US6236901B1 — Manufacturing system and method for assembly of c…

Claim 1

Independent Claim 340 words

A build-to-order product assembly system comprising: a control unit capable of receiving a product order describing a product to be assembled, the control unit including a list of product components for the product to be assembled, wherein the product is a computer system including a chassis, a processor supported by the chassis and a memory coupled to the processor; a kitting unit coupled to the control unit and receiving the list of product components, the kitting unit including: a plurality of kit trays; a plurality of stored product components; and a product component list display device, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of the product using the product components from the prepared kit tray; a chassis preparation unit coupled to the control unit and receiving the list of product components, the chassis preparation unit including: a plurality of chassis components; and a chassis preparation work space in which a chassis is prepared for a computer system according to the list of product components; and a joining area coupled to the kitting unit and to the chassis preparation unit, the joining area receiving a prepared chassis and a prepared kit tray the prepared chassis being added to the prepared kit tray before being sent to the assembly unit, wherein the control unit delivers the list of product components to the chassis preparation unit at a first time, and the control unit delivers the list of product components to the kitting unit at a second time, the first time and the second time being selected by the control unit so the prepared chassis and the prepared kit tray arrive at the joining area at approximately the same time.

Claim 2

Dependent Claim 340 words

A build-to-order product assembly system comprising: a control unit capable of receiving a product order describing a product to be assembled, the control unit including a list of product components for the product to be assembled, wherein the product is a computer system including a chassis, a processor supported by the chassis and a memory coupled to the processor; a kitting unit coupled to the control unit and receiving the list of product components, the kitting unit including: a plurality of kit trays; a plurality of stored product components; and a product component list display device, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of the product using the product components from the prepared kit tray; a chassis preparation unit coupled to the control unit and receiving the list of product components, the chassis preparation unit including: a plurality of chassis components; and a chassis preparation work space in which a chassis is prepared for a computer system according to the list of product components; and a joining area coupled to the kitting unit and to the chassis preparation unit, the joining area receiving a prepared chassis and a prepared kit tray the prepared chassis being added to the prepared kit tray before being sent to the assembly unit, wherein the control unit delivers the list of product components to the chassis preparation unit at a first time, and the control unit delivers the list of product components to the kitting unit at a second time, the first time and the second time being selected by the control unit so the prepared chassis and the prepared kit tray arrive at the joining area at approximately the same time.

Claim 3

Dependent Claim 40 words

The build-to-order product assembly system of claim 1 wherein each of the plurality of kit trays includes: a plurality of foam-lined tray compartments to accommodate the product components; and a lip to support the chassis on top of the tray.

Claim 4

Dependent Claim 46 words

The build-to-order product assembly system of claim 1 further comprising an extended test unit coupled to the assembly unit, the extended test unit receiving an assembled computer system from the assembly unit and including a plurality of extended test positions for quality testing the computer system.

Claim 5

Dependent Claim 41 words

The build-to-order product assembly system of claim 3 wherein the plurality of extended test positions are controlled and monitored by a smart burn-in monitoring system including a test status indicator providing test information about a computer system in a test position.

Claim 6

Dependent Claim 38 words

The build-to-order product assembly system of claim 4 wherein the smart burn-in monitoring system includes information about a computer system that fails a test in the extended test unit, the information being supplied to the first work cell.

Claim 7

Dependent Claim 62 words

The build-to-order product assembly system of claim 4 further comprising a repair unit including a repair work space, a computer system that fails a test in the extended test unit being received by the repair unit from the extended test unit, the repair unit being capable of supplying information about the computer system that fails a test to the first work cell.

Claim 8

Dependent Claim 83 words

The build-to-order product assembly system of claim 1 wherein the assembly unit includes a quick test cell coupled to the first work cell and operable to receive the assembled product, the quick test cell including a quick test work space for testing of basic functionality of the assembled product and providing at least one of information about failure of the test of basic functionality and the assembled product to the first work cell when the assembled product fails the test of basic functionality.

Claim 9

Dependent Claim 18 words

The build-to-order product assembly system of claim 7 wherein the first work cell includes the quick test cell.

