Dynamic buffer for conveyor modules

Abstract

A method of operating an automotive production line including the steps of advancing a plurality of self-propelled carriages along a conveyor of the production line. The carriages are continuously advanced at a fixed operational speed and a fixed operational pitch to obtain a fixed processing time at a plurality of work stations along the production line. Any one of the carriages are stopped when a reduced pitch is obtained due to a stoppage of the immediately preceding carriage. The reduced pitch is less than the operational pitch and is preferably the minimum pitch available between the carriages. Stopped carriages are restarted when the reduced pitch returns to the operational pitch due to the restarting of the immediately preceding carriage. Production losses are reduced by continuing operations upstream of a stoppage to form a dynamic online buffer upstream of the stoppage. Production losses are further reduced when the dynamic online buffer is utilized to prevent the formation of a gap due to a subsequent stoppage located upstream of the dynamic online buffer. Production losses are even further reduced when previously existing gaps located upstream of the stoppage are closed as a result of continuing operations upstream of the stoppage.