[0001] This application relates generally to factories, and more specifically, to systems and methods for controlling mechanical components in factories. BACKGROUND

[0002] In many existing factories, manufacturing lines are fixedly designed to make certain items. For example, a manufacturing line may be specifically designed to make a cell phone having component X. Such manufacturing line may run continuously to make multiple cell phones having components X, and may not be capable of selectively making different cell phones with different variations of components X (e.g., X1, X2, X3, etc.) that are different from each other.

[0003] Sometimes, a manufacturing line may be reconfigured to make different products. However, reconfiguring a manufacturing line is labor intensive, requires extensive planning, and may take a long time to implement. Also, reconfiguring a manufacturing line may require re-programming of robots.

[0004] In addition, sometimes a new manufacturing line may be set up in a factory to make a different product. However, it is very expansive to design and set up a manufacturing line. Also, an existing factory may not have the space and/or setup to accommodate a new manufacturing line.

[0005] For the foregoing reasons, factories generally want to take only big orders that would take up an entire manufacturing line, and it is generally costly to support small scale manufacturing.

[0006] Another problem with existing manufacturing lines is that they are mounted on floors in factories. As a result, vertical space above the manufacturing lines and ceiling space are not being used in factories.

[0007] Systems and methods for providing flexible and just-in-time manufacturing are described herein. Such systems and methods address one or more of the above problems, and can be scaled up and down conveniently. SUMMARY

[0008] A factory control system is configured for operating a factory having a transport line and a plurality of manufacturing stations, wherein one of the

manufacturing stations is configured to make a first product, wherein the transport line is configured to transport and deliver one or more physical components for the one of the manufacturing stations to make the first product, and wherein the one of the manufacturing stations is at a first elevation in the factory, the transport line is at a second elevation in the factory, the second elevation being different from the first elevation, the factory control system configured to obtain manufacturing information, wherein the factory control system comprises a transport control configured to generate first signal(s) based on the manufacturing information to operate a mechanical component in the transport line to deliver the one or more physical components for the one of the manufacturing stations to make the first product.

[0009] Optionally, the second elevation for the transport line is higher than the first elevation for the one of the manufacturing stations.

[0010] Optionally, the mechanical component in the transport line is configured to move along a path that traverses spatial regions above multiple ones of the

manufacturing stations.

[0011] Optionally, a path of the mechanical component in the transport line is configurable.

[0012] Optionally, the transport line comprises one or more rails for supporting the mechanical component at multiple locations in association with the respective manufacturing stations.

[0013] Optionally, the transport line comprises one or more mechanical arms configured to carry the one or more physical components.

[0014] Optionally, the mechanical component is moveably supported at least in part by one or more wall(s) and/or one or more column(s).

[0015] Optionally, the mechanical component is moveably supported at least in part by one or more beam(s).

[0016] Optionally, the first product is for a custom-order.

[0017] Optionally, the factory control system further includes a selector configured to select the one of the manufacturing stations for making the first product.

[0018] Optionally, the selector is configured to select the one of the manufacturing stations for making the first product based on a functional capability of the one of the manufacturing stations.

[0019] Optionally, the selector is configured to select the one of the manufacturing stations for making the first product based on a workload of the one of the

manufacturing stations. [0020] Optionally, the selector is configured to select an other one of the manufacturing stations for making a second product; and wherein the transport control is configured to generate second signal(s) to operate the mechanical component in the transport line to deliver one or more physical components to the other one of the manufacturing stations to make the second product.

[0021] Optionally, the selector is configured to select the one of the manufacturing stations for making a second product, the second product and the first product having different respective features; and wherein the transport control is configured to generate second signal(s) to operate the mechanical component in the transport line to deliver one or more physical components to the selected one of the manufacturing stations to make the second product.

[0022] Optionally, the factory control system further includes a database storing information regarding features of the respective manufacturing stations and/or constraints of the respective manufacturing stations; wherein the selector is

communicatively coupled to the database.

[0023] Optionally, the transport control is configured to generate the first signal(s) to operate the mechanical component in the transport line based on a layout of the factory.

[0024] Optionally, the factory control system further includes a non-transitory medium storing a map of the factory indicating the layout of the factory.

[0025] Optionally, an operation of the transport line is product-by-product based.

[0026] Optionally, the factory control system further includes a communication interface configured to receive an end user’s custom order.

[0027] Optionally, the factory control system further includes a factory real-time monitoring system configured to monitor a state of the transport line, and/or a state of the one of the manufacturing stations.

[0028] Optionally, the factory real-time monitoring system is also configured to monitor a progress of a making of the first product.

[0029] Optionally, the mechanical component is a drone, and the transport line comprises an aerial transport path; and wherein the factory control system is configured to provide air traffic control for the drone.

[0030] Optionally, the factory is divided into different zones for different respective customers, and the factory control system is configured to control one or more of the manufacturing stations, and/or the transport line, based on information regarding the different zones. [0031] Optionally, the factory comprises factory sensors, and the factory control system is configured to control one or more of the manufacturing stations, and/or the transport line, based on output from the factory sensors.

[0032] A method performed by a factory control system to operate a factory having a transport line and a plurality of manufacturing stations, includes: obtaining

manufacturing information by the factory control system; and generating first signal(s), by a transport control of the factory control system, based on the manufacturing information to operate a mechanical component in the transport line to deliver one or more physical components for one of the manufacturing stations to make the first product, wherein the one of the manufacturing stations is at a first elevation in the factory, the transport line is at a second elevation in the factory, the second elevation being different from the first elevation.

[0033] Optionally, the mechanical component in the transport line is operated to move along a path that traverses spatial regions above multiple ones of the

manufacturing stations.

[0034] Optionally, the method further includes configuring a path of the mechanical component in the transport line.

[0035] Optionally, the first product is for a custom-order.

[0036] Optionally, the method further includes selecting, by a selector of the factory control system, the one of the manufacturing stations for making the first product.

[0037] Optionally, the one of the manufacturing stations is selected for making the first product based on a functional capability of the one of the manufacturing stations.

