first functional zone, said second ftinctional zone and said third functional zones, off-line, if necessary.

26. The method of claim 25 including storing defects and repairs.

27. A method of assembly, comprising:

at a first functional zone on a first assembly line:

assembling at an assembly zone a first assembly; inspecting at an inspection zone said first assembly for a first set of defects; and at a repair zone, where possible, repairing at least some of said first set of defects; at a second functional zone on a second assembly line:

28. The method of claim 27 further comprising:

developing a first countermeasure in respect of one of said first set of defects at said first functional zone inspection zone or said first functional zone repair zone; communicating said first countermeasure to said first functional zone assembly zone; and implementing said first counterineasure at said first functional zone assembly zone.

29. The method of claim 28 further comprising:

3 30- A system for tracking an assembly comprising:

a plurality of functional zones; and each of said functional zones having:

a zone for assembly; an inspection area for identification of defects; and a repair area for repairing identified defects; and said signals containing information corresponding to C, defects identified at said inspection area and repairs performed at said repair area of each of said plurality of functional zones of each of said plurality of assembly lines; a transmitter for transmitting signals to said plurality of functional zones of said plurality of assembly lines, said transmitted signals containing information relating to said information received by said receiver.

The system of claim -3) 0 wherein said receiver and said transmitter form part of a computer network, said computer network further comprising a memory for storing said information received.

3 2. The system of claim 3 1 further comprising:

for each of said functional zones:

an input device for inputting data for transmission to said receiver, said data forming part of said information received by said receiver; an output device for receiving signals transmitted by said transmitter; and said input device and said output device being in conununication with said computer network.

1-3. The system of claim -3)0 further comprising one or more processors for (i) developing countermeasure data from said received signals containing information corresponding to defects identified and repairs performed; and (ii) modifying assembly instructions for use by at least one said zone for assembly based on said countermeasure data.

e13 3)4.An assembly line comprising:

a plurality of functional zones, each functional zone having, in :M downstream order, an assembly area, an inspection area for identifyingdefects, and a repair area for repairing defects; M a communication terminal associated with each said assembly station, inspection station, and repair station; a communication network interconnectinc, each said 0 communication terminal and having a remote network connection to another assembly line; memory associated with said communication network for storing build sheet data and assembly sheet data for each said functional zone; at least one processor associated with said communication network for modifying said assembly sheet data based on input from communication terminals and input received over said remote network connection.

-3) 5. The assembly line of claim 3-)4 wherein said inspection area communication terminal inputs defect data to said communication network, said repair area communication terminal receives defect data from said communication network and inputs repair data to said communication network, and said assembly station communication terminal receives current assembly sheet data from said communication network.

36. The assembly line of claim 35 including means for developing countermeasure data from said repair data and for receiving countermeasure data from said remote network connection and for modifying said assembly sheet data based on said countermeasure data.

-37. A method of operating an assembly line, comprising:

at each of a plurality of functional zones:

at an assembly area, receiving current assembly sheet and build sheet data from a communication network and assembling in accordance with said data; at an inspection area, inspecting an assembly output from said assembly area for defects and outputting defect data to said network; at a repair area, receiving defect data from said com.munication network, repairing said assembly based on said 1 defect data, and outputting repair data to said communication network; receiving countermeasure data from another network associated with another assembly line; developing countermeasure data based on said repair data; modifying at least one of said assembly sheet data and said build sheet data based on said countermeasure data.

38. A method for operating assembly lines, comprising:

providing, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receiving from an inspection area of each of said plurality of functional zones, data relating to identified defects; receiving from a repair area of each of said plurality of functional zones, repair data; 6 sending to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; developing countermeasures based on received defect data and repair data; and revising assembly sheet and build sheet data based on said developing 39. A computer software media, which when loaded into a processor adapts said processor to:

provide, to an assembly area of each of a plurality of serially arranged functional zones of each of a plurality of assembly lines, current assembly sheet and build sheet data; receive from an inspection area of each of said plurality of functional zones, data relating to identified defects; receive from a repair area of each of said plurality of functional zones, repair data; send to at least some of said plurality of functional zones of a given assembly line, defect data received from a functional zone of said given assembly line upstream of said at least some of said plurality of functional zones; develop countermeasures based on received defect data and repair data; and revise assembly sheet and build sheet data based on developed countermeasures.

40. An apparatus for assembling substantially as hereiribefore described with I reference to the accompanying drawings.

41. A method of assembling substantially as hereinbefore described with reference to the accompanying drawings.