GB2444583A - A process for manufacturing a bespoke product - Google Patents
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Abstract
A process 1 for manufacturing a bespoke product. From the general specification 3, reference apparatus specifications 7 and component lists are created spanning a limited range of the apparatus attributes. In order to manufacture a bespoke product, various rules are defined to first of all obtain a suitable reference apparatus specification 20 from a memory and thereafter modify 27, 29 the component list of that apparatus specification using a configurator 21 in order to generate a new component list 31 for the bespoke product. This new component list 21 is used in the manufacture of the bespoke product and the component list 21 and the apparatus identifier associated therewith are stored 33 in memory for subsequent use in the manufacture 37 of other bespoke products.
Description
"A process for manufacturing a bespoke product handling apparatus"
Introduction
This Invention relates to a process for manufacturing a bespoke product handling apparatus and in particular to a process for manufacturing a bespoke product handling apparatus with a wide range of apparatus attributes.
Throughout this specification the terms bespoke product and bespoke product handling apparatus will be used Interchangeably and it will be understood that the terms bespoke product or bespoke product handling apparatus when used with reference to the present invention are both intended to mean product handling equipment including but not limited solely to conveyor lines, conveyor assemblies, elevator assemblies and the like equipment. Essentially, the terms are used to describe equipment that is used to manoeuvre items such as goods in or around a factory, warehouse or other installation.
These items are bespoke due to the fact that the purchasers of the product handling apparatus specify the product handling apparatus that fits their specific handling requirements and needs.
In many industries such as manufacturing, goods are transported around a warehouse or other installation using a product handling apparatus. The product handling apparatus may for example include an assembly line and or a distribution line to deliver the goods to or from a desired location such as a storage area or a shipment area in the warehouse. The design and functionality of the product handling apparatus will depend on numerous factors including the type of goods that are being handled, the size and shape of goods being handled, the number of goods being handled, the manufacturing process steps involved, the size and shape of the warehouse or factory and the layout of ie factory or warehouse itself. The product handling apparatus may require a number of conveyor assemblies to take goods from one part of a factory to another and lifting Y) equipment may be required to move goods from one conveyor to another. Furthermore, elevators may be required to transport some of the goods off a particular conveyor line to another location vertically separated from the conveyor. The elevators themselves may have to receive the goods onto an elevator platform from one direction and distribute the goods from the platform in an entirely different direction due to the layout of the factory or warehouse. Accordingly, it is most unusual to have a standard product handling apparatus that fits the requirements of two separate installations. Usually, there will be gnificant differences between the requirements of one installation and another installation However, it is highly desirable to provide a product handling apparatus that perfectly fits a particular installation and indeed in many cases due to space requirements it is essential to provide a product handling apparatus that utilises the available space in the best way possible.
However, typically, product handling apparatus is not provided in such a fashion and usually a limited range of equipment is provided which is adapted if possible to suit the particular application. In many cases, the product handling apparatus is not entirely suitable for the intended purpose which introduces difficulties in manufacturing and results in product handling apparatus that does not operate as efficiently and effectively as might be hoped for. By way of example, conveyor assemblies will be discussed in greater depth below but it will be understood that many of the problems experienced with conveyor assemblies are also experienced in those other components of product handling apparatus including elevators and the like.
Heretofore, there have been two ways in which manufacturers and in particular manufacturers of conveyor assemblies have operated. The first way was to provide a -ited range of conveyors to the customer, typically comprising five or six different models of conveyor assembly and for each model of conveyor assembly, five or six different implementations of that conveyor assembly were also provided. In this way, the customer had the choice of approximately thirty or so conveyor assemblies and they could choose the conveyor assembly that best suited their requirements. This method was advantageous for the conveyor assembly manufacturer as they were able to provide the customer with an exact quote for the conveyor assembly as they would have already determined the exact cost of materials and construction for the specific conveyor assembly.
jre importantly though, by offering a limited range of conveyor assembly, the manufacturer had readily available to them the design schematics of each of the conveyors and more particularly a component list from which the conveyor assembly could be constructed. By having the component list, this enabled the conveyor assembly manufacturer to begin construction of the conveyor assembly without delay and enabled the manufacturer to provide the goods to the customer in as short a time frame as possible. No additional design worl was needed to provide the apparatus to the customer. However, this method suffered from the disadvantage that the customer was limited in choice to the range provided by the manufacturer and the selection of conveyor assemblies on offer may have been either wholly inadequate for the customers needs or may have been less than ideal for the customer and required extensive modification of the conveyor assembly by them in order to suit their specific application which was undesirable.
l'he second way in which conveyor assembly manufacturers have operated in the past was to provide bespoke or "made to order" conveyor assemblies. Although this approach s much more desirable to the customer in that they are provided with a conveyor assembly that exactly meets their requirements, there were disadvantages to both the customer and the conveyor assembly manufacturer. In particular, this method was highly Inconvenient for the conveyor assembly manufacturer as they were required to initially quote the customer for producing the conveyor assembly which was often a best estimate based on the dimensions provided by the customer. It was not uncommon for unforeseen cost overruns to occur and frequently the profits of the conveyor assembly manufacturer were adversely affected.