[0038] Optionally, the one of the manufacturing stations is selected for making the first product based on a workload of the one of the manufacturing stations.

[0039] Optionally, the method further includes selecting an other one of the manufacturing stations for making a second product; and generating second signal(s) to operate the mechanical component in the transport line to deliver one or more physical components to the other one of the manufacturing stations to make the second product.

[0040] Optionally, the selected one of the manufacturing stations is also for making a second product, the second product and the first product having different respective features; and generating second signal(s) to operate the mechanical component in the transport line to deliver one or more physical components to the selected one of the manufacturing stations to make the second product. [0041] Optionally, the factory control system comprises a database storing information regarding features of the respective manufacturing stations and/or constraints of the respective manufacturing stations; and wherein the selector is communicatively coupled to the database.

[0042] Optionally, the first signal(s) is generated by the transport control of the factory control system based on the selected one of the manufacturing stations.

[0043] Optionally, the first signal(s) is generated by the transport control to operate the mechanical component in the transport line based on a layout of the factory.

[0044] Optionally, the factory control system comprises a non-transitory medium storing a map of the factory indicating the layout of the factory.

[0045] Optionally, the transport line is operated on a product-by-product basis.

[0046] Optionally, the method further includes receiving an end user’s custom order via a communication interface of the factory control system.

[0047] Optionally, the method further includes monitoring a state of the transport line, and/or a state of the one of the manufacturing stations, using a factory real-time monitoring system.

[0048] Optionally, the method further includes monitoring a progress of a making of the first product using a factory real-time monitoring system.

[0049] Optionally, the mechanical component is a drone, and the transport line comprises an aerial transport path; and wherein the first signal(s) is generated to provide air traffic control for the drone.

[0050] Optionally, the factory is divided into different zones for different respective customers, and wherein the method further comprises: obtaining information regarding the different zones; and controlling, by the factory control system, one or more of the manufacturing stations, and/or the transport line, based on the information regarding the different zones.

[0051] Optionally, the factory comprises factory sensors, and wherein the method further comprises: obtaining output from the factory sensors; and controlling, by the factory control system, one or more of the manufacturing stations, and/or the transport line, based on the output from the factory sensors.

[0052] Other and further aspects and features will be evident from reading the following detailed description of the embodiments. BRIEF DESCRIPTION OF THE DAWINGS

[0053] The drawings illustrate the design and utility of embodiments, in which similar elements are referred to by common reference numerals. These drawings are not necessarily drawn to scale. In order to better appreciate how the above-recited and other advantages and objects are obtained, a more particular description of the embodiments will be rendered, which are illustrated in the accompanying drawings. These drawings depict only typical embodiments and are not therefore to be considered limiting of its scope.

[0054] FIGS.1A-1F illustrate examples of a factory having manufacturing stations, a transport line, and a factory control system in accordance with some embodiments.

[0055] FIGS.2A-2B illustrate examples of a factory having manufacturing stations, transport lines, and a factory control system in accordance with some embodiments.

[0056] FIG.3A illustrates an example of a factory in which embodiments described herein may be implemented.

[0057] FIG.3B illustrates an example of a manufacturing line that includes multiple manufacturing stations with multiple machines.

[0058] FIG.3C illustrates an example of a building structure for a factory.

[0059] FIG.3D illustrates another example of a factory with multiple manufacturing stations, and transport lines implemented above the manufacturing stations.

[0060] FIG.4A illustrates an example of a transport line being supported by beams.

[0061] FIG.4B illustrates an example of a transport line being supported by a wall.

[0062] FIG.4C illustrates an example of a transport line being supported by columns.

[0063] FIG.5A illustrates an example of a mechanical component of a transport line.

[0064] FIG.5B illustrates the mechanical component of the transport line of FIG.5A being supported by beams.

[0065] FIG.5C illustrates the mechanical component of the transport line of FIG.5A being supported by a wall.

[0066] FIG.5D illustrates the mechanical component of the transport line of FIG.5A being supported by columns.

[0067] FIG.6 illustrates an example of a factory control system in accordance with some embodiments.

[0068] FIG.7A illustrates an example of a factory.

[0069] FIG.7B illustrates a factory control system for the factory environment of FIG.7A, particularly showing the factory control system integrating with other modules. [0070] FIG.7C illustrates a factory control system for the factory environment of FIG.7A, particularly showing the factory control system including with other modules.

[0071] FIG.8 illustrates a method performed by the factory control system of FIG.6.

[0072] FIG.9 illustrates an example of an implementation of the factory control system of FIG.6. DESCRIPTION OF THE EMBODIMENTS

[0073] Various embodiments are described hereinafter with reference to the figures. It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are represented by like reference numerals throughout the figures. It should also be noted that the figures are only intended to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention or as a limitation on the scope of the invention. In addition, an illustrated embodiment needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated.

[0074] FIG.1A illustrates an example of a factory 10 having manufacturing lines 20, a transport line 30, and a factory control system 40 in accordance with some

embodiments. The factory 10 may be any factory that is configured to manufacture one or more products. The product(s) may be any consumer products or components thereof. In some cases, the products may be mass-produced products having identical features, or alternatively, customized-products having one or more features that are different from others.

[0075] The manufacturing lines 20 comprise respective manufacturing stations 22 that are configured to perform manufacturing functions, such as assembling, combining, forming, fastening, gluing, shaping, drilling, bending, heating, cooling, strengthening, painting, printing, sanitizing, packaging, etc., to make products. For example, in each manufacturing station 22, there may include machine(s), such as robotic arm(s), drilling machine(s), molding machine(s), printing machine(s), shaper(s), sanitizer(s), heater(s), cooler(s), etc., or any combination of the foregoing, configured to perform one or more of the above functions. The transport line 30 is configured to transport physical components to and/or from the manufacturing stations 22.

[0076] In the illustrated example, there are three manufacturing lines 20 (20a-20c) with three respective manufacturing stations 22a-22c. In other embodiments, the factory 10 may have fewer than three manufacturing lines 20, or more than three manufacturing lines 20. Also, in other embodiments, the factory 10 may have fewer than three manufacturing stations 22, or more than three manufacturing stations 22. In some embodiments, a manufacturing line 20 may have multiple manufacturing stations 22.

