Zero mistakes with Poka Yoke

Here it is up to the responsible persons to avoid these faulty actions, such as skipping work steps or mixing up parts, as much as possible by means of supporting systems.

The IPM PG software prevents and identifies human error in all production phases through freely definable workflows. IPM PG is not an additional work step, but a part of the process. Users can therefore achieve error-free production with little investment and thus improve their product quality.

Avoid unfortunate mishaps

Rejects and rework make the production process really expensive. In its IPM Production Guide (IPM PG), CSP GmbH & Co. KG has therefore integrated various elements with which the zero-defect concept "Poka Yoke" is implemented.

Errors immediately visible

Poka Yoke (see box) is considered to be the essential, globally accepted method of preventing or immediately detecting errors on the basis of technical precautions and equipment. These precautions are not additional work steps, but part of the process. A final inspection is not required. Preventive measures include, for example, that only the correct materials and tools can be used for each work step, processes only start when certain preconditions have been fulfilled, and for some work steps the workers have to acknowledge information.

 tightening error

Among other things, the following elements in the IPM PG worker guidance system contribute to high product quality in the bolting process: In order for the work process to start, the worker first scans a barcode. This contains the part number and serial number. Each work step is visualized on a screen. The connected tools are only enabled for bolting when this is actually the next work step in the sequence. If a worker note is displayed beforehand, the tool remains locked until the worker has confirmed that he has read the note.

During the actual screwdriving process, the software automatically transmits the correct screwdriving parameters to the tool, so that no error can occur when selecting the parameters. With IPM PG, pick-by-light support ensures that the correct tools are always selected. For example, for each screwdriving process with nut selectors, a light flashes to indicate the required screwdriving attachment. Another safety measure is that a user with extended authorizations must explicitly release the workflow again when a screw has been screwed three times with the status NOK.

High process reliability

"Errors caused by people can be prevented very well by these technical precautions in the workflow," explains Matthias Bösl, Product Manager IPM PG at CSP. "Customers confirm to us that the operator control has significantly optimized the quality in production. This is due in particular to the consistent implementation of the poka-yoke principle."

IPM PG is a plant guidance system that guides the employee safely through the production process with the help of visual support. Based on digitized work plans, a uniform sequence with step-by-step instructions is generated, which the worker follows in the specified sequence. By using IPM PG, companies achieve process reliability with lower manufacturing costs. A key additional aspect of the solution for many companies is that the process is fully documented. This means that the requirements of the Product Liability Act can be met and reliable information can be provided in the event of warranty claims. Worker management is ideal when production is carried out with a high number of variants or when employees at the stations change frequently.

CSP customers also use the solution in some cases specifically to easily implement required rework. Due to the continuous data acquisition, the rework is easier to realize. IPM PG can be parameterized as a rework station or quality gate and retrieve data from the higher-level IPM system.

Rework made easy

fen. In this way, all problems that occur in the production process are clearly visualized for the worker. Rework can thus be easily carried out at the problem areas or the product can be accepted as IO/NIO at the quality gate.