Furthermore, and most importantly, if the conveyor assembly manufacturer was successful in their tender for the job in question and they received an order to manufacture the bespoke conveyor assembly, they had to go through the entire design process of the bespoke conveyor from scratch which was lengthy, inconvenient and expensive. Unlike the previous case whereby the conveyor assembly manufacturer only had thirty or so conveyor assemblies to manufacture and therefore only had to have the component lists for the thirty or so conveyor assemblies available to them with no additional design work required, the conveyor assembly manufacturer of bespoke 2C conveyor assemblies could conceivably be required to manufacture a conveyor assembly from thirty thousand possible alternative configurations of conveyor assembly.
It was simply not feasible for the bespoke conveyor assembly manufacturer to provide a component list and a design schematic for each of the thirty thousand alternative configurations as to do so would take an inordinate amount of time and resources and require a vast amount of storage capacity. Therefore, each time a new order for a conveyor came in, the design team would have to begin from scratch and design the bespoke conveyor assembly for the customer before creating a component list for the conveyor assembly and assembling the conveyor assembly. This significantly increased the difficulty in providing the conveyor assembly and Increased the time taken to get the product to the customer.
However, as mentioned above, in the current marketplace, more and more customers are now demanding bespoke solutions and in order to keep up with the competition and in order to satisfy their customers needs, more and more conveyor assembly manufacturers are having to provide the option of bespoke solutions to their customers.
This has Introduced a significant burden on the conveyor assembly manufacturers in the form of design spend and time to manufacture as they are no longer able to simply provide a range of standard sized conveyor assemblies and most conveyor assemblies provided by them will of necessity be one-off bespoke solutions. This requires significant investment in design engineering and the cost of providing the goods to the customers has increased significantly as there are potentially thousands of different configurations of bespoke products that they may be required to produce and each product must be made from scratch.
Although described in terms of conveyor assemblies, it will be understood that the invention also applies to a wide range of goods whereby there are a large range of options that may be specified by the customer that the manufacturer will endeavour to provide. Furthermore, by conveyor assembly what is meant is not only simply the conveyor itself but the conveyor assembly may also incorporate additional equipment in the assembly such as sorting machines, packaging devices, elevators and the like used in the entire production line of an entity and the conveyor assembly may itself include numerous disparate elements.
t is an object trierefore of the present invention to provide a process for manufacturing a Despoke product that overcomes at least some of the disadvantages associated with the known processes.
Statements of Invention
According to the invention there is provided a process for manufacturing a bespoke product handling apparatus compnsing the initial steps of: preparing a general apparatus specification containing a plurality of apparatus attributes; specifying an apparatus nomenclature for the apparatus based around and indicative of the apparatus attributes; preparing a plurality of reference apparatus specifications across the range of apparatus attributes, each of the reference apparatus specifications including a component list of all the components required for the manufacture of an apparatus according to the reference apparatus specification, the component list including both pre-assembled compound components and unitary components, both the compound components and the unitary components being used in the assembly of the product handling apparatus; allocating an apparatus identifier to each of the reference apparatus specifications in accordance with the apparatus nomenclature and storing the apparatus identifiers and the component list associated therewith in a memory; defining a set of relationships between the apparatus attnbutes and the components in the component list and a set of relationships between the components in the component list and other components in the component list and storing those relationships in a configurator; and on receipt of an order for a bespoke product handling apparatus, the order containing at least a list of the ordered apparatus attnbutes, the method further iprises the steps of: allocating an ordered apparatus identifier to the ordered apparatus in accordance with the specified apparatus nomenclature; comparing the ordered apparatus identifier with the apparatus identifiers of the reference apparatus specifications stored in memory and retrieving the apparatus identifier that most closely matches the ordered apparatus identifier, along with its associated component list, from memory; providing the ordered apparatus identifier, the retrieved apparatus identifier and the component list to the configurator; I U the configurator identifying the different apparatus attributes between the ordered apparatus identifier and the retrieved apparatus identifier; the configurator determining the initial changes to both the compound components and the unitary components in the component list retrieved from memory due to the different apparatus attributes between the ordered apparatus identifier and the retneved apparatus identifier; the configurator thereafter determining any subsequent changes to the compound components and the unitary components in the component list retrieved from memory due to the initial changes to that component list, the configurator modifying the retrieved component list with those changes to the component list to generate a new component list associated with the ordered apparatus identifier; retneving the components in the new component list by interfacing with a stock control system and determining those components in the new component list already in stock, placing a hold on those components and for components in the new component list not in stock, generating a purchase order for those missing components and ordering the missing components; manufacturing the bespoke product handling apparatus from the components in the new component list, and storing the ordered apparatus identifier and the new component list in memory as a reference apparatus specification for subsequent use.
By having such a process for manufactunng bespoke product handling apparatus, it is possible to provide the component list for a new bespoke apparatus order in a relatively short space of time. The process according to the invention determines the closest iatching apparatus design stored in memory and thereafter determines the changes that need to be made to that design in order to provide the new bespoke product handling apparatus to the customer. This is achieved by defining the relationships between certain apparatus attributes and the components and by defining the elationships between the components themselves in a configurator and thereafter providing the existing and bespoke apparatus requirements to the configurator which determines the changes to the existing available component list that must be made in order to provide the new apparatus. It is no longer necessary to spend significant time creating new designs and component lists from scratch. The invention enables the manufacturer of the bespoke product handling apparatus to provide the apparatus to the customer much quicker than was previously the case and also significantly reduces the time and expertise required to design the bespoke product handling apparatus. This also allows the manufacturer to provide far more accurate quotations to their customers and ensure that they do not expose themselves to unforeseen cost overruns. Furthermore, by operating such a process, it is not necessary to use a vast amount of resources to provide each combination of the design as it is only necessary to provide a few designs in the range that may be modified. It will also be possible to update the body of existing reference apparatus specifications the more the system is used. These reference apparatus specifications may be reused or used in the subsequent design of other apparatus, thereby providing even closer reference designs for modification requiring even less computation in the future.