[0077] In the illustrated example, the manufacturing stations 22 are supported on a floor of the factory 10, and the transport line 30 is supported at an elevation that is higher than that of the manufacturing stations 22. This configuration is advantageous in that the transport line 30 may transport physical components without being interfered by the manufacturing stations 22. In other embodiments, the transport line 30 may be supported on a floor of the factory 10, and the manufacturing stations 22 may be supported at an elevation that is higher than that of the transport line 30. In further embodiments, the manufacturing stations 22 may be supported at different elevations with respect to each other. Also, in other embodiments, an equipment at a

manufacturing station 22 may have an elevation that is adjustable, and/or an equipment at the transport line 30 may have an elevation that is adjustable. As used in this specification, the term“elevation” may refer to a single elevation, or to an elevation range (having multiple elevations).

[0078] In some embodiments, any of the manufacturing lines 20 may include machine(s) configured to transport physical components. By means of non-limiting examples, the machine(s) may include robotic arms, grippers, conveyers, clamps, holders, gears, rollers, belts, or any combination of the foregoing. Thus, as used in this specification, the term“manufacturing line” should not be limited to a operational line in a factory that performs manufacturing function(s), and may be a transport line

configured to transport physical components. Similarly, the transport line 30 may include machine(s) configured to perform assembling, combining, fastening, gluing, shaping, drilling, bending, etc., to make products. Accordingly, the term“transport line” may refer to an operational line that performs other functions such as manufacturing function(s), in addition to transport functions. Furthermore, as used in this specification, the term“product” is not limited to an item that is completely made, and may refer to an item that is partially made. Thus, the term“product” may refer to a component, a portion, or a part of a final product to be made, or may refer to a final product.

[0079] As shown in FIG.1A, the transport line 30 intersects multiple ones of the manufacturing lines 20. This configuration is advantageous in that it allows the transport line 30 to be selectively configured to deliver components to different ones of the manufacturing lines 20. In the illustrated example, each manufacturing line 20 has conveying mechanism, such as conveyer belt, transporter, etc., that moves

components along the manufacturing line 20. In one implementation, the conveying mechanism may be a moving mechanism that is coupled to, or that is a part of a manufacturing station 22. In one example of use, a mechanical component 32 at the transport line 30 may be controlled to selectively deliver component(s) to the

manufacturing line 20a by moving the machine to position 50a, to the manufacturing line 20b by moving the machine to position 50b, or to the manufacturing line 20c by moving the machine to position 50c.

[0080] In the illustrated embodiments, operation of the manufacturing stations 22 and/or the transport line 30 may be controlled by the factory control system 40. The factory control system 40 is communicatively coupled to the manufacturing stations 22 and the transport line 30. In some embodiments, the factory control system 40 allows the manufacturing stations 22 and/or the transport line 30 to be selectively configured (e.g., programmed, controlled, operated, etc.) so that the transport line 30 can deliver different components to different ones of the manufacturing stations 22 to make different products. The factory control system 40 will be described in further detail.

[0081] In the above embodiments, the transport line 30 is illustrated as having rectilinear configuration, such that the mechanical component 32 at the transport line 30 moves along a rectilinear path. In other embodiments, at least a part of the transport line 30 may have a curvilinear configuration (FIG.1B), such that the mechanical component 32 at the transport line 30 can move along a curvilinear path.

[0082] Also, in the above embodiments, the transport line 30 is illustrated as having free ends. In other embodiments, the transport line 30 may have a loop configuration (FIG.1C). In such cases, the mechanical component 32 at the transport line 30 may move along a loop path.

[0083] In further embodiments, the transport line 30 may have more than two free ends, and may include intersection 80 from which branches of the transport line 30 extend (FIG.1D).

[0084] In other embodiments, the mechanical component 32 at the transport line 30 may be configured to deliver component(s) directly to one or more manufacturing stations 22. For example, as shown in FIG.1E, the mechanical component 32 at the transport line 30 may deliver component(s) to location 50a where the manufacturing station 22a can receive the component(s), to location 50b where manufacturing line 20b can receive the component(s) for transport to the manufacturing station 22b, or to location 50c where the manufacturing station 22c can receive the component(s).

[0085] In any of the embodiments described herein, instead of having only one mechanical component 32 the transport line 30, the transport line may include multiple mechanical components 32 (FIG.1F). In some embodiments, the factory 10 may have respective mechanical components 32 dedicated to service respective ones of the manufacturing stations 22. In other embodiments, the mechanical components 32 may be selectively configured so that they can selectively service different manufacturing stations 22. As shown in the illustrated example, there are two mechanical components 32 at the transport line. Each mechanical component 32 can be selectively driven to any of the manufacturing stations 22a-22c, to an inventory station 82 (where

components may be picked up and/or dropped off), or to a docking or servicing station 84.

[0086] In some embodiments, the mechanical component 32 at the transport line 30 may be configured to deliver component(s) to manufacturing station(s) 22, but does not pick up finished product(s) from the manufacturing station(s) 22. For example, the mechanical component 32 may be configured to pick up component(s) from an inventory station, and deliver the component(s) to the manufacturing station(s) 22 or manufacturing line(s) 20. In other embodiments, the mechanical component 32 at the transport line 30 may be configured to deliver component(s) to manufacturing station(s) 22, and to pick up finished product(s) from the manufacturing station(s) 22. For example, the mechanical component 32 at the transport line 30 may be configured to pick up a finished product from manufacturing station 22a, and deliver it to

manufacturing station 22b for additional processing.

[0087] In the above embodiments, the factory 10 is described as having one transport line 30. In other embodiments, the factory 10 may include multiple transport lines 30. FIG.2A illustrates another example of a factory 10 having manufacturing stations 22, transport lines 30, and a factory control system 40 in accordance with some embodiments. The mechanical components 32a, 32b in the transport lines 30a, 30b can deliver component(s) to and/or from manufacturing station(s) 22 and/or

manufacturing line(s) 20.