Claim 10

Dependent Claim 93 words

The build-to-order product assembly system of claim 7 wherein the assembly unit further comprises: a second work cell coupled to the quick test cell and including a work space allowing a second work cell to assemble the product using the product components from the prepared kit tray, the quick test cell being shared by the first work cell and the second work cell; and a queue operable to accumulate at least one prepared kit tray and provide the prepared kit tray to one of the first work cell and the second work cell.

Claim 11

Dependent Claim 49 words

The build-to-order product assembly system of claim 1 wherein the first work cell includes a first operator and a second operator, the first operator installing a first one of the product components into the product while the second operator prepares a second product component for installation into the product.

Claim 12

Dependent Claim 39 words

The build-to-order product assembly system of claim 1 wherein the first work cell includes an electronic work instruction display operable to receive information about the product to be assembled and to display instructions about the product to be assembled.

Claim 13

Dependent Claim 43 words

The build-to-order product assembly system of claim 11 wherein the electronic work instruction display is coupled to the control unit and receives the information about the product to be assembled from at least one of the control unit and the prepared kit tray.

Claim 14

Dependent Claim 26 words

The build-to-order product assembly system of claim 1 wherein the product component list display device is one of a pick-to-lights system and a component display screen.

Claim 15

Dependent Claim 21 words

The build-to-order product assembly system of claim 1 wherein the kitting unit is coupled to the assembly unit by a conveyor.

Claim 16

Dependent Claim 217 words

A manufacturing system for assembly of computer system in a build-to-order environment comprising: a kitting unit housing kit trays and computer system components, the kitting unit: including a code for generating a signal to indicate a list of components for assembling an ordered computer system; and displaying the list of components in a pick-to-lights system to at least one kitting operator to allow respective kit trays to be prepared with computer system components for the ordered computer system by pulling selected computer system components from those housed at the kitting unit; an assembly unit constructed to receive prepared kit trays from the kitting unit, the assembly unit having a plurality of work cells operable in parallel, at least one work cell: providing work space and tools to allow a team of work cell operators to assemble an ordered computer system using the computer system components from a prepared kit tray; and providing an integrated quick test, shared by at least one other work cell, to allow a quick test operator to test the assembled computer system for basic functionality; and an extended test unit constructed to receive assembled computer system from the work cells, the extended test unit providing work space and tools to allow at least one extended test operator to quality test assembled computer systems.

Claim 17

Dependent Claim 217 words

A manufacturing system for assembly of computer system in a build-to-order environment comprising: a kitting unit housing kit trays and computer system components, the kitting unit: including a code for generating a signal to indicate a list of components for assembling an ordered computer system; and displaying the list of components in a pick-to-lights system to at least one kitting operator to allow respective kit trays to be prepared with computer system components for the ordered computer system by pulling selected computer system components from those housed at the kitting unit; an assembly unit constructed to receive prepared kit trays from the kitting unit, the assembly unit having a plurality of work cells operable in parallel, at least one work cell: providing work space and tools to allow a team of work cell operators to assemble an ordered computer system using the computer system components from a prepared kit tray; and providing an integrated quick test, shared by at least one other work cell, to allow a quick test operator to test the assembled computer system for basic functionality; and an extended test unit constructed to receive assembled computer system from the work cells, the extended test unit providing work space and tools to allow at least one extended test operator to quality test assembled computer systems.

Claim 18

Dependent Claim 129 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising: a chassis preparation unit: receiving a list of chassis and motherboard components for assembling the ordered computer system, and displaying the list of chassis and motherboard components to at least one chassis preparation operator for pulling chassis and motherboard components from chassis and motherboard components housed at the chassis preparation unit; preparing the chassis by assembling the chassis and motherboard components for the ordered computer system; and a joining unit operable to receive prepared chassis and prepared kit trays, the joining unit: identifying corresponding prepared kit trays and prepared chassis; and placing a prepared chassis on the corresponding prepared kit tray before the prepared kit tray is sent to the assembly unit.

