PARTS MANAGEMENT SYSTEM AND METHOD OF USE

Abstract

A parts management system includes a compartment having a plurality of cup-shaped cells formed in the base of the compartment. Side walls of the compartment include notches formed therein. The parts management system further includes dividers that may be engaged with the notches to subdivide the parts management system into smaller subcompartments. In use, smaller parts, such as fasteners, are detached from an item to be disassembled and placed in the cup-shaped cells within particular subcompartments. The larger components associated with the fasteners are removed from the item to be disassembled and are also loaded into the subcompartments in proximity to their associated fasteners. The parts can be loaded into the parts management system in sequential order during disassembly of the item. The parts can then be unloaded from the parts management system in a reverse order during reassembly of the item.

Description

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to organizational systems. More specifically, the present invention relates to a system for efficiently managing parts during disassembly and assembly of an item.

BACKGROUND OF THE INVENTION

Motor vehicles, such as automobiles, trucks, buses, and so forth inevitably require maintenance, repairs, or some other service. The repair and maintenance of a motor vehicle often requires small parts to be removed and placed aside for later re-installation. During the repair or servicing, a professional or amateur mechanic must keep track of the parts and components being removed from the motor vehicle so that they may later be reinstalled onto the motor vehicle. Efficient management of the removed parts and reinstallation of those same parts can be daunting for the mechanic. This problem may be exacerbated when multiple mechanics are servicing the same vehicle. For example, one mechanic may not have a clear understanding of where a part or parts were removed from the vehicle by another mechanic, and how those parts should be reinstalled. Additionally, during disassembly and reassembly of a motor vehicle, the small parts can be easily misplaced.

In a professional motor vehicle repair or service environment, confusion between mechanics, misplaced parts, and mistakes made during automotive servicing can increase the time to repair or service a vehicle, thus significantly decreasing the efficiency of an automotive shop. Consequently, a professional mechanic's inefficiency results in increased costs for the automotive shop, which in turn can result in increased costs for the consumer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:

FIG. 1 shows a perspective view of a parts management system in accordance with an embodiment;

FIG. 2 shows a top view of the parts management system of FIG. 1;

FIG. 3 shows a side view of the parts management system;

FIG. 4 shows a perspective view of a divider used with the parts management system;

FIG. 5 shows a side view of the divider; and

FIG. 6 shows a partial perspective of the part management system in use.

DETAILED DESCRIPTION

Embodiments entail a parts management system and a method of managing parts using the parts management system. The parts management system can be used during disassembly and assembly of an item in order to organize and retain small parts, such as fasteners, together with their larger components. The parts management system is implemented in an organizational process in which parts that are disassembled are loaded in a specific order into the parts management system and can subsequently be unloaded from the parts management system in the reverse order for reassembly. Accordingly, reassembly of the item can be performed by another individual or individuals since those individuals can ascertain from the parts management system where the parts go and in what order they are to be reassembled.

Such a parts management system may be useful in an automotive shop when removing parts from a motor vehicle in order to repair the motor vehicle. Thus, multiple mechanics with varying degrees of ability and present during different work shifts can disassemble and reassemble a vehicle or portion of a vehicle with increased efficiency. Increased efficiency of disassembly, repair, and reassembly can decrease the cycle time, i.e., the amount of time that elapses between the between the beginning and end of an automotive repair, thereby decreasing cost for automotive repairs. Furthermore, improved organization of parts can lead to a decrease in misplaced parts and/or a decrease in mistakes made during automotive servicing. Although the parts management system and methodology are discussed below in connection with automotive servicing, it will become readily apparent that the parts management system and associated methodology may be implemented in a variety of environments in which an item having multiple parts is to be disassembled and later reassembled.

Referring to FIGS. 1-3, FIG. 1 shows a perspective view of a parts management system 20 for managing a plurality of parts in accordance with an embodiment. FIG. 2 shows a top view of parts management system 20, and FIG. 3 shows a side view of parts management system 20. Parts management system 20 generally includes a first compartment 22 and a second compartment 24 coupled to first compartment 22. In an embodiment, parts management system 20 may be a tray structure formed from a thermoplastic material, such as, polyethylene, polypropylene, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), nylon, and the like. Thus, parts management system 20 including first and second compartments 22 and 24, respectively, may be manufactured utilizing a suitable molding process, such as injection molding, blow molding, rotational molding, and so forth. A thermoplastic material and a molding technique are desirable for making parts management system 20 due to cost effective production, as well as, high durability, corrosion resistance, and light weight of the finished product. In alternative embodiments, parts management system may be manufactured using other suitable materials and manufacturing processes.