[0088] Also, in some embodiments, the transport lines 30a, 30b may be connected to each other via a connecting segment 200 (FIG.2B). This allows the mechanical component 32a at the transport line 30a to be selectively driven to the transport line 30b via the connecting segment 200. In some embodiments, the connecting segment 200 may be considered as a part of the transport line 30a and/or transport line 30b. Thus, as used in this specification, the term“transport line” may refer to a segment or a part of an entire path along which a mechanical component (e.g., machine, device, apparatus, etc.) may move, or may refer to the entire path.

[0089] In the above embodiments, the manufacturing lines 20 and the manufacturing stations 22 are schematically illustrated in block diagrams. It should be appreciated that an actual factory environment may include many different types of manufacturing lines 20 and/or manufacturing stations 22. FIG.3A illustrates an example of a factory 10 in which embodiments described herein may be implemented. For example, one or more transport lines 30 with mechanical component(s) 32 described previously may be supported above the manufacturing stations shown in the figure, and may move across the spaces above the manufacturing stations. FIG.3B illustrates an example of a manufacturing line 20 that includes multiple manufacturing stations 22 with multiple machines. mechanical component(s) 32 at transport line(s) 30 described previously may move across space at elevation that is higher than the manufacturing stations 22 to deliver components directly to the manufacturing stations 22 or to the manufacturing line 20. FIG.3C illustrates an example of a building structure for the factory 10. The mechanical component(s) 32 at the transport line(s) 30 described herein may be supported by column(s) 340, beam(s) 350, wall(s) 360, or any combination of the foregoing. FIG.3D illustrates another example of the factory 10 with multiple

manufacturing stations 22. As shown in the figure, multiple transport lines 30 are implemented above the manufacturing stations 22. The transport lines 30 are supported at least partially by beams at the factory 10. The transport lines 30 form a network overhanging the manufacturing stations 22, so that the transport lines 30 are at elevation(s) that is different from the manufacturing stations 22. This allows one or more mechanical components of transport lines 30 to move to different manufacturing stations 22 to move product components to and/or from the manufacturing stations 22. In some embodiments, the transport lines 30 may be arranged to form a grid or a network, which allows one or more mechanical components to be selectively moved to different locations in the factory 10 through spatial region that is higher in elevation than the manufacturing stations 22.

[0090] As discussed, in some embodiments, the transport line 30 may be supported by beam(s) at the factory 10. FIG.4A illustrates an example of a transport line 30 being supported by beams 400a, 400b. The beams 400a, 400b may be original structural members of the factory 10, or alternatively, may be retrofitted members that are added to the factory 10 for supporting the transport line 30. In the illustrated example, the transport line 30 includes rail 402 that defines a path of the mechanical component 32 at the transport line 30. The rail 402 may be mechanically secured to the beams 400a, 400b via connections 410. The transport line 30 also includes a mechanical component 32 configured to move along the rail 402. The mechanical component 32 is illustrated as a mechanical arm in the example. In other

embodiments, the mechanical component 32 may be of other types, and may have different configurations. For example, in other embodiments, the mechanical component 32 may simply be one or more grippers that are configured to grip components to be delivered to manufacturing station(s) 22. The mechanical

component 32 is configured to move along the rail 402. In some embodiments, the mechanical component 32 may include wheels, rollers, bearings, etc., configured to moveably support the mechanical component 32 along the rail 402. Alternatively, the mechanical component 32 may be moveably coupled to the rail 402 using a frictionless mechanism, such as a magnetic (e.g., electromagnetic) device that spaces the mechanical component 32 at a distance away from the rail 402. Also, in some embodiments, the rail 402 may include chains, cables, ropes, pulleys, etc. that are configured pull the mechanical component 32 to move along a path of the rail 402. Alternatively, the mechanical component 32 itself may include a motor for actuating the mechanical component 32 to move along a path of the rail 402.

[0091] In other embodiments, the rail 402 of the transport line 30 may be supported by a wall 450 of the factory 10 (FIG.4B). The rail 402 may be mechanically secured to the wall 450 via connections 452. The wall 450 may be an original structural member of the factory 10, or alternatively, may be a retrofitted member that is added to the factory 10 for supporting the transport line 30.

[0092] In further embodiments, the rail 402 of the transport line 30 may be supported by columns 470a, 470b of the factory 10 (FIG.4C). The rail 402 may be mechanically secured to the columns 470a, 470b via connections 472. The columns 470a, 470b may be original structural members of the factory 10, or alternatively, may be retrofitted members that are added to the factory 10 for supporting the transport line 30.

[0093] In the above embodiments, the transport line 30 is described as having a rail. In other embodiments, the transport line 30 may include multiple rails configured to support the mechanical component 32 at different sides of the mechanical component 32. Also, in other embodiments, the transport line 30 may not include any rail. For example, as shown in FIG.5A, the transport line 30 may include a mechanical component 32 that is fixedly secured to a location in the factory 10. In such cases, the mechanical component 32 may include a first arm 502, and a second arm 504 that is moveably coupled to the first arm 502 via a joint 506. Such configuration allows the mechanical component 32 to selectively deliver component 510 to location 50a, location 50b, or to location 50c for the respective manufacturing stations 22a, 22b, 22c. Thus, as used in this specification, the term“transport line” is not limited to a physical structure that guides the mechanical component 32, and may alternatively refer to a set of possible operative locations for the mechanical component 32 to deliver components. The mechanical component 32 of FIG.5A may be supported by a wall 450 of the factory 10 (FIG.5B), a column 470 of the factory 10 (FIG.5C), or a beam 400 of the factory 10 (FIG.5D), at an elevation that is different from the manufacturing stations.

[0094] In other embodiments, the mechanical component 30 may include other types of mechanical arm(s) or positioners, including those that can translate a product component in different directions (e.g., X, Y, Z directions) and/or rotate product component about different axes (e.g., X, Y, Z axes).

[0095] FIG.6 illustrates an example of the factory control system 40 in accordance with some embodiments. The factory control system 40 includes a transport control 408 configured to generate first signal(s) to operate a mechanical component in the transport line 30 to deliver one or more physical components for a selected one of the manufacturing stations 22 to make a product. For example, the first signal(s) may cause the mechanical component in the transport line 30 to deliver physical

component(s) to a selected one of the manufacturing line 20 or to a selected

manufacturing station 22.