Claim 19

Dependent Claim 32 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein the motherboard components include a motherboard and at least one of a processor and a memory.

Claim 20

Dependent Claim 36 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising a queue operable to accumulate prepared kit trays and provide them to one of the plurality of work cells.

Claim 21

Dependent Claim 60 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein the quick test operator provides at least one of: (1) information about failure of the test of basic functionality, and (2) an assembled computer system to the work cell that assembled the computer system when the computer system fails the test of basic functionality.

Claim 22

Dependent Claim 51 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 wherein ones of the plurality of work cells includes an electronic work instruction display operable to receive information about the computer system to be assembled and to display instructions about the computer system to be assembled.

Claim 23

Dependent Claim 57 words

The manufacturing system for assembly of computer systems in a build-to-order environment of claim 15 further comprising a repair unit: receiving a computer system that fails a test in the extended test unit; repairing the computer system; and supplying information about the computer system that fails the test to the work cell that assembled the computer system.

Claim 24

Independent Claim 99 words

A method of assembling a build-to-order product comprising: receiving and display a list of components for assembling an ordered product; providing a kit tray; coding the kit tray; generating a signal from the coded kit tray to indicated a list of product components; identifying the product components from the list in a pick-to-lights system; selecting the identified product components; placing the product components in the kit tray; transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and assembling the ordered product in the assembly unit using the product components from the prepared kit.

Claim 25

Independent Claim 99 words

A method of assembling a build-to-order product comprising: receiving and display a list of components for assembling an ordered product; providing a kit tray; coding the kit tray; generating a signal from the coded kit tray to indicated a list of product components; identifying the product components from the list in a pick-to-lights system; selecting the identified product components; placing the product components in the kit tray; transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and assembling the ordered product in the assembly unit using the product components from the prepared kit.

Claim 26

Dependent Claim 67 words

The method of claim 22 wherein the assembly unit includes a plurality of work cells operable in parallel, the method further comprising routing prepared kit trays to one of the work cells; and wherein preparing the kit tray includes: pulling components from a plurality of stored components and according to the list of components for assembling an ordered product; and placing pulled components in the kit tray.

Claim 27

Dependent Claim 61 words

The method of claim 23 further comprising: routing a prepared kit tray to an available work cell; testing the assembled product for basic functionality in a quick test cell associated with the work cell; transferring the assembled product to an extended test unit operable to receive assembled products; and performing a quality test on assembled products in the extended test unit.

Claim 28

Dependent Claim 29 words

The method of claim 22 wherein the ordered product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

Claim 29

Dependent Claim 40 words

The method of claim 25 further comprising: preparing a chassis for the ordered computer system; transferring the prepared chassis to the assembly unit; and joining the prepared chassis to a corresponding prepared kit tray prior to assembling the ordered product.

Claim 30

Dependent Claim 19 words

The method of claim 26 wherein the preparing the kit tray and the preparing the chassis occur in parallel.

Claim 31

Dependent Claim 18 words

The method of claim 22 further comprising queuing at least one prepared kit tray prior to the routing.

Claim 32

Dependent Claim 30 words

The method of claim 22 further comprising returning the assembled product to the work cell where the assembled product was assembled when the assembled product fails a basic functionality test.

Claim 33

Dependent Claim 20 words

The method of claim 22 further comprising repairing, in a repair unit, an assembled product that fails the extended test.

Claim 34

Dependent Claim 26 words

The method of claim 22 further comprising providing information about the failure of the assembled product to the work cell where the assembled product was assembled.

Claim 35

Dependent Claim 33 words

The method of claim 22 wherein the available work cell includes the quick test cell, and wherein the assembling the ordered product and the testing the assembled product are performed by an operator.

Claim 36

Dependent Claim 120 words

A build-to-order computer system comprising: a chassis; a processor support by the chassis; and a memory coupled to the processor, the computer system assembled by: receiving and displaying a list of components for assembling the build-to-order computer system; providing a kit tray; coding the kit tray; generating a signal from the coded kit tray to indicate a list of product components; identifying the product components from the list in a pick-to-lights system; selecting the identified product components; placing the product components in the kit tray; transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and assembling the ordered product in the available work cell using the build-to-order computer system components from the prepared kit.

