Systems and methods for identifying and alerting of footprint over-cycle risks on multi-product general assembly lines

Abstract

A system includes a module configured to, for each footprint of a conveyor, identify vehicle groups having different vehicle characteristics and over-cycle distributions for each vehicle group or a back-to-back sequence of any given vehicle group by calculating, for each vehicle characteristic, over-cycle distributions for a first vehicle group having the vehicle characteristic and a second vehicle group not having the vehicle characteristic, determining whether either the number of vehicles in the first or second vehicle group or a difference between the over-cycle distributions for the first and second vehicle groups satisfies a threshold condition, and in response, cease identifying the vehicle groups. The module is configured to identify, for a received actual vehicle sequence, over-cycle risks based on the identified vehicle groups and the over-cycle distributions for each vehicle group or a back-to-back sequence of any given vehicle group. Other examples systems and methods are also disclosed.