[0096] The factory control system 40 also includes a selector 410 configured to select one of the manufacturing stations 22 for making the product. In some

embodiments, the selector 410 may be configured to select one of the manufacturing stations 22 for making a product based on one or more criteria. By means of non- limiting examples, the one or more criteria may be a functional capability of one of the manufacturing stations 22, workloads of the respective manufacturing stations 22, capabilities of the transport line 30, geometrical constraint(s) in the factory 10, or any combination of the foregoing. For example, if a manufacturing station 22 does not have the functional capability to make a product (e.g., because the manufacturing station 22 does not have a machine that can create a desired characteristic for the product), then the selector 410 may select another manufacturing station 22 that has the functional capability to make a product. Geometrical constraint(s) in the factory 10 may be an obstacle, a layout conflict, a spatial constraint, which may prevent the transport line 30 from delivering component(s) to a manufacturing station 22 or to a manufacturing line 20 (e.g., because an obstacle is in the way, and/or because the transport line 30 does not reach a certain manufacturing line 20 or manufacturing station 22), and/or which may prevent the robotic line 20 from making a product (e.g., because the product may not fit in an operational space for the manufacturing station 22). In one implementation, if there are multiple manufacturing stations 22 that can make the same product, and if they are not limited by any geometrical constraint in the factory 10, the selector 410 may be configured to select one of the manufacturing stations 22 that has the lowest workload.

[0097] After the selector 410 has selected a manufacturing station 22 for making a certain product, the transport control 408 of the factory control system 400 then generates signal(s) (e.g., first signal(s)) to operate a mechanical component in the transport line 30 to deliver one or more physical components for the selected

manufacturing station 22. Thus, the operation of the mechanical component in the transport line 30 may be based on the selected manufacturing station 22. In one implementation, the transport control 408 may operate the mechanical component in the transport line 30 based (directly or indirectly) on output from the selector 410, wherein the output from the selector 410 indicates, or is associated with, a selected one of the manufacturing station 22. In some cases, the transport control 408 may be configured to operate the mechanical component in the transport line 30 based also on a layout of the factory 10, so that obstacles and/or conflicts with other machines can be avoided.

[0098] In some embodiments, after the selector 410 has selected a manufacturing station 22 to make a product (e.g., first product), the selector 410 may be configured to select another manufacturing station 22 for making another product (e.g., a second product). The second product may be identical in configuration as the first product. Alternatively, the second product may be different from the first product (i.e., the first and second products made by different manufacturing stations 22 may have different respective features). In some embodiments, the transport control 408 is configured to generate first signal(s) to operate a mechanical component in the transport line 30 to deliver one or more physical components for one of the manufacturing stations 22 to make a first product, and to generate second signal(s) to operate the mechanical component in the transport line 30 (or in another transport line 30) to deliver one or more physical components to another one of the manufacturing stations 22 to make a second product.

[0099] In other embodiments, the same manufacturing station 22 may have the ability to make different products with different features. In such cases, the selector 410 may select the same manufacturing station 22 for making both the first and the second products with different respective features.

[0100] As shown in FIG.6, the factory control system 400 further includes a database 430 storing information regarding features and/or constraints of the manufacturing station(s) 22, and/or the transport line(s) 30. The database 430 may be one or more non-transitory media, located in the factory 10, or remote from the factory 10. The selector 410 is communicatively coupled to the database 430, so that the selector 410 can select manufacturing station(s) 22 and/or the transport line 30 based on the information (e.g., information regarding features and constraints of

manufacturing station(s) 22, and/or the transport line(s) 30) in the database 430. The data base 430 may also store information regarding customers’ manufacturing requests. By means of non-limiting examples, information regarding customers’ manufacturing requests may include size of a product, shape of a product, color of a product, functionality of a product, a printed material for a product, delivery time for a product, etc., or any combination of the foregoing. In such cases, the selector 410 can select manufacturing station(s) 22 and/or the transport line 30 based on the information regarding the customers’ manufacturing requests (as well as features and/or constraints of the manufacturing station(s) 22, and/or the transport line(s) 30) stored in the database 430. Additionally or alternatively, the database 430 of the factory control system 400 may include a non-transitory medium storing a map of the factory 10 indicating a layout of the factory 10. The map may indicate where the manufacturing stations 22 are located, where product parts are stored, delivery destination of completed products in the factory, and physical constraints (e.g., columns, walls, beams, etc.) in the factory. This allows the selector 410 and the transport control 408 to perform their functions based on the layout of the factory 10.

[0101] In some embodiments, the database 430 may store information regarding manufacturing stations 22 using data structure that associates identifiers of

manufacturing stations 22 with respective features associated with the manufacturing stations 22, such as capabilities (e.g., functionalities, speed, etc.) of the manufacturing stations 22, constraints of the manufacturing stations 22, workloads of the

manufacturing stations 22, schedules of the manufacturing stations 22, etc., or any combination of the foregoing. Also, the database 430 may store information regarding customers’ orders using data structure that associates customers’ identifiers with features associated with their orders. By means of non-limiting examples, the features associated with the orders may be products identifiers, product types, product quantities, product characteristics (e.g., required components), order times, requested completion dates, etc., or any combination of the foregoing. Furthermore, the database 430 may store information regarding the transport lines 30 using data structure that associates identifiers of the transport lines 30 with respective features associated with the transport lines 30. By means of non-limiting examples, the features associated with the transport lines 30 may be capabilities (functionalities, speed, etc.) of the transport lines 30, constraints of the transport lines 30, workloads of the transport lines 30, schedules of the transport lines 30, etc., or any combination of the foregoing. In some embodiments, the transport control 408 and the selector 410 of the factory control system 40 may be specifically configured (e.g., designed, programmed, etc.) to process data received from the database 430 based on the data structures described above.