Claim 37

Dependent Claim 120 words

A build-to-order computer system comprising: a chassis; a processor support by the chassis; and a memory coupled to the processor, the computer system assembled by: receiving and displaying a list of components for assembling the build-to-order computer system; providing a kit tray; coding the kit tray; generating a signal from the coded kit tray to indicate a list of product components; identifying the product components from the list in a pick-to-lights system; selecting the identified product components; placing the product components in the kit tray; transferring the prepared kit tray to an assembly unit operable to receive prepared kit trays; and assembling the ordered product in the available work cell using the build-to-order computer system components from the prepared kit.

Claim 38

Dependent Claim 228 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray; at least one of: a quick test cell coupled to the first work cell, the quick test cell operable to receive the assembled product and perform a test of basic functionality of the assembled product; and an extended test unit coupled to the assembly unit, the extended test unit operable to receive the assembled product from the assembly unit and perform a quality test of the assembled product; and the at least one of a quick test cell and an extended test unit operable to provide information about failure of the respective test to the first work cell.

Claim 39

Dependent Claim 228 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray; at least one of: a quick test cell coupled to the first work cell, the quick test cell operable to receive the assembled product and perform a test of basic functionality of the assembled product; and an extended test unit coupled to the assembly unit, the extended test unit operable to receive the assembled product from the assembly unit and perform a quality test of the assembled product; and the at least one of a quick test cell and an extended test unit operable to provide information about failure of the respective test to the first work cell.

Claim 40

Dependent Claim 25 words

The build-to-order product assembly system of claim 34 wherein the information is used by the first work cell during a subsequent assembly of a product.

Claim 41

Dependent Claim 23 words

The build-to-order product assembly system of claim 34 wherein the information is used by the first work cell to repair the assembled product.

Claim 42

Dependent Claim 55 words

The build-to-order product assembly system of claim 34 further comprising a repair unit operable to receive an assembled product that fails a test in the at least one of a quick test cell and an extended test unit, and operable to provide additional information about failure of the respective test to the first work cell.

Claim 43

Dependent Claim 32 words

The build-to-order product assembly system of claim 34 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

Claim 44

Dependent Claim 267 words

A build-to-order product assembly system comprising: a kitting unit receiving a first list of product components and a second list of product components, the kitting unit including: a plurality of kit trays; a plurality of stored product components; a first product component list display device, the first product component list display device displaying the first list of product components so that a first kit tray with product components pulled from the stored product components and according to the first product component list display device can be prepared; and a second product component list display device, the second product component list display device displaying the second list of product components so that a second kit tray with product components pulled from the stored product components and according to the second product component list display device can be prepared; the product components of the first prepared kit tray having at least one difference with the product components of the second prepared kit tray; and an assembly unit coupled to the kitting unit, the assembly unit operable to receive the first and the second prepared kit trays from the kitting unit, the assembly unit having a work cell including a work space for assembly of a product using the product components from one of the first and second prepared kit trays, assembly beginning when all of the components for the product are in the one of the first and second prepared kit tray, wherein all of the assembly of the product using the product components from one of the first and second prepared kit trays occurs in the assembly unit.

Claim 45

Dependent Claim 267 words

A build-to-order product assembly system comprising: a kitting unit receiving a first list of product components and a second list of product components, the kitting unit including: a plurality of kit trays; a plurality of stored product components; a first product component list display device, the first product component list display device displaying the first list of product components so that a first kit tray with product components pulled from the stored product components and according to the first product component list display device can be prepared; and a second product component list display device, the second product component list display device displaying the second list of product components so that a second kit tray with product components pulled from the stored product components and according to the second product component list display device can be prepared; the product components of the first prepared kit tray having at least one difference with the product components of the second prepared kit tray; and an assembly unit coupled to the kitting unit, the assembly unit operable to receive the first and the second prepared kit trays from the kitting unit, the assembly unit having a work cell including a work space for assembly of a product using the product components from one of the first and second prepared kit trays, assembly beginning when all of the components for the product are in the one of the first and second prepared kit tray, wherein all of the assembly of the product using the product components from one of the first and second prepared kit trays occurs in the assembly unit.

