Summarizes results of a five-year, multi-disciplinary, university-industry collaborative effort investigating design issues in agile manufacturing. The focus of the project is specifically on light mechanical assembly, with the demand that new assembly tasks be implementable quickly, economically, and effectively. Key to achieving these goals is the ease of equipment and software reuse. Design choices for both hardware and software must strike a balance between the inflexibility of special-purpose designs and the impracticality of overly general designs. We review both our physical and software design choices and make recommendations for the design of agile manufacturing systems.

In support of rapid-response manufacturing, we propose a new technique for automated design and fabrication of fixture and gripper tooling for mechanical assembly. Our technique uses geometric computations on CAD part descriptions to derive form and frictional form closure tooling. In addition, we invoke rapid prototyping technology to fabricate the computed tooling directly from the derived CAD descriptions. This paper introduces the concepts of our approach to automatic tooling generation, illustrates initial results, and surveys the additional work to be done to further exploit the technique.

The flexibility required of an agile manufacturing system must be achieved largely through computer software. The system's control software must be adaptable to new products and to new system components without becoming unreliable or difficult to maintain. This requires designing the software specifically to facilitate future changes. As part of the Agile Manufacturing Project at Case Western Reserve University, we have developed a software architecture for control of an agile manufacturing workcell, and we have demonstrated its flexibility with rapid changeover and introduction of new products. In this paper, we describe the requirements for agile manufacturing software and how our software architecture addresses them.

An agile workcell has been developed for light mechanical assembly in collaboration with industrial sponsors. The workcell includes multiple Adept robots, a Bosch conveyor system, multiple flexible parts feeders at each robot's workstation, CCD cameras for parts feeding and hardware registration, and a dual VMEbus control system. Our flexible pairs feeder design uses multiple conveyors to singulate the parts and machine vision to locate them. Specialized hardware is encapsulated on modular grippers and modular worktables which can be quickly interchanged for assembly of different products. Object-oriented software (C++) running under VxWorks, a real-time operating system, is used for workcell control. An agile software architecture was developed for rapid introduction of new assemblies through code re-use. A simulation of the workcell was developed so that controller software could be written and tested off-line, enabling the rapid introduction of new products.

This paper introduces a design for agile manufacturing workcells intended for light mechanical assembly of products made from similar components (i.e. parts families). We define agile manufacturing as the ability to accomplish rapid changeover from the assembly of one product to the assembly of another product. Rapid hardware changeover is made possible through the use of robots, flexible part feeders, modular grippers and modular assembly hardware. The flexible feeders rely on belt feeding and binary computer vision for Dose estimation. This has a distinct advantage over non-flexible feeding schemes such as bowl feeders which require considerable adjustment to changeover from one part to another. Rapid software changeover is being facilitated by the use of a real-time, object-oriented software environment, modular software, graphical simulations for off-line software development, and an innovative dual VMEbus controller architecture. These agile features permit new products to be introduced with minimal downtime and system reconfiguration.