[0102] As shown in the figure, the factory control system 40 further includes a communication interface 440 configured to receive a custom order. In some

embodiments, the communication interface 440 may be a network interface configured to receive signals from a user’s device. In some cases, the network interface may be a connector configured to couple to the user’s device via a cable. Alternatively, the network interface may be a wireless transceiver configured to communicatively couple to the user’s device wirelessly. In further embodiments, the communication interface 440 may be an input of a processing unit. In still further embodiments, the

communication interface 440 may be an application configured to provide a graphical user interface (e.g., for display on the user’s device), which allows the user to provide input via the user’s device.

[0103] The user’s device that communicates with the communication interface 440 of the factory control system 40 may be an administrator’s device (e.g., a computer, a handheld device such as a cell phone or a tablet, etc.). In such cases, the

administrator of the factory control system 40 may provide input for the factory control system 40 via the communication interface 440 based on manufacturing requests received by customers. By means of non-limiting examples, the input from the administrator may be a selection of certain manufacturing station(s) 22, selection of a transport line 30, path of a transport line, selection of components to be delivered by a transport line 30, timing of operation by the transport line 30, timing of operation by the manufacturing station(s) 22, or any combination of the foregoing.

[0104] Alternatively, any of the above parameters may be automatically determined by the factory control system 40. In such cases, the input from the administrator may be simply a confirmation of the above parameters. For example, the input from the administrator may be a confirmation of a selection of certain manufacturing station(s) 22, a confirmation of selection of a transport line 30, a confirmation of path of a transport line, a confirmation of selection of components to be delivered by a transport line 30, a confirmation of timing of operation by the transport line 30, a confirmation of timing of operation by the manufacturing station(s) 22, or any combination of the foregoing.

[0105] In other embodiments, the user’s device that communicates with the communication interface 440 of the factory control system 40 may be a customer’s device. In such cases, customers may provide manufacturing requests (including desired manufacturing features, specs, etc.) to the factory control system 40 via the communication interface 440, and the factory control system 40 will automatically (e.g., without requiring input from an administrator of the factory control system 40) operate the factory based on the requests to manufacture the requested items.

[0106] In further embodiments, the communication interface 440 of the factory control system 40 may be configured to communicate both with customers and with the administrator of the factory control system 40. For example, different customers may registers with the factory control system 40 (e.g., using respective login names and passwords), and may send manufacturing requests to the factory control system 40 via the communication interface. The factory control system 40 and/or the administrator of the factory control system 40 may then determine which manufacturing station(s) to operate to fulfill the manufacturing requests, and which transport line and/or which transport path to implement to deliver components for the selected manufacturing station(s).

[0107] As shown in FIG.6, the factory control system 40 further includes a factory real-time monitoring system 450 configured to monitor a state of the transport line(s) 30, and/or a state of the manufacturing line(s) 20. In some cases, the factory real-time monitoring system 450 may also be configured to monitor product(s)-making progress. For example, one or more sensors at a manufacturing station 22 in a manufacturing line 22, or at transport line 30, may be configured to sense state(s) of the machine, and may provide information regarding the sensed state(s) to the factory control system 40. Alternatively, or additionally, the factory 10 may include one or more cameras viewing the manufacturing line(s) 20 and/or the transport line(s) 30. In such cases, the camera(s) may be configured to provide image(s) or video(s) of the condition of the factory 10 to the factory real-time monitoring system 450.

[0108] As illustrated in the above embodiments, the factory control system 40 and the transport line(s) 30 are advantageous because they optimize or at least improve factory usage, both in the spatial sense and operational sense. In particular, because the transport line(s) 30 are at different elevation(s) from that of the manufacturing stations 22, movement of physical components at the transport line(s) 30 will not be interfered by the manufacturing stations 22 (or other objects, such as those on the floor of the factory 10). Also, because the physical components of the transport line(s) 30 are at different elevation(s) from that of the manufacturing stations 22, there is a reduced risk of collision with the machines. In addition, because the physical components at the transport line(s) 30 can be driven over the space above the manufacturing stations 22, delivery of product components by the physical components of the transport line(s) 30 will be very efficient. In particular, the physical components of the transport line(s) 30 do not have to maneuver between manufacturing stations 22 (and other objects) on the floor, which would have been the case if the transport line(s) 30 are implemented on the same elevation as the manufacturing stations. Since components can be delivered to the manufacturing stations 22 faster using the transport line(s) 30 and the factory control system 40, downtime of manufacturing stations 22 will be reduced or minimized, and productivity by the manufacturing stations 22 will increase.

[0109] In addition, the transport line(s) 30 and the factory control system 40 are advantageous because they allow small orders, including custom-orders, to be manufactured. With the transport line(s) 30 and factory control system 40 in place, factory lines can become very flexible. For example, through dynamic control, a manufacturing line 20 can be quickly and selectively configured (e.g., programmed, provisioned, controlled, etc.) to produce different products at different times. In some cases, the configuring of the manufacturing line 20 may occur in substantially real-time (shortly after a customer has placed an order for a product), such as within 30 minutes after a placement of an order, or more preferably within 15 minutes after a placement of an order, or even more preferably within 5 minutes after a placement of an order, or even more preferably within 1 minute after a placement of an order. [0110] Furthermore, the transport line(s) 30 may be implemented using low cost technology, and the factory control system 40 may be easily incorporated into existing factory systems. Also, implementation of the transport line(s) 30 and the factory control system 40 may not require any change to existing manufacturing floor layout.

[0111] Although embodiments of the factory control system 40 have been described, it should be noted that the factory control system 40 is not limited to the exemplary embodiments described, and that the factory control system 40 may have other configurations in other embodiments. For example, in other embodiments, the factory control system 40 may not include one or more of the components (e.g., the transport control 408, the selector 410, real-time monitoring system 450, database 430, etc.) discussed. Also, in other embodiments, two or more of the components discussed may be combined. For example, in other embodiments, the transport control 408 and the selector 410 may be combined and implemented into a single module.

