Verification methods and systems for use in computer directed assembly and manufacture

Abstract

Verification methods, systems, and computer program products verify the completion of assembly instructions used in light-manufacturing. Using position guides in a user interface, an in-use component is aligned and ready for verification through a first set of images of the in-use component. A visual highlight area on the user interface overlaying the in-use component indicates where to perform the assembly instructions. To create a traceable record, a second set of images are stored in an assembly record database when the assembler points a wand where the in-use component has been assembled. Another verification approach includes pointing an image capture device over the in-use component and receiving a first voice command authorizing image acquisition. A second voice command confirms accuracy of the image and proper assembly. Storing first and second voice commands and images of the in-use component being assembled in an assembly record database creates another traceable record useful for verification.

What is claimed is: 
     
         1 . A computer-implemented method of verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the method comprising:
 displaying position guides in a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;   processing a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;   displaying an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;   processing a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the component that the assembler indicates has been worked upon; and   storing the second set of one or more images of the component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.   
     
     
         2 . The method of  claim 1  wherein the assembler performs assembly instructions with the component placed on an assembly workstation. 
     
     
         3 . The method of  claim 1  wherein the assembler performs assembly instructions with the component located adjacent to the assembly workstation. 
     
     
         4 . The method of  claim 1  wherein the materials associated with the manufactured product are extracted directly from a Bill of Materials in an enterprise database system. 
     
     
         5 . The method of  claim 1  wherein the position guides appear on the user interface as a pair of cross-hairs positioned diagonally and separated by a distance corresponding to at least one dimension of the in-use component. 
     
     
         6 . The method of  claim 1  wherein the first set of one or more images are taken using an image capture device having a capture mode selected from a set including a single image mode and a video image mode. 
     
     
         7 . The method of  claim 1  wherein processing a second set of one or more images occurs upon receiving confirmation that the assembler has completed the assembly instructions associated with the operation as provided through the user interface. 
     
     
         8 . The method of  claim 1  further comprising associating a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates that the assembler did not place the tip of the wand in a visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database. 
     
     
         9 . A computer program product for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, tangibly stored on a computer readable medium, comprising instructions operable to cause a programmable processor to:
 display position guides in a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;   process a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;   display an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;   process a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the component that the assembler indicates has been worked upon; and   store the second set of one or more images of the component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.   
     
     
         10 . The computer program product of  claim 9  wherein the instructions that process the second set of one or more images occur upon receiving confirmation that the assembler has completed the assembly instructions associated with the operation as provided through the user interface. 
     
     
         11 . The computer program product of  claim 9  further comprising instructions, when executed, associate a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates the assembler did not place the tip of the wand in a visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database. 
     
     
         12 . An apparatus for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the apparatus comprising:
 a processor capable of executing instructions; and   a memory holding instructions that when executed by the processor cause the processor to:   display position guides on a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;   process a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;   display an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;   process a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the in-use component that the assembler indicates has been worked upon; and   store the second set of one or more images of the in-use component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.   
     
     
         13 . The apparatus of  claim 12  wherein the memory further comprises instructions, when executed, that associate a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates that the assembler did not place the tip of the wand in the visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database.