First compartment 22 includes a first end wall 26, a second end wall 28, a first side wall 30 and a second side wall 32, where first and second side walls 30 and 32 extend between first and second end walls 26 and 28, respectively. A base 34 of first compartment 22 is surrounded by first and second end walls 26 and 28, and first and second side walls 30 and 32. More particularly, a bottom edge 36 of each successive one of first end wall 26, first side wall 30, second end wall 28, and second side wall 32 is coupled to an outer perimeter 38 of base 34. Thus, first end wall 26, first side wall 30, second end wall 28, and second side wall 32 extend above an upper surface 40 of base 34.

Base 34 includes a plurality of generally cup-shaped cells 42 extending below upper surface 40, and each of cup-shaped cells 42 has an opening 44 formed through upper surface 40. In an embodiment, cup-shaped cells 42 may be arranged in multiple rows 46 oriented transverse to a length 48 of first compartment 22. In this exemplary configuration, first compartment 22 includes thirteen rows 46 of cup-shaped cells 42, with each row 46 including three of adjacent cup-shaped cells 42 (see particularly FIG. 2). However, alternative embodiments of parts management system 20 may include fewer or more cells 42 than that shown, and cells 42 may be arranged differently and/or may be made in differing sizes than that which is shown. As will be discussed below in connection with FIG. 6, cup-shaped cells 42 are configured to contain a plurality of parts separate from one another.

Interior surfaces 50 of first and second end walls 26 and 28, as well as, interior surfaces 52 of first and second side walls 30 and 32 define first compartment 22 having base 34 with cup shaped cells 42. In an embodiment, interior surface 52 of first side wall 30 includes spaced apart notches 54 formed therein. Likewise, interior surface 52 of second side wall 32 includes spaced apart notches 56 formed therein. One each of notches 54 formed in first side wall 30 directly opposes one each of notches 56 formed in second side wall 32 to form pairs of notches 58. Each pair of notches 58 may be located between adjacent rows 46 of cup-shaped cells 42.

Parts management system 20 further includes one or more dividers 60. Dividers 60 are configured to slideably engage with pairs of notches 58. That is, one each of dividers 60 may be concurrently slid into one of notches 54 formed in first side wall 30 and one of notches 56 in second side wall 32 such that first compartment 22 is subdivided into two or more subcompartments 62. Dividers 60 are not shown in FIG. 2 for clarity of illustration. However, in the example shown in FIG. 1, four dividers 60 have been engaged in opposing pairs of notches 58 so that first compartment 22 is subdivided into five subcompartments 62. As will become apparent in the ensuing discussion any suitable quantity of dividers 60 may be utilized to subdivide first compartment 22 into subcompartments 62 when organizing parts in parts management system 20.

With continued reference to FIGS. 1-3, second compartment 24 includes a third end wall 64 formed adjacent to first end wall 26 of first compartment 22, a fourth end wall 66 formed adjacent to second end wall 28, and a third side wall 68 extending between third and fourth end walls 64 and 66. Third side wall 68 is laterally displaced away from second side wall 32. Thus, second side wall 32, third end wall 64, third side wall 68, and fourth end wall 66 surround a base 70 of second compartment 24. In an embodiment, base 70 may be substantially planar, as opposed to base 34 of first compartment 22 having cup-shaped cells 42 formed therein.

As shown in FIG. 3, first compartment 22 exhibits a first height 72 from a first upper edge 74 of first compartment 22 to a bottom surface 76 of cup-shaped cells 42. Second compartment 24 exhibits a second height 78 from a second upper edge 80 of second compartment 24 to base 70. In an embodiment, first and second heights 72 and 78 are substantially equal for simplicity of manufacture and to facilitate the stacking of multiple parts management systems 20 together. However, in alternative embodiments, second height 78 need not be equivalent to first height 72.