In one embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus in which the process further comprises the step of grading the apparatus attributes in a hierarchical manner, and the step of retrieving the apparatus identifier that most closely matches the ordered apparatus identifier further comprises choosing the apparatus identifier that differs from the ordered apparatus identifier by the apparatus attribute lowermost in the apparatus attribute hierarchy, when compared with the differing apparatus attributes of the other apparatus identifiers.
This is seen as a useful way of choosing between two or more reference apparatus specifications that may be similar to the ordered apparatus. One reference apparatus specification may differ only in speed or some relatively minor feature whereas another reference apparatus specification may differ in some structural way such as length, carrying capacity or the like which may require more significant redesign of the reference apparatus specification. By ordering the attributes in a hierarchical manner, it is possible u to determine the apparatus identifier and hence the reference apparatus specification that differs least to the ordered apparatus and therefore will require the least computation and alteration.
In another embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus in which the apparatus attributes are each given a weighting, and the step of retrieving the apparatus identifier that most closely matches the ordered apparatus identifier further comprises calculating the weighting of the differing apparatus attribute of the apparatus identifiers and choosing the apparatus identifier with the lowest weighting of the differing apparatus attribute. This is also seen as a useful way of determining the most closely matching apparatus identifier and hence eference apparatus specification for modification. By using the weightings, an apparatus specification that may differ in numerous relatively insignificant ways to the ordered apparatus may be chosen instead of a reference apparatus specification that may only vary in a single yet highly relevant and important way. Again, this ensures that the least amount of computation is required and the least amount of modification to an existing design is required.
In a further embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the step of creating a purchase order further comprises specifying component criteria and searching one or more component libranes stored in memory containing pricing information and ordering information for the component criteria, retrieving any rnponent from the component library that matches the component criteria and choosing the most suitable component based on a set of predetermined design rules. By having such a process, the components may be chosen automatically from the existing component libraries and ordered in a seamless manner requiring the minimum in human intervention.
In one embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus in which on a plurality of components matching the component cnteria being returned from the search of the component library, the step of choosing the most suitable component further compnses prompting an apparatus designer to select one of the plurality of components that have been returned. In this way, the designer may choose the component based on their design criteria which may fl for example be cost, dual redundancy and/or minimum potential failure. This also enables the designer to dictate the new components being used in the design and tailor the apparatus order more specifically for the clients needs.
In another embodiment of the invention there is provided a process for manufactunng a bespoke product handling apparatus in which there are provided a plurality of vendors, each of which periodically transmits their component library to the bespoke product handling apparatus manufacturer for storage and in which the process further comprises the step of cross-referencing old components with new components in the apparatus libraries and thereafter updating the reference apparatus specifications containing the old components with the new components. In this way, the most up-to-date components may be used in the manufacture of an ordered apparatus and the reference apparatus specifications will be updated if and when necessary.
In a further embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the process further compnses the step of on comparing the ordered apparatus identifier with the apparatus identifiers stored in memory and determining that an apparatus identifier identical to the ordered apparatus identifier is stored in memory, using the component list associated with the dentical apparatus identifier. Once a number of reference apparatus peciflcations are created, it may be possible to provide an exact match of reference apparatus specification for the client and similarly secondary orders for the same piece of equipment may be catered for without having to redesign a reference apparatus
specification at all. 10.
In one embodiment of the invention there is provided a process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the process further compnses the steps of assigning a unique job number to each order for a bespoke apparatus, associating the unique job number with the components in the new component list and storing the components in the component list already in stock in a construction area until assembly the components in the construction area being catalogued with the unique job number to which they relate. This is seen as a particularly useful way of keeping track of the components in store and ensuring that if a job order is 0 received and components are allocated to that job order, then those components will be available when it comes time to build the ordered bespoke product handling apparatus.
In another embodiment of the invention there is provided a process for manufactunng a bespoke product handling apparatus as claimed in any preceding claim in which prior to saving the new component list, the process further comprises the step of requesting confirmation from the apparatus designer that the component list is in order.
.ed Description of the Invention
The Invention will now be more clearly understood from the following description of some embodiments thereof, given by way of example only, in which.-Figure 1 is a flow diagram of the process for manufacturing a bespoke product handling apparatus in accordance with the present invention; Figure 2 is a diagrammatic representation of a product identifier for a conveyor assembly used in the process for manufacturing a bespoke product handling apparatus in accordance with the present invention, Figure 3 s a diagrammatic representation of a product identifier for a roller conveyor assembly used in the process according to the present invention along with some samples of complete product identifiers, 11..
Figure 4 is a diagrammatic representation of a product identifier for a point to point electric elevator used in the process according to the present invention.