Claim 46

Dependent Claim 32 words

The build-to-order product assembly system of claim 39 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

Claim 47

Dependent Claim 101 words

The build-to-order product assembly system of claim 40 further comprising: a chassis preparation unit receiving the first list of product components, the chassis preparation unit including: a plurality of chassis components; and a chassis preparation work space in which a chassis is prepared for a computer system according to the first list of product components; and a joining area coupled to the kitting unit and to the chassis preparation unit, the joining area receiving a prepared chassis and the first prepared kit tray, the prepared chassis being added to the first prepared kit tray before being sent to the assembly unit.

Claim 48

Dependent Claim 28 words

The build-to-order product assembly system of claim 39 wherein the first product component list display device and the second product component list display device are the same device.

Claim 49

Dependent Claim 105 words

The build-to-order product assembly system of claim 39 further comprising at least one of: a quick test cell coupled to the work cell, the quick test cell operable to receive the assembled product and perform a test of basic functionality of the assembled product; and an extended test unit coupled to the assembly unit, the extended test unit operable to receive the assembled product from the assembly unit and perform a quality test of the assembled product; the at least one of a quick test cell and an extended test unit operable to provide information about failure of the respective test to the work cell.

Claim 50

Dependent Claim 158 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray, the assembly occurring in an order and with a number of steps reducing damage to the product components.

Claim 51

Dependent Claim 158 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray, the assembly occurring in an order and with a number of steps reducing damage to the product components.

Claim 52

Dependent Claim 52 words

The build-to-order product assembly system of claim 44 wherein the first work cell includes an electronic work instruction display operable to receive information about the product to be assembled and to display instructions about the product to be assembled, the instructions including assembly steps ordered to reduce damage to the product components.

Claim 53

Dependent Claim 27 words

The build-to-order product assembly system of claim 44 wherein damage to product components is reduced by reducing the number of times components are touched by an operator.

Claim 54

Dependent Claim 32 words

The build-to-order product assembly system of claim 44 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor.

Claim 55

Dependent Claim 162 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays, at least one of the kit trays including a plurality of component retaining features, the component retaining features operable to reduce impact to product components stored therein from kitting tray movement; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray.

Claim 56

Dependent Claim 162 words

A build-to-order product assembly system comprising: a kitting unit receiving a list of product components, the kitting unit including: a plurality of coded kit trays, at least one of the kit trays including a plurality of component retaining features, the component retaining features operable to reduce impact to product components stored therein from kitting tray movement; a plurality of stored product components; and a product component list display device including a pick-to-lights system actuated by the coded kit trays, the product component list display device displaying the list of product components so that a kit tray with product components pulled from the stored product components and according to the product component list display device can be prepared; and an assembly unit coupled to the kitting unit and receiving the prepared kit tray from the kitting unit, the assembly unit having a first work cell including a work space for assembly of a product using the product components from the prepared kit tray.

Claim 57

Dependent Claim 59 words

The build-to-order product assembly system of claim 48 wherein the assembled product is a computer system including a chassis, a processor supported by the chassis, and a memory coupled to the processor, the plurality of component retaining features of the at least one of the kit trays providing greater protection than the chassis for at least one product component.

Claim 58

Dependent Claim 24 words

The build-to-order product assembly system of claim 48 wherein at least one of the plurality of component retaining features includes a mechanically insulating material.

Claim 59

Dependent Claim 15 words

The build-to-order product assembly system of claim 50 wherein the mechanically insulating material is foam.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-05-21	2004-11-20	2005-05-22	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-05-21	2008-11-20	2009-05-22	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-05-21	2012-11-20	2013-05-22	$7700.00	Window Closed / Lapsed

Manufacturing system and method for assembly of computer systems in a build-to-order environment

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