Unlike first compartment 22, second compartment 24 may not include cup-shaped cells and/or notches. Instead, second compartment 24 extending length 48 of first compartment 22 may be better suited for larger components that may not fit in subcompartments 62 of first compartment 22. Of course, in alternative embodiments second compartment 24 may include cup-shaped cells and notches so that compartment 24 may also be subdivided into subcompartments 62. And in still other embodiments, a parts management system 20 may include only first compartment 22 without having second compartment 24.

Referring to FIGS. 4-5, FIG. 4 shows a perspective view of one of dividers 60 that may be used with parts management system 20, and FIG. 5 shows a side view of divider 60. The following discussion applies equally to each of dividers 60 that may be engaged with first compartment 22 (FIG. 1). Divider 60 includes a body 82 having a lower edge 84, and upper edge 86, and side edges 88 and 90, respectively. Lower edge 84 is configured for abutment with upper surface 40 (FIG. 1) of base 34 (FIG. 1), and side edges 88 and 90 are configured for engagement with notes 54 and 56 (FIG. 1) of any of pair of notches 58 (FIG. 1).

A rigid flap 92 may be fixed to upper edge 86 of body 82. In an embodiment, rigid flap 92 may be bent out of alignment with body 82 of divider 60. For example, rigid flap 92 may be bent downwardly so that when engaged with pair of notches 58 (FIG. 1), rigid flap 92 is directed downwardly toward base 34 (FIG. 1) of first compartment 22. Divider 60 may be formed from a metal, such as aluminum. Thus, rigid flap 92 can be readily bent into the appropriate shape. Alternatively, divider 60 may be suitably manufactured from another material, such as a thermoplastic material. The bent configuration of rigid flap 92 provides a handhold so that a user may readily slide divider 60 into or out of pair of notches 58. Additionally, rigid flap 92 may provide a useful surface upon which a user may write labels identifying the particular parts stored in one of subcompartments 62 (FIG. 1). For example, when divider 60 is manufactured from a slick, non-porous material, a non-permanent marker may be used to temporarily label rigid flap 92. Later, the erasable ink may be removed from rigid flap 92 so that divider 60 can be re-used.

FIG. 6 shows a partial perspective of parts management system 20 in use when disassembling and reassembling parts from an item. In an exemplary scenario, the parts are to be removed from a motor vehicle 94, which is shown in dashed line form for illustrative purposes. For example, a mechanic may remove a door panel so as to repair body damage, to replace a malfunctioning component in the door panel, and so forth. Removal of a door panel can entail the disassembly of a plurality of parts. These parts can include smaller parts, such as fasteners 96, and the associated components 98 that are connected to motor vehicle 94 via fasteners 96.

In general, a method by which parts management system 20 may be used to manage or organize a plurality of parts entails detaching the smaller parts, e.g. fasteners 96, that retain a particular component 98 onto motor vehicle 94 so that component 98 is removed from motor vehicle. Fasteners 96 are placed in cup-shaped cells 42 in first compartment 22 of parts management system 20. The mechanic may engage one of dividers 60 in a suitable pair of notches 58 in first and second side walls 30 and 32, respectively to form one of subcompartments 62. In this illustration, the mechanic may form a first subcompartment, labeled subcompartment 62A. Thus, the mechanic loads fasteners 96 into one or more cup-shaped cells 42 in first subcompartment 62A.

Once fasteners 96 are loaded into cells 42 within first subcompartment 62A, the larger part, e.g., component 98, may also be loaded into first subcompartment 62A. The mechanic may additionally mark flap 92 of divider 60 with one or more identifiers 100 that identify the parts, e.g., fasteners 96 and/or component 98, contained in first subcompartment 62A. Preferably, the mechanic or mechanics repeats the operations of detaching fasteners 96, engaging dividers 60 to form subcompartments 62, placing fasteners 96 into cells 42 within a particular one of subcompartments 62, and loading the associated component 98 into the particular one of subcompartments 62 for successive parts to be removed from motor vehicle 94. Thus, the disassembled components 98 and their corresponding fasteners 96 are loaded into subcompartments 62 in a sequential order, for example from front to back as indicated by an arrow 102.