[0112] In addition, in other embodiments, the factory control system 40 may be configured to provide other functionalities. For example, in other embodiments, the factory control system 40 may provide environment management, energy management, people analytics, asset tracking, or any combination of the foregoing. Alternatively, instead of providing the above functionalities, the factory control system 40 may integrate with, and/or may communicatively couple with, systems/modules providing the above functionalities. For example, in some embodiments, the factory control system 40 may communicate with, or may integrate with (1) Enterprise Resource Planning (ERP) system, which has information regarding customers’ orders, product designs, manufacture specifications, parts to use, etc., (2) manufacturing line control systems so that it has full access to what each manufacturing station 22 is making, whether a manufacturing line is available, whether a manufacturing line is on-line, etc., (3) asset tracking system configured to track inventory of parts and products, (4) people analytic system configured to monitor people in the factory, detect behaviors of people, generate metrics regarding the people, (5) energy management system configured to monitor energy consumption in the factory, control energy usage in the factory, etc., or (6) any combination of the foregoing.

[0113] FIG.7A illustrates an example of a factory that may be controlled by the factory control system 40. FIG.7B illustrates a factory control system 40 for the factory environment of FIG. particularly showing the factory control system 40 integrating with other modules, such as an environment management module 600, an asset tracking module 602, a people analytic module 604, an energy management module 606. The factory control system 40 may be the one shown in FIG.6 in some embodiments. The factory control system 40 may provide a user interface 610 for providing information to user, and/or for allowing a user to interact (e.g., control) the factory control system 40 and/or the modules 600, 602, 604, 606.

[0114] FIG.7C illustrates a factory control system 40 for the factory environment of FIG.7A, particularly showing the factory control system 40 including other modules, such as an environment management module 600, an asset tracking module 602, a people analytic module 604, an energy management module 606. The factory control system 40 may be the one shown in FIG.6 in some embodiments. The factory control system 40 may provide a user interface 610 for providing information to user, and/or for allowing a user to interact (e.g., control) the factory control system 40 and/or the modules 600, 602, 604, 606.

[0115] Also, in other embodiments, components of the transport line(s) 30 may not be coupled to physical structures in the factory 10. For example, in other embodiments, transport of product components to different manufacturing stations 22 may be implemented using one or more drones that are configured to fly within the factory 10 at elevation that is above the manufacturing stations 22. Thus, a mechanical component of a transport line may be a drone in some embodiments, and the term“transport line” may refer to an airline of drones in some embodiments. In such cases, the factory control system 40 is configured to control the drone(s) by sending commands to the drone(s) so that the drone(s) can fly to different locations in the factory 10. For example, the factory control system 40 may direct a drone to fly to a station to pick up a product component, and to then fly to a manufacturing station 22 to deliver the product component. The factory control system 40 may also direct the drone to pick up a product component from a first manufacturing station 22, and fly to a second

manufacturing station 22 or to another factory station to deliver the product component. In the factory 10 has multiple drones, the factory control system 40 may operate the drones so that they do not collide with each other and with structures in the factory 10. Accordingly, the factory control system 40 may function as air traffic controller that controls the drones in the factory 10.

[0116] In addition, in some embodiments, the manufacturing area in the factory 10 may be divided into different zones, and the factory control system 40 may be configured to manage and operate these different zones. For example, a first zone in the manufacturing area may be assigned to a first customer to build a product, a type of products, or different types of products, and a second zone in the manufacturing area may be assigned to a second customer to build a product, a type of products, or different types of products. Each zone may have one or more manufacturing stations 22. In some embodiments, different customers may“lease” different zones in the factory 10 for different durations. Sensors (such as internet-of-things (IOT) sensors) may be employed in the factory 40 to prevent people and/or machines (e.g., robots or mechanical components in manufacturing line and/or transport line) from crossing a zone boundary. Also, sensors (such as internet-of-things (IOT) sensors) may be employed in the factory 40 to monitor and keep track of people and/or machines (e.g., robots or mechanical components in manufacturing line and/or transport line) that have crossed a zone boundary.

[0117] In some cases, the factory control system 40 is configured to obtain information regarding the different zones, and control mechanical components in the manufacturing station(s) 22 and transport line(s) 30 based on such information. By means of non-limiting examples, the information regarding the zones may be location of the zones in the factory 10, boundaries of the zones, numbers and types of

manufacturing stations 22 in the different zones, customers who are assigned for the different zones, schedules for operating different manufacturing stations 22 in the different zones, etc. One or more of these information may be stored in a non- transitory medium and/or may be transmitted to the non-transitory medium or to the factory control system 40 by another device or module. In one implementation, a certain zone in the factory may be assigned to a customer to make a product based on a certain scheduled time. In such cases, the factory control system 40 is configured to operate a component in the transport line 30 to deliver component(s) to certain manufacturing station(s) 22 in the zone assigned for such customer, and operate the manufacturing station(s) 22 to make the product in accordance with the scheduled time.

[0118] Also, in some cases, output from the factory sensors may be received by the factory control system 40, and the factory control system 40 may be configured to control the manufacturing station(s) 22 and/or the control line(s) 30 based on such output. For example, if a sensor output indicates that a certain person or machine has entered into a zone without authorization, the factory control system 40 may then provide a control signal to stop a manufacturing station 22 in that zone, and/or may provide a control signal to stop a control line 30 or to change a path of the control line 30. As another example, if a sensor output indicates that a certain person or machine has entered into a zone expectedly according to a time schedule, the factory control system 40 may then provide a control signal to operate a manufacturing station 22 in that zone to perform manufacturing function(s), and/or may provide a control signal to operate a control line 30 or to change a path of the control line 30 so that component(s) of the control line 30 can deliver components for the manufacturing station 22 in that zone.

[0119] FIG.8 illustrates a method 700 performed by the factory control system of FIG.6. The method 700 is performed by the factory control system to operate a factory having a transport line and a plurality of manufacturing stations. The method 700 includes: obtaining manufacturing information by the factory control system (item 702); and generating first signal(s), by a transport control of the factory control system, based on the manufacturing information to operate a mechanical component in the transport line to deliver one or more physical components for one of the manufacturing stations to make the first product, wherein the one of the manufacturing stations is at a first elevation in the factory, the transport line is at a second elevation in the factory, the second elevation being different from the first elevation (item 704).

