Assembly line control system and method

1 . An assembly line system comprising:

a programable controller;

a priority component comprising a filler configured to fill empty containers with one or more of a liquid and a dispensable product, thus producing filled containers;

a first section upstream of the priority component configured to deliver the empty containers to the priority component and including at least one upstream backup detecting sensor; and

a second section downstream of the priority component configured to receive and transport filled containers away from the priority component and including at least one downstream backup detecting sensor,

wherein the programable controller is configured to:

determine whether there is an upstream backup along the first section based on signals from the upstream backup detecting sensor, the upstream backup indicating too few empty containers being delivered to the priority component;

determine whether there is a downstream backup along the second section based on signals from the downstream backup detecting sensor, the downstream backup indicating a lack of space for filled containers along the second section;

determine a number of speed changes instances that an operating speed of the priority component has already been adjusted within a predetermined preceding time period;

determine a speed change elapsed time that the operating speed of the priority component has already been adjusted within the predetermined preceding time period; and

adjust the operating speed of the priority component if

one or more of the upstream backup and the downstream backup is present,

the number of speed change instances within the predetermined preceding time period is less than a speed change instance threshold, and

the speed change elapsed time within the predetermined preceding time period is less than a speed change elapsed time threshold.

2 . The assembly line system of claim 1 , wherein the first section includes a depalletizer configured to remove unfilled containers from pallets.

3 . The assembly line system of claim 1 , wherein the second section includes

a pasteurizer configured to pasteurize one or more of the liquid and the dispensable product;

one or more accumulation tables;

a packer configured to package groups of filled containers; and

a palletizer configured to place the groups of filled containers onto pallets.

4 . The assembly line system of claim 1 , wherein the programable controller is further configured to adjust a speed of a conveyer belt that is located within the first section upstream of the priority component.

5 . The assembly line system of claim 1 , wherein the programable controller is further configured to set the operating speed of the priority component to high in response to determining that there is no upstream backup in the first section or downstream back up in the second section.

6 . The assembly line system of claim 1 , wherein the programable controller is further configured to set the operating speed of the priority component to low in response to determining that the upstream backup is present in the first section or the downstream backup is present in the second section.

7 . The assembly line system of claim 1 , wherein the programable controller is further configured to:

calculate an upstream accumulation percentage based on a current status of the at least one upstream backup detecting sensor; and

determine whether the upstream backup is present in the first section based on the upstream accumulation percentage.

8 . The assembly line system of claim 1 , wherein the programable controller is further configured to:

determine a maximum downstream accumulation percentage;

determine a current accumulation percentage; and

determine whether the downstream backup is present in the second section based on the maximum downstream accumulation percentage and the current accumulation percentage.