Referring to the drawings and initially to Figure 1 thereof there is shown a flow diagram of the process for manufacturing a bespoke product handling apparatus in accordance with the present invention, indicated generally by the reference numeral 1 shown in sequential steps. The process comprises the initial step 3 of preparing a general apparatus specification containing a plurality of apparatus attributes In step 5, an apparatus nomenclature is specified based around and indicative of the apparatus attributes. In step 7, a plurality of reference apparatus specifications are prepared across the range of apparatus attributes, each of the reference apparatus specifications including a component list of all the components required for the manufacture of a apparatus in accordance with the reference apparatus specification. Once the plurality of reference apparatus specifications have been prepared, the reference apparatus specifications are each assigned an apparatus identifier in step 9 in accordance with the apparatus nomenclature determined in step 5 and these apparatus identifiers are stored along with their associated component lists in memory in step 11. In step 13, the relationships between the apparatus attnbutes and the components in the component list and the relationships between the components in the component list and other components are defined and these relationships are stored in a configurator (not shown) in step 15. This step 15 concludes the initial setup steps of the process and these steps are carried out on setup of the system and need not be carried out each time the process is performed.
After setup, in step 17, an order for a bespoke product handling apparatus is received containing at least a list of the ordered apparatus attributes and the ordered apparatus is allocated with an apparatus identifier, hereinafter referred to as an ordered apparatus dentifier, in accordance with the specified apparatus nomenclature defined in step 5. In step 19, the ordered apparatus identifier is compared with the apparatus identifiers of the reference apparatus specifications stored in memory and the apparatus identifier stored in memory that most closely matches the ordered apparatus identifier is retrieved, along with its associated component list, from memory in step 20. In step 21, the ordered apparatus identifier, the apparatus identifier retrieved from memory and the component list are provided to the configurator. The different attributes between the ordered -12-apparatus identifier and the retneved apparatus identifier are identified in step 23 and in step 25 those attributes are used by the configurator for analysis. In step 27, the configurator determines the initial changes to the component list based on the changes to the attributes and in step 29 the configurator determines whether there are any subsequent changes to the component list due to the initial changes to the component list In step 31, the configur-ator modifies the retrieved component list with the changes to provide a new component list particular to that ordered apparatus identifier. It will be understood that the original component list for the retrieved apparatus identifier will still be stored in memory and will not be altered in any way but rather a retrieved copy of the original component list will be altered. In step 33, the ordered apparatus identifier and the new apparatus component list are stored in memory as a reference apparatus specification for subsequent use while in step 35, the components in the new component list are retrieved before the bespoke product handling apparatus is manufactured from the components in step 37 The step 35 of retrieving the components further comprises the individual steps (not shown) of interfacing with a stock control system and determining those components on the component list that are already in stock. The components that are already in stock are held by associating a job number, different to the ordered apparatus identifier, of the present bespoke product handling apparatus with the component in the stock control stem and those components may be moved to a construction area away from the normal stocks to ensure that they are readily available for manufacture of the ordered apparatus when the time comes. For those items not in stock, the process entails reviewing one or more libraries (not shown) of components stored in memory having the purchase details including supplier number/reference, component price, component order number and component order information. The process entails obtaining this information and thereafter generating a purchase order for the missing components and ordering the components. The most suitable component may be selected either by an apparatus designer who will be prompted to choose a component from a given selection or alternatively the component may be chosen in accordance with predetermined design as such as lowest cost, most reliable, maximum time between failures and the like.
The predetermined design rules may be specified from order to order depending on the quirements of the customer or alternatively may be set for all bespoke product handling apparatus orders as a design methodology of the manufacturer, It is envisaged that the reference apparatus specifications and in particular their component lists may be updated from time to time on receipt of a new component library from a component supplier whereby the component lists may be cross referenced with the new component libraries in order to ensure that the correct components and component references are stored in memory and that the most up to date equipment is being used if desired.
Furthermore, step 19, in which the ordered apparatus identifier iscompared with the apparatus identifiers of the reference apparatus specifications stored in memory, and the apparatus identifier stored in memory that most closely matches the ordered apparatus identifier is retrieved, along with its associated component list from memory, may further comprise determining the apparatus identifier that differs from the ordered apparatus identifier by an apparatus attribute that is lowermost in an apparatus attribute hierarchy when compared with the differing apparatus attributes of the other apparatus identifiers.
This will require the apparatus attributes to be arranged in an attribute hierarchy. Certain attributes will require very little modification to the reference apparatus specification whereas others may require significant modification. By sorting the apparatus attributes in a hierarchy, any disputes may be reconciled in a relatively straighiforward manner.
For example, when producing a belt conveyor, two of the attributes may be the grip of the conveyor belt and the carrying capacity of the conveyor. It may be found that one reference apparatus specification in memory varies from the ordered apparatus identifier simply by the amount of grip provided by the belt whereas the other reference apparatus specification varies from the ordered apparatus identifier in that a different weight load is to be transported on the conveyor. In this instance, the belt grip attribute may be lower in 2' e hierarchy than the carrying capacity attribute as a change in the belt grip simply requires a different belt type to be used while all of the other components remain unchanged and the vast majority of the design is already available. This requires very little modification to the existing reference apparatus specification. On the other hand, the reference apparatus specification with a different weight carrying capacity may have to be altered significantly structurally in order to be able to handle a heavier weight of goods or may be modified significantly to avoid having to use much heavier gauge tquipment than was otherwise proposed in the reference apparatus specification. This would require a more thorough redesign of the reference apparatus specification and although both reference apparatus specifications differ from the ordered apparatus -14-identifIer in a single respect, it can be seen that the choice of reference apparatus specification may be important and materially affect the amount of redesign and effort that it is required.