During reassembly, components 98 can be unloaded from parts management system 20 in the reverse order. That is, the earliest fasteners 96 and components 98 loaded into parts management system 20 are the last fasteners 96 and components 98 to be unloaded from parts management system 20. Likewise, the last fasteners 96 and components 98 loaded into parts management system 20 are the earliest fasteners 96 and components 98 to be unloaded from parts management system 20. Accordingly, this disassembly methodology enables the parts from a disassembled item, e.g., a portion of motor vehicle 94, to be organized in a way that another individual or individuals who may be reassembling the item knows what parts go where and in what sequential order the item is to be reassembled.

Components 98 are loaded into the appropriate one of subcompartments 62, e.g., first subcompartment 62, when the subcompartment 62 is sized to accommodate component 98. That is, dividers 60 may be engaged with pair of notches 58 to create an adequately sized subcompartment 62. On occasion, however, the component may be too large to fit into its corresponding subcompartment 62. In such a situation, the component may be loaded into second compartment 24. By way of example, a second component 104 is placed in second compartment 24. However, its corresponding fasteners 96 are placed in cup-shaped cells 42 of the next successive subcompartment 62, e.g., a second subcompartment 62B. Of course, additional smaller parts (not shown) associated with second component 104 may be placed in second subcompartment 62B, as well. Divider 60 used to form second subcompartment 62B may be suitably marked with identifiers that identify fasteners 96 in second subcompartment 62B and that identify second component 104 loaded into second compartment 24.

Embodiments described herein entail a parts management system and a method of managing parts using the parts management system. The parts management system can be used during disassembly and assembly of an item in order to organize and retain small parts, such as fasteners, together with their larger components. That is, subcompartments can be dynamically formed and appropriately sized using dividers that engage with notches formed in side walls of the system. The subcompartments include cup-shaped cells in which the smaller parts, such as fasteners, can be placed while the larger components associated with the fasteners can also be loaded into the same subcompartment. Thus, the parts management system is implemented in an organizational process in which parts that are disassembled are loaded in a specific order into the parts management system and can subsequently be unloaded from the parts management system in the reverse order for reassembly. Consequently, reassembly of the item can be performed by another individual or individuals since those individuals can ascertain from the parts management system where the parts go and in what order they are to be reassembled. Such a parts management system and organizational process enables multiple users with varying degrees of ability and various specialties and/or working on different work shifts to disassemble and reassemble an item with increased efficiency. Increased efficiency of disassembly and reassembly can decrease the cycle time of the process, thereby decreasing costs. Furthermore, improved organization of parts can lead to a decrease in misplaced parts and/or a decrease in mistakes made during disassembly and reassembly.

Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. For example, the parts management system can be configured in various shapes and sizes, and can have fewer than or more than the quantity of compartments and the quantity and arrangement of cup-shaped cells shown in the presented figures.

Claims

1. A system for managing a plurality of parts comprising:

a first end wall;

a second end wall;

a first side wall;

a second side wall, said first and second side walls extending between said first and second end walls; and

a base surrounded by said first and second end walls and said first and second side walls, said base including a plurality of generally cup-shaped cells configured to contain said plurality of parts separate from one another.

2. A system as claimed in claim 1 wherein said base includes an upper surface and said cup-shaped cells extend below said upper surface.

3. A system as claimed in claim 2 wherein each of said cells has an opening formed through said upper surface of said base.

4. A system as claimed in claim 2 wherein a bottom edge of each successive one of said first end wall, said first side wall, said second end wall, and said second side wall are coupled to an outer perimeter of said upper surface of said base such that said first end wall, said first side wall, said second end wall, and said second side wall extend above said upper surface of said base.

5. A system as claimed in claim 1 wherein said first and second end walls and said first and second side walls define a first compartment having said base with said plurality of cup-shaped cells formed therein, and said system further comprises a second compartment adjacent to and extending a length of said second side wall.

6. A system as claimed in claim 5 wherein said second compartment comprises:

a third end wall formed adjacent to said first end wall;

a fourth end wall formed adjacent to said second end wall;

a third side wall extending between said third and fourth end walls and laterally displaced away from said second side wall; and

a substantially planar base surrounded by said second side wall, said third end wall, said third side wall, and said fourth end wall.

7. A system as claimed in claim 6 wherein said first compartment exhibits a first height from a first upper edge of said first compartment to a bottom surface of said cup-shaped cells, and said second compartment exhibits a second height from a second upper edge of said second compartment to said substantially planar base, said second height being substantially equivalent to said first height.

