When an operator puts the last part in an instrument panel (IP) module at a factory near Chrysler's Belvidere, Ill., auto assembly plant, he does more than complete the manufacturing process. He also starts that module on a completely automated journey from the manufacturing line to the auto assembly line. Learn more about Chrysler's auto assembly process.

“That operator is the last human to touch the IP until it's been installed in one of our cars and someone is actually testing it,” says Steven Brostek, Chrysler's director of production control operations.  “It's our prototype for lights-out manufacturing.”

The idea behind lights-out manufacturing is to create a manufacturing and assembly process that is so automated, it could be run in the dark without human intervention. “If you're going to do lights-out manufacturing,” Brostek adds, “it's expected that lights out delivery of parts to the line will be involved as well.”

In this instance, the process for lights-out materials handling begins when Chrysler sends an electronic signal to the IP manufacturer that a specific vehicle has left the paint line and will require an instrument panel within a few hours.

The supplier manufactures the instrument panel for that specific vehicle and loads it on a pallet. The pallet carrying the finished module travels by conveyor (1) to an automated storage and retrieval system (AS/RS) (2), where it is putaway. When it's time to deliver the module to Chrysler, the AS/RS automatically sequences the IP, along with others for that delivery, in the reverse order that they'll be needed at the plant. Conveyor (3) delivers the pallet to an automatic insertion system (4) loads the pallets (5) onto the truck (6).

At Chrysler's plant (7), the instrument panels are unloaded in sequence by a robotic arm (8) onto an AGV (9). That vehicle delivers the module to the assembly line workstation (10) where another robot (8) will unload the pallet from the AGV (9). The operator (11) will use an ergonomic assist device to install the module into the vehicle, where it will finally be attached.

“That operator working the ergonomic arm is the first operator to see the IP since it came off our supplier's manufacturing line,” says Brostek. “We really consider this to be the materials handling of tomorrow.”