Alternatively or in addition to this, weightings may be given to the attributes of the reference apparatus specification and in particular the apparatus identifier associated therewith ln this way, the apparatus identifier that differs from the ordered apparatus identifier by the least weighted value may be chosen. It is envisaged that in certain instances, a reference apparatus specification may differ from the ordered apparatus identifier in numerous relatively minor ways. However, another reference apparatus specification may differ in only a single yet far more significant way. Similarly, the differences may be of the same hierarchical order and inseparable in that regard. The weighting given to the difference may be chosen so that the reference apparatus specification with the least amount of modification and computation required to achieve the new component list may be chosen. Alternatively, separate rules may be written to determine the closest apparatus identifier and hence reference apparatus specification to the ordered apparatus identifier.
Taking the specific example given above in relation to conveyors, the general apparatus specification may determine that the essential attributes of the conveyor are the machine ype, the belt width, the conveyor length, the guide type, the top of belt height, the belt colour, the speed, i.e. whether fixed speed or variable speed and if so the speed or the ige of speeds required, the friction type, whether an inverter is required and whether a plug is needed. An apparatus nomenclature is created depending on the attributes and thereafter a plurality of reference apparatus specifications including the component lists of the reference apparatus specifications spanning the range of apparatus attributes are rreated and each is assigned an apparatus identifier before being stored in memory.
The component list includes everything required to construct the conveyor assembly including for example the number of legs supporting the conveyor assembly, the length and strength of these legs and the number and type of nuts and bolts or other means for "urlng the legs to the remainder of the conveyor assembly frame. This is in addition to the information on belts, rollers, drive motors and their associated components, bearings, fastenings and the like. Essentially, there is an entire specification for the construction of the bespoke product handling apparatus. It would also include the type of conveyor belt used such as a low friction belt and the components for coupling the conveyor belt with the motor(s) of the conveyor assembly. Essentially, there is a full pdrts list provided which can enable the apparatus manufacturer to construct an apparatus according to that specification. A number of reference apparatus specifications are created spanning the range of apparatus attributes for each particular apparatus.
In this example, the entire range of conveyors offered may span lengths of between 1 metre and 12 metres. In that case, it may be decided to provide reference specifications for a 1 metre conveyor, a 2 metre conveyor, a 3 metre conveyor and thereafter a reference specification for conveyors separated by 1 metre in length e.g. 4 metres, 5 metres, 6 metres and so on up to and including 12 metres. The reference apparatus specifications associated with those apparatus are stored in memory along with the apparatus identifiers and the component lists. Similarly, for the conveyors produced the irinlmum belt width may be 100mm up to a maximum belt width of 700 mm and for each of the given lengths of conveyor for which a reference apparatus specification has been produced, it may be desirable to provide a reference apparatus specification for a u0mm width conveyor belt, a 400mm width conveyor belt and a 700mm width conveyor belt. Furthermore, for each length and width combination, it may be desirable to provide a reference apparatus specification for four separate heights of conveyor belt height spanning the range 500mm to 1400mm, e.g. 500mm height, 800mm height, 1100mm height and 1400mm height. Therefore, once all of the reference apparatus specifications and their associated component lists and apparatus identifiers are stored in memory, an order for a bespoke product handling apparatus may be given an ordered apparatus identifier and that identifier is compared with the apparatus identifiers in memory. The closest reference apparatus specification is chosen from the comparison and the component list of this reference apparatus specification may be modified to obtain the component list for the ordered bespoke apparatus.
3fl For example, an order for a bespoke conveyor assembly may be received with the attributes of conveyor length 1.65 metres, conveyor belt height 1100mm and belt width 400mm along with the remaining attributes of machine type, the guide type, the belt colour, the speed, the fnction type, whether an inverter is required and whether a plug is needed. In that instance, the order will be given an ordered apparatus identifier which will be compared with the apparatus identifiers stored in memory. It may be found that there is an apparatus identifier and hence a reference apparatus specification in memory having a conveyor belt height of 1100mm and a belt width of 400mm but the nearest reference apparatus specification has a conveyor length of 2.0 metres. The reference apparatus specification and more particularly the component list for this reference apparatus specification are retneved from memory and they are fed to the comparator which identifies the different apparatus attributes, in this case the length of the conveyor.
The configurator determines the initial changes to the component list which in this case may be instead of providing four separate conveyor sections each 0.5 metres in length, it may now be preferable to provide three separate conveyor sections each of 0.55 metres n length. Similarly, the number of inter-connectors such as the actual nuts and bolts required to join the separate conveyor sections together may be reduced by one entire set and the component list may be altered accordingly. The configurator then determines from the relationships between components whether other changes are necessary. For example, it may be determined that by using 0.55 metre conveyors, additional leg supports must be provided or a more powerful motor must be provided for each conveyor section and these changes will be determined. All of the changes are calculated using the configurator and the configurator then modifies the retrieved component list with the changes to create the new component list and thereafter save the new component list with the ordered apparatus identifier in memory as a reference
paratus specification for future use.