8. A system as claimed in claim 1 wherein:

interior surfaces of said first and second side walls and said first and second end walls define a compartment having said base with said plurality of cup-shaped cells, said interior surfaces of said first and second side walls having notches formed therein; and

said system further includes at least one divider engaged with said notches in each of said first and second side walls and extending between said first and second side walls such that said compartment is subdivided into at least two subcompartments.

9. A system as claimed in claim 8 wherein one of said notches on said first side wall directly opposes one of said notches on said second side wall to form a pair of said notches for engagement with said at least one divider, said pair of said notches being located between adjacent rows of said cup-shaped cells.

10. A system as claimed in claim 8 wherein said at least one divider comprises:

a body having a lower edge, an upper edge, and side edges, said lower edge being configured for abutment with an upper surface of said base, and said side edges being engaged with said notches; and

a rigid flap fixed to said upper edge and bent out of alignment with said body.

11. A system as claimed in claim 10 wherein said rigid flap is bent downwardly toward said base.

12. A method of managing a plurality of parts using a parts management system, said parts management system including a compartment, said compartment including a base surrounded by first and second end walls and first and second side walls extending above an upper surface of said base, said base including a plurality of generally cup-shaped cells extending below said upper surface of said base, and said method comprises:

detaching smaller ones of said plurality of parts from an item being disassembled;

removing larger ones of said plurality of parts associated with said smaller parts from said item;

placing said smaller parts into said cup-shaped cells; and

loading said larger parts associated with said smaller parts into said parts management system in proximity to said smaller parts.

13. A method as claimed in claim 12 wherein:

said parts management system further includes a divider configured to engage with notches formed in interior surfaces of said first and second side walls;

said smaller parts are fasteners, said larger parts are components connected to said item via said fasteners;

said removing operation comprises disconnecting said fasteners from one of said components and removing said one of said components;

said method further comprises engaging said divider in a pair of said notches in said first and second side walls so that said divider extends between said first and second side walls to form a subcompartment in said compartment;

said placing operation comprises placing said fasteners in at least one of said cells located in said subcompartment of said compartment; and

when said subcompartment is sized to accommodate said one of said components, said loading operation comprises loading said one of said components into said subcompartment.

14. A method as claimed in claim 13 further comprising repeating said detaching, removing, engaging, placing, and loading operations for successive parts to be removed from said item.

15. A method as claimed in claim 13 wherein said compartment is a first compartment, and said part management system further includes a second compartment formed adjacent to said first compartment, and said method further comprises loading said one of said components in said second compartment when said subcompartment is too small to accommodate said one of said components.

16. A method as claimed in claim 13 wherein said divider includes a body and a rigid flap, said body having a lower edge, an upper edge, and side edges, said lower edge abutting an upper surface of said base when said divider is engaged in said notches, and said rigid flap being fixed to said upper edge and bent out of alignment with said body, and said method further comprises marking said rigid flap with identifiers that identify said one of said components and said fasteners.

17. A system for managing a plurality of parts comprising:

a first compartment including a first end wall, a second end wall, a first side wall, a second side wall, and a base wherein said first and second side walls extend between said first and second end walls and said base is surrounded by said first and second end walls and said first and second side walls, said base includes an upper surface and a plurality of generally cup-shaped cells extending below said upper surface, and said cells are configured to contain said plurality of parts separate from one another; and

a second compartment coupled to and extending the length of said second side wall.

18. A system as claimed in claim 17 wherein a bottom edge of each successive one of said first end wall, said first side wall, said second end wall, and said second side wall are coupled to an outer perimeter of said upper surface of said base such that said first end wall, said first side wall, said second end wall, and said second side wall extend above said upper surface of said base, and each of said cells has an opening formed through said upper surface of said base.

19. A system as claimed in claim 17 wherein:

interior surfaces of said first and second side walls have notches formed therein; and

said system further includes at least one divider engaged with said notches in each of said first and second side walls and extending between said first and second side walls such that said compartment is subdivided into at least two subcompartments.

20. A system as claimed in claim 19 wherein said at least one divider comprises:

a body having a lower edge, an upper edge, and side edges, said lower edge being configured for abutment with said upper surface of said base, and said side edges being engaged with said notches; and

a rigid flap fixed to said upper edge and bent out of alignment with said body.