Smart Conveyor Throughput Optimization

Engineering Context

Falcon Manufacturing must raise output without purchasing a second line. The conveyors, robot, and routing cylinders are not synchronized, producing idle time in some zones and part bunching in others. Teams will optimize the coordinated process.

What You Will Practice

• Measure system throughput and spacing
• Analyze interactions between robot and conveyor timing
• Use data to optimize a multi-device process
• Balance speed, accuracy, and reliability

What You Need

• VEX CTE Workcell
• Conveyors
• Sensors
• Pneumatics
• 6-Axis Arm if used
• Thirty parts
• Stopwatch
• Spreadsheet

Instructions

1. Run a ten-part baseline trial and record total time, part spacing, and failures.
2. Measure the time required by each major station.
3. Identify the bottleneck station and explain your evidence.
4. Propose at least three software changes.
5. Test one change at a time with ten parts.
6. Choose final conveyor speeds and release logic.
7. Run a thirty-part final trial.
8. Calculate throughput in parts per minute and percent improvement.

Engineering Requirements

• Increase throughput by at least 20%
• Maintain zero collisions and correct routing
• Keep at least the approved minimum spacing between parts
• Complete thirty final parts without manual intervention

Constraints & Safety

• Do not move hardware
• Conveyor speed may not exceed approved classroom limits
• Safety-stop code must remain active
• Final settings must be documented

What You Submit

• Baseline and final code
• Station-time study
• Throughput and spacing data
• Before/after graph
• Bottleneck explanation
• Reflection

Reflection Questions

1. Which station controlled maximum throughput?
2. Why did increasing one conveyor not always improve the full line?
3. How did reliability influence your final setting?
4. What buffer would help the system?