In this way, the component list for the bespoke apparatus may be constructed in a quick and efficient manner without requiring an entire re-design process. By having a plurality of reference apparatus specifications across the range of apparatus, it is possible to quickly modify these reference apparatus specifications without having to carry out significant modifications. By saving the ordered apparatus identifier and the new component list in memory as a reference apparatus specification, the reference specification thus created may be then used the next time an individual is looking for a 1 65 metre long conveyor with or without further minor modifications or alternatively the next time an individual is looking for a 1.66 metre conveyor the reference apparatus specification for the 1.65 metre conveyor assembly may be the closest reference apparatus specification and may only need relatively minor alterations by the configurator in order to change the component list to create the 1.66 metre conveyor assembly. By stonng the individual specifications each time, a database of specifications is built up over time so that less and less modifications will have to be carned out to the reference apparatus specifications allowing the manufacturer to provide exact component lists and accurate quotations in a much quicker time frame and furthermore will allow the manufacturer to proceed to manufacture much sooner than was heretofore the case.
Referring to Figure 2 of the drawings there is shown a diagrammatic representation of an apparatus identifier for a conveyor assembly used in the process for manufacturing a bespoke product handling apparatus in accordance with the present invention. The apparatus identifier, indicated generally by the reference numeral 41, comprises a 20 character alphanumeric code representative and indicative of the apparatus attributes. In the apparatus identifier 41, reading from the left hand side, the first three characters 43 determine the make and model of the conveyor, the next two characters 45 determine the nominal belt width, the next four characters 47 determine the conveyor length, the following three characters 49 determine the guide type to be used with the conveyor, the three characters 51 after that indicate the top of belt height, the next character 53 determines the belt colour, the following character 55 indicates the speed of the conveyor, the next character 57 indicates the friction type of the conveyor, the penultimate character 59 indicates whether an inverter is required and the right-most, al character 61 indicates whether a plug is required. By consistently describing the ordered apparatus and the apparatus identifiers in this manner, the ordered apparatus identifier and the apparatus identifiers may be compared quickly with the minimum of difficulty. When the closest matching apparatus identifier is found in memory, the component list associated therewith may also be retrieved from memory for provision to the configurator and the configuration algorithm in due course to determine the new component list It can be seen that in some of the fields such as the length field, belt width field and the guide type fields there are three or four spaces for inputting attnbute data. This allows for a thousand and ten thousand different combinations respectively when using a decimal numbering system and therefore it can be seen how to build an tire reference apparatus specification for each permutation and combination of bespoke product handling apparatus would be highly impractical but the process cribed overcomes these problems by providing a limited range of the apparatus as reference apparatus specificatIons for comparison and evaluation in order to create a new apparatus.
Referring now to Figure 3, there is shown a diagrammatic representation of an apparatus identifier for a roller conveyor assembly along with some samples of complete apparatus identifiers. Again, a 20 character apparatus identifier, indicated generally by the reference numeral 62 is used The apparatus identifier 62 in turn comprises a number of sections each of which represent a apparatus attribute. The section with the first two characters 63, reading from the left, relate to the type of machine, a roller conveyor. The second section 65 with the third character relates to the duty type of the conveyor, light, edium or heavy duty. The next section 67 relates to the drive type of conveyor, namely gravity, drive roller, underbelt drive roller or line shaft and the following section 69 relates to the roller pitch. In this case there are five separate options for roller pitch, ranging from 75mm up to 200mm but further pitch ranges could of course be accommodated. The next section 71 determines the materials used for construction, stainless steel, mild steel or aluminium and the section 73 following that determines the length of a zone of the conveyor. Three characters are provided to allow for a relatively precise length of zone uS this is often important when providing a bespoke product handling apparatus. The next section 75 indicates the number of drive rollers per zone and the section 77 after that indicates the speed or throughput of the conveyor. Finally, there is a conveyor width 3ctIon 79 separated from a total conveyor length section 81 section by a partition section 83. The partition section 83 is essentially a spare section that may be used to expand the range of options available in any one of the other sections if required.
From the examples shown, there are shown four apparatus identifiers, 85(a), 85(b), 85(c) and 85(d). Apparatus identifier 85(a) indicates that the conveyor is a roller conveyor of medium duty. It further indicates that the conveyor is a gravity conveyor with a roller pitch of 125mm, constructed from mild steel. There are no zones in the conveyor and there are no drive rollers for the conveyor. As the conveyor is not driven, there is no speed to the conveyor (indicated as Urn/mm) and finally the conveyor is 500mm wide and 3000mm long, it is possible to save that apparatus identifier in memory along with a component list for the apparatus identifier and thereafter use the component list if an identical conveyor is required or modify the component list to generate a new component st if a very similar ordered apparatus identifier is provided by a customer.
Apparatus identifier 85(b) relates to a medium duty roller conveyor, having a dnve roller with a roller pitch of 100mm and constructed from mild steel The conveyor has zones of 1100mm in length and there are two drive rollers per zone. The conveyor handles goods at a speed of 30m/min and the conveyor width is set at 960mm while the conveyor length is set at 2200mm. Apparatus identifier 85(c) relates to a roller conveyor of medium duty having an under belt dnve roller construction, a roller pitch of 125mm and is made from mild steel. There are no zones and there are no drive rollers per se as they are not mounted on the zone and are therefore not indicated. The speed of the conveyor is set at 20m/min and the conveyor width is set at 600mm whereas the conveyor length set at 2500mm. Finally, apparatus identifier 85(d) relates to a roller conveyor, again of medium duty with a line shaft drive. The pitch is set at 200mm and the conveyor is constructed from stainless steel. There are no zones but there is provided a drive section th the motor mounted. The conveyor operates at 40m/min and has a conveyor width of 1000mm and a conveyor length of 2000mm. Each of these apparatus identifiers may be stored in memory along with associated component lists as reference apparatus
specifications.
