Abstract: A method for error proofing body shop component begins by scheduling the production of a vehicle body using an assembly plant controller. A version of a sheet metal component is then selected. The version of the sheet metal component determines what body type will be produced. To insure that the proper body type is being produced, the assembly plant controller verifies the version of the sheet metal component by using a plurality of sensors. If the wrong sheet metal component is detected, then the body shop process is stopped and the wrong sheet metal part is replaced with the correct sheet metal part. Once all correct sheet metal parts are in place, they are spot welded together to produce a vehicle body.

Abstract: A method for monitoring assembly plant production and quality, particularly relative to painting processes for vehicles. The method includes painting a plurality of vehicles, inspecting each vehicle for paint defects, and recording production quantity data and processing defect data for vehicles using a touch screen. The touch screen includes a computer-generated template of multiple views the vehicle, such that, the location of each paint defect can be recorded. The data is accessible through a network connection and is used to determine required production time and corrective actions for paint defect trends.

Abstract: A method for preventing computer down time, particularly relative to painting processes for vehicles. The method includes dividing the order into groups based on color, painting them in color order, and then sequencing them into the original build order. Between each different color, a paint purging process occurs. A primary computer is used to control the entire process. To insure continuous function, a secondary computer is provided in the event of primary computer failure. The functional status of the secondary computer is constantly monitored. As long as the secondary computer is functional, the primary computer will update the secondary computer. If the secondary computer is not functional, the primary computer updates itself.