Error Proofing
The implementation of an effective error proofing system, enables the modern manufacturing facility to guarantee production build quality and provide complete process traceability.
Through the use of interlocked build procedures and formal process controls, systems can be created which prevent operator error and allow complete process visibility, from factory floor to the management desktop.
To meet this demand for full traceability, and an accurate means of tracking product variants data, Bytronic has developed the TrackIT™ traceability system. This system is currently used by numerous world-class customers, helping them to ensure that the optimum levels of quality are achieved.
A Typical System
A typical example of an error proofing system from Bytronic will take the form of a PC, mounted within an industrial floor standing cabinet. Next to this, a custom-made test station will be fixed. The PC will be running our Windows based TrackIT™ the traceability product based on National Instruments LabVIEW™.
Initially, the system will receive a electronic copy of the automotive build order and automatically configure the pick sequence for the job. Our Pick to Light system will then illuminate the variants in stock, to be picked and display this on the PC for the operator's reference. The operator will then collect the part and place it in the test station.
If an error is made during this process, it will be highlighted on the PC screen, and will stop the build until the error has been corrected. This system of test often incorporates a vision system, which will confirm whether the product is of the correct variant and also check the authenticity of the components, i.e. studs correctly fitted, aerial fitted straight etc. If any error is found the operator will be notified on the PC screen and the system will not continue until the faulty product has been scanned into the 'rework stilage'. A correct component will then be manually taken from the test station and scanned into the shipping stilage.
Once the Pick sequence has been completed and the product has been correctly assembled into the variant the PC will print a stilage shipping ticket for reference purposes. In other words, no shipping Ticket means an unapproved stilage and therefore, will not be shipped. The Bytronic system will also provide a shift report, which will summarise the performance during a particular shift, and provide details of the number of errors during that time.