If an order is received to provide a roller conveyor with a mild steel construction, medium duty load having a roller pitch of 100mm and a drive roller mechanism, separated into three zones each 700mm in length with one drive roller per zone, operating at 30m/min and having a conveyor width of 800mm and a conveyor length of 2100mm, the order would first be given an ordered apparatus identifier. In this case the ordered apparatus identifier would be 12MD2M070130080-2100 This apparatus identifier is then compared th the apparatus identifiers stored in memory and in the examples given it would be found that it is relatively similar to apparatus identifier 85(b). The apparatus identifiers would be compared and it would be identified that the zone length of the ordered dpparatus identifier is only 70mm as opposed to 110mm, there is only a single drive roller per zone instead of two (yet there is an extra zone in this case) and therefore three drive rollers will be needed as opposed to four, the conveyor width is 800mm as opposed to 960mm and the length of the conveyor is 2100mm as opposed to 2200mm.
These differences may be put into the configurator to see what changes will be made to the component list of the reference apparatus specification. Those changes are then used to modify the component list retrieved from memory previously associated with the -20 -apparatus identifier 85(b) to provide a new component list associated with the new apparatus identifier. The components of the new component list may then be obtained and the roller conveyor manufactured while the new apparatus number and the new component list may be stored in memory for future use as a reference apparatus specification or for reorder of an identical roller conveyor to that roller conveyor.
Figure 4 is a diagrammatic representation of a apparatus identifier for a point to point electric elevator used in accordance with the present invention. Essentially, the apparatus specification may be used to represent a single good that may be constructed using a number of ranges for dimensions and the like or alternatively the apparatus dentifier may represent a more substantial apparatus such as an entire assembly line and there may be other apparatus identifiers subsidiary to the main apparatus identifier and associated therewith. Essentially then, the apparatus identifier may be related to a number of other apparatus identifiers that may form separate components in a greater apparatus. The point to point electric elevator apparatus identifier 91 comprises a 20 character code. Reading from the left, the section 93 with the first two characters indicate the machine type, in this case an electric elevator. The next section 95 indicates the product weight, section 97 indicates the cycle time of the elevator and section 99 indicates the opening required above the conveyor for the product to be handled.
Section 101 indicates the elevator type, section 103 indicates the lower level loading/unloading requirement while the section 105 indicates the upper level loading/unloading requirements (i.e. the side that the goods must be able to be loaded/unloaded to and from). Section 107 represents the motor position, section 109 represents the maintenance door position, section 111 indicates the lower feed height while section 113 indicates the upper feed height. Section 115 represents the conveyor type (in the elevator), section 116 is a separator, section 117 represents the base width and section 119 represents the base depth. Reference apparatus specifications may be created in the manner previous described above for the conveyor implementations and similarly the design of bespoke elevators within a given range may be significantly simplified in the manner described above.
It can be seen from the foregoing how a number of different apparatus may all use the me apparatus identifier nomenclature. The first couple of characters may be used to identify the device type while the remaining characters may be used to define the attributes of the apparatus. In order to search the records, first of all the configurator will look at the first couple of digits of the apparatus identifier and determine the type of apparatus, i.e. is it a standard conveyor, a roller conveyor, an electric elevator or other component and thereafter the configurator will go about matching the attributes of the conveyor, elevator or other apparatus with the apparatus identifiers of the conveyors, elevators or other apparatus stored in memory before finding the closest matching apparatus identifier and retnevirig the component list associated with the closest matching apparatus identifier for modification if necessary.
In this specification the terms "comprise, comprises, comprised and comprising" and the terms "include, includes, included and including" are all deemed totally interchangeable and should be afforded the widest possible interpretation.
rhe,rvcrtion is in no way limited to the embodiments hereinbefore described but may be varied in both construction and detail within the scope of the claims.
Claims (10)
- C'aims 1\ A process for manufacturing a bespoke product handlingapparatus comprising the initial steps of: prepanng a general apparatus specification containing a plurality of apparatus attributes; specifying an apparatus nomenclature for the apparatus based around and indicative of the apparatus attributes; preparing a plurality of reference apparatus specifications across the range of apparatus attributes, each of the reference apparatus specifications including a component list of all the components required for the manufacture of an apparatus according to the reference apparatus specification, the component list including both pre-assembled compound components and unitary components, both the compound components and the unitary components being used in the assembly of the product handling apparatus; allocating an apparatus identifier to each of the reference apparatus specifications in accordance with the apparatus nomenclature and storing the apparatus identifiers and the component list associated therewith in a memory; defining a set of relationships between the apparatus attributes and the components in the component list and a set of relationships between the components in the component list and other components in the component list and storing those relationships in a configurator; and on receipt of an order for a bespoke product handling apparatus, the order containing at least a list of the ordered apparatus attnbutes, the method further comprises the steps of: -23 -allocating an ordered apparatus identifier to the ordered apparatus in accordance with the specified apparatus nomenclature; comparing the ordered apparatus identifier with the apparatus identifiers of the reference apparatus specifications stored in memory and retrieving the apparatus identifier that most closely matches the ordered apparatus identifier, along with its associated component list, from memory; providing the ordered apparatus identifier, the retrieved apparatus identifier and the component list to the configurator; the configurator identifying the different apparatus attributes between the ordered apparatus identifier and the retrieved apparatus identifier; the configurator determining the initial changes to both the compound components and the unitary components in the component list retrieved from memory due to the different apparatus attributes between the ordered apparatus identifier and the retrieved apparatus identifier; the configurator thereafter determining any subsequent changes to the compound components and the unitary components in the component list retrieved from memory due to the initial changes to that component list; the configurator modifying the retrieved component list with those changes to the component list to generate a new component list associated with the ordered apparatus identifier; retrieving the components in the new component list by interfacing with a stock control system and determining those components in the new component list already in stock, placing a hold on those components and for components in the new component list not in stock, generating a purchase order for those missing components and ordering the missing components; -24 -manufacturing the bespoke product handling apparatus from the components in the new component list; and storing the ordered apparatus identifier and the new component list in memory as a reference apparatus specification for subsequent use.