[0120] Optionally, in the method 700, the mechanical component in the transport line is operated to move along a path that traverses spatial regions above multiple ones of the manufacturing stations.

[0121] Optionally, the method 700 further includes configuring a path of the mechanical component in the transport line.

[0122] Optionally, in the method 700, the first product is for a custom-order.

[0123] Optionally, the method 700 further includes selecting, by a selector of the factory control system, the one of the manufacturing stations for making the first product.

[0124] Optionally, in the method 700, the one of the manufacturing stations is selected for making the first product based on a functional capability of the one of the manufacturing stations.

[0125] Optionally, in the method 700, the one of the manufacturing stations is selected for making the first product based on a workload of the one of the

manufacturing stations.

[0126] Optionally, the method 700 further includes selecting an other one of the manufacturing stations for making a second product; and generating second signal(s) to operate the mechanical component in the transport line to deliver one or more physical components to the other one of the manufacturing stations to make the second product. [0127] Optionally, in the method 700, the selected one of the manufacturing stations is also for making a second product, the second product and the first product having different respective features; and generating second signal(s) to operate the

mechanical component in the transport line to deliver one or more physical components to the selected one of the manufacturing stations to make the second product.

[0128] Optionally, in the method 700, the factory control system comprises a database storing information regarding features of the respective manufacturing stations and/or constraints of the respective manufacturing stations; and wherein the selector is communicatively coupled to the database.

[0129] Optionally, in the method 700, the first signal(s) is generated by the transport control of the factory control system based on the selected one of the manufacturing stations.

[0130] Optionally, in the method 700, the first signal(s) is generated by the transport control to operate the mechanical component in the transport line based on a layout of the factory.

[0131] Optionally, in the method 700, the factory control system comprises a non- transitory medium storing a map of the factory indicating the layout of the factory.

[0132] Optionally, in the method 700, the transport line is operated on a product-by- product basis.

[0133] Optionally, the method 700 further includes receiving an end user’s custom order via a communication interface of the factory control system.

[0134] Optionally, the method 700 further includes monitoring a state of the transport line, and/or a state of the one of the manufacturing stations, using a factory real-time monitoring system.

[0135] Optionally, the method 700 further includes monitoring a progress of a making of the first product using a factory real-time monitoring system.

[0136] FIG.9 illustrates an example of an implementation of the factory control system of FIG.6. As shown in FIG.9, the factory control system may include a processing unit 1200 having a bus 1202 or other communication mechanism for communicating information, and a processor 1204 coupled with the bus 1202 for processing information. The processing unit 1200 also includes a main memory 1206, such as a random access memory (RAM) or other dynamic storage device, coupled to the bus 1202 for storing information and instructions to be executed by the processor 1204. The main memory 1206 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by the processor 1204. The processing unit 1200 further includes a read only memory (ROM) 1208 or other static storage device coupled to the bus 1202 for storing static

information and instructions for the processor 1204. A data storage device 1210, such as a magnetic disk or optical disk, is provided and coupled to the bus 1202 for storing information and instructions.

[0137] The processing unit 1200 may be coupled via the bus 1202 to a display 1212, such as a flat panel, for displaying information to a user. An input device 1214, including alphanumeric and other keys, is coupled to the bus 1202 for communicating information and command selections to processor 1204. Another type of user input device is cursor control 1216, such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor 1204 and for controlling cursor movement on display 1212. This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.

[0138] The processing unit 1200 may be used for performing various functions (e.g., calculation) in accordance with the embodiments described herein. According to one embodiment, such use is provided by processing unit 1200 in response to processor 1204 executing one or more sequences of one or more instructions contained in the main memory 1206. Such instructions may be read into the main memory 1206 from another computer-readable medium, such as storage device 1210. Execution of the sequences of instructions contained in the main memory 1206 causes the processor 1204 to perform the process acts described herein. One or more processors in a multi- processing arrangement may also be employed to execute the sequences of

instructions contained in the main memory 1206. In alternative embodiments, hard- wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.

[0139] The term "computer-readable medium" as used herein refers to any medium that participates in providing instructions to the processor 1204 for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical or magnetic disks, such as the storage device 1210. Volatile media includes dynamic memory, such as the main memory 1206. Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise the bus 1202. Transmission media can also take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.

[0140] Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD- ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.

[0141] Various forms of computer-readable media may be involved in carrying one or more sequences of one or more instructions to the processor 1204 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to the processing unit 1200 can receive the data on the telephone line and use an infrared transmitter to convert the data to an infrared signal. An infrared detector coupled to the bus 1202 can receive the data carried in the infrared signal and place the data on the bus 1202. The bus 1202 carries the data to the main memory 1206, from which the processor 1204 retrieves and executes the instructions. The instructions received by the main memory 1206 may optionally be stored on the storage device 1210 either before or after execution by the processor 1204.

[0142] The processing unit 1200 also includes a communication interface 1218 coupled to the bus 1202. The communication interface 1218 provides a two-way data communication coupling to a network link 1220 that is connected to a local network 1222. For example, the communication interface 1218 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, the communication interface 1218 may be a local area network (LAN) card to provide a data

communication connection to a compatible LAN. Wireless links may also be

implemented. In any such implementation, the communication interface 1218 sends and receives electrical, electromagnetic or optical signals that carry data streams representing various types of information.

[0143] The network link 1220 typically provides data communication through one or more networks to other devices. For example, the network link 1220 may provide a connection through local network 1222 to a host computer 1224 or to equipment 1226 such as a radiation beam source or a switch operatively coupled to a radiation beam source. The data streams transported over the network link 1220 can comprise electrical, electromagnetic or optical signals. The signals through the various networks and the signals on the network link 1220 and through the communication interface 1218, which carry data to and from the processing unit 1200, are exemplary forms of carrier waves transporting the information. The processing unit 1200 can send messages and receive data, including program code, through the network(s), the network link 1220, and the communication interface 1218.

[0144] Although particular embodiments have been shown and described, it will be understood that they are not intended to limit the claimed inventions, and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the claimed inventions. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense. The claimed inventions are intended to cover alternatives, modifications, and equivalents.