Disclosed herein is a method of controlling an assembly line, comprising
the steps of providing an article assembly line; designating, on the
assembly line, an upstream processing station and a downstream processing
station; delivering a first article to the upstream processing station;
monitoring an upstream processing function on the first article within
the upstream processing station; and if, the upstream processing function
in the upstream processing station on a first article is not complete;
issuing a signal to an operator in the upstream processing station that
the upstream processing function on the first article is not complete;
extending the length of the upstream processing station to allow the
upstream operator more time to complete the upstream processing function;
monitoring the upstream processing function in the extended upstream
processing station; and if the upstream processing function on the first
article is still not complete; associating a label with the first article
in the over travel processing station for downstream remedial attention;
advancing the first article downstream from the extended upstream
processing station; advancing a second article to the upstream processing
station for the upstream processing function; and if the upstream
processing function on the first article is complete; advancing the first
article downstream from the extended upstream processing station;
advancing a second article to the upstream processing station for the
upstream processing function.