- 2) A process for manufacturing a bespoke product handling apparatus as claimed in claim 1 in which the process further comprises the step of grading the apparatus attributes in a hierarchical manner, and the step of retrieving the apparatus identifier that most closely matches the ordered apparatus identifier further comprises choosing the apparatus identifier that differs from the ordered apparatus identifier by the apparatus attribute lowermost in the apparatus attribute hierarchy, when compared with the differing apparatus attributes of the other apparatus identifiers.
- 3) A process for manufacturing a bespoke product handling apparatus as claimed in claim 1 or 2 in which the apparatus attributes are each given a weighting, and the step of retrieving the apparatus identifier that most closely matches the ordered apparatus identifier further comprises calculating the weighting of the differing apparatus attribute of the apparatus identifiers and choosing the apparatus identifier with the lowest weighting of the differing apparatus attnbute.
- 4) A process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the step of creating a purchase order further comprises specifying component criteria and searching one or more component libraries stored in memory containing pricing information and ordering information for the component cnteria, retrieving any component from the component library that matches the component criteria and choosing the most suitable component based on a set of predetermined design rules.
- 5) A process for manufacturing a bespoke product handling apparatus as claimed in claim 4 in which on a plurality of components matching the component criteria being returned from the search of the component library, the step of choosing the -25 -most suitable component further comprises prompting an apparatus designer to select one of the plurality of components that have been returned.
- 6) A process for manufacturing a bespoke product handling apparatus as claimed in claim 4 or 5 in which there are provided a plurality of vendors, each of which periodically transmits their component library to the bespoke product handling apparatus manufacturer for storage and in which the process further comprises the step of cross-referencing old components with new components in the apparatus libranes and thereafter updating the reference apparatus specifications containing the old components with the new components.
- 7) A process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the process further comprises the step of on comparing the ordered apparatus identifier with the apparatus identifiers stored in memory and determining that an apparatus identifier identical to the ordered apparatus identifier is stored in memory, using the component list associated with the identical apparatus identifier.
- 8) A process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which the process further compnses the steps of assigning a unique job number to each order for a bespoke apparatus, associating the unique job number with the components in the new component list and stonng the components in the component list already in stock in a construction area until assembly, the components in the construction area being catalogued with the unique job number to which they relate.
- 9) A process for manufacturing a bespoke product handling apparatus as claimed in any preceding claim in which prior to saving the new component list, the process further comprises the step of requesting confirmation from the apparatus designer that the component list is in order.
- 10) A process for manufacturing a bespoke product handling apparatus substantially as hereinbefore described with reference to and as illustrated by the accompanying drawings.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IE2006/0883A IE85293B1 (en) | 2006-12-05 | A process for manufacturing a bespoke product handling apparatus |
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| GB0717142D0 GB0717142D0 (en) | 2007-10-17 |
| GB2444583A true GB2444583A (en) | 2008-06-11 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2020230040A3 (en) * | 2019-05-13 | 2021-02-04 | Bergogni Food Machinery S.R.L.S. | Method implemented by software instructions for manufacturing a belt conveyor and/or a series of belt conveyors and related system |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111861340A (en) * | 2020-07-27 | 2020-10-30 | 上海控软网络科技有限公司 | Information processing method and device for production material purchasing and automatic production |
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|---|---|---|---|---|
| JP2003030620A (en) * | 2001-07-19 | 2003-01-31 | Le Tekku:Kk | Read and write method for magnetic card |
| JP2003177812A (en) * | 2001-12-10 | 2003-06-27 | Mazda Motor Corp | Production management method, device and computer program |
| US20050010495A1 (en) * | 2003-07-07 | 2005-01-13 | Pochun Shih | Custom product order management system |
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2007
- 2007-09-04 GB GB0717142A patent/GB2444583A/en not_active Withdrawn
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003030620A (en) * | 2001-07-19 | 2003-01-31 | Le Tekku:Kk | Read and write method for magnetic card |
| JP2003177812A (en) * | 2001-12-10 | 2003-06-27 | Mazda Motor Corp | Production management method, device and computer program |
| US20050010495A1 (en) * | 2003-07-07 | 2005-01-13 | Pochun Shih | Custom product order management system |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2020230040A3 (en) * | 2019-05-13 | 2021-02-04 | Bergogni Food Machinery S.R.L.S. | Method implemented by software instructions for manufacturing a belt conveyor and/or a series of belt conveyors and related system |
| US20220221841A1 (en) * | 2019-05-13 | 2022-07-14 | Bergogni Food Machinery S.R.L.S. | Method implemented by software instructions for manufacturing a belt conveyor and/or a series of belts conveyor and related system |
Also Published As
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| GB0717142D0 (en) | 2007-10-17 |
| IE20060883A1 (en) | 2008-09-17 |
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