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    Error Proofing and Poka Yoke

    picking parts from a bin

    Prevent Errors in Lean Manufacturing Environments

    Error proofing refers to preventing a process from resulting in defects by stopping mistakes at the source, rather than down the line.  

    Another word for error proofing is poka-yoke (which is Japanese for avoiding inadvertent errors). Poka-yoke design is often used to avoid human error by either warning operators when they are about to make a mistake or preventing them from making a mistake at all. Poka-yoke design makes it virtually impossible for an operator to complete an action incorrectly. 

    Preventing mistakes at the source can significantly improve productivity by keeping mistakes from becoming bigger problems downstream.  

    Overview
    Applications
    Products
    Benefits of Reliable Error Proofing
    smart camera inspects car door
    Never Waste Value

    Quality Inspection at the Source

    Error-proofing takes quality control to the next level by checking for mistakes and defects before those defects can proceed to the next stage of production.  Preventing defects from proceeding from one stage of production to the next avoids wasted time and resources spent working on defective parts. 

    In manual processes, such as bin picking, visual warnings clearly indicate  to operators when their actions are correct or incorrect using colored and/or animated lights. Light-guided assembly is an excellent example of using visual indication for error-proofing.

    Meanwhile, in more automated processes, error proofing solutions like sensors and vision systems can be used to ensure poblems are corrected before a process can proceed.  

    Banner Engineering provides sensor, vision, and light-guided solutions for error proofing to help manufacturers increase efficiency, improve quality, and reduce downtime.  Keep reading to learn more, or contact us to discuss your specific application. 

    3 Common Technologies for Error Proofing
    laser sensor verifies that a metal sheet is indexed on a stamping press
    Sensors for Error Proofing
    • Laser measurement sensors are often a reliable solution to error-proofing applications.  
    • Laser sensors from Banner detect and measure the most challenging targets, for error-proofing solutions manufacturers can trust. 
    • For example, in metal stamping applications, it is critical to ensure that metal sheets are properly indexed on the press before stamping to avoid material waste and damage to the press die. 
    • The press cannot operate until the sensor verifies the leading edge of the material and confirms that the metal sheet is both present and properly indexed.  
    ivu color sensor detects the wrong color trim on a car door
    Vision for Error Proofing
    • In some applications, a vision solution can be an excellent choice for error-proofing.
    • For example, in automotive assembly, interior trim pieces are interchangeable, but vary in color, making it easy to install the wrong piece.  As assembly progresses, correcting errors becomes more difficult.
    • If an error is detected (the wrong color trim is placed), the error must be remedied before the automotive assembly can proceed to the next step. 
    ivu color sensor detects the wrong color trim on a car door
    A pick-to-light solution at an assembly station
    Pick-to-Light for Error Proofing
    • Perhaps one of the most common error-proofing technologies in assembly processes is light-guided picking, also known as pick-to-light. 
    • Pick-to-light devices use colored LEDs to visually guide assemblers to pick the correct parts, in the right quantities, and in the proper sequence.
    • This reduces the risk of human errors and speeds up build times to ensure high quality while maximizing productivity. 
    Featured Products
    Q4X laser distance sensor
    Q4X Series

    Rugged Laser Distance Sensor

    坚固耐用的多功能型激光测距传感器性能卓越，能够检测出亚毫米级的距离变化。

    • 开关量，模拟量（0-10 V或4-20 mA），透明物体检测，可提供IO-Link型号
    • 可靠的检测范围，近至25毫米，远至610毫米
    • 根据距离检测各种各样的目标颜色、材质和表面
    • 双示教模式（强度+距离），是防错应用的理想选择，可实现透明物体检测，无需反射板
    • 坚固耐用的FDA级不锈钢外壳，防护等级达IP69K
    iVu color vision sensor
    iVu Series

    Vision Sensor

    iVu 和 iVu 彩色图像传感器用于监测零部件的类型、尺寸、方向、形状、位置、颜色或颜色变化。 

    • 一体化解决方案，包括相机、控制器、镜头和指示灯
    • 使用 Vision Manager PC 软件、板载触摸屏显示器或远程触摸屏在短短几分钟内即可配置完毕
    • 使用各种灰度或颜色工具进行多点检验
    • 紧凑、坚固的外壳，防护等级达 IP67，配备各种颜色的集成环形灯，其中包括红色、蓝色、绿色、白色、红外和紫外灯
    • 可互换镜头，包括 C 卡口，最大程度实现应用灵活性
    • 以太网/IP™、Modbus/TCP、PROFINET®、PCCC 和串行 RS-232
    iVu color vision sensor
    PTL110 pick-to-light device

    PTL110 Series

    Scalable, Versatile Pick-to-Light Devices

    PTL110 拾取指示设备是多功能指示灯，可选配触摸按钮、 光学传感器和三位数显，通过串联打造强大的拾取系统。PTL110 系统响应迅速，安装灵活，可提高拾取、套件制作及相关应用的速度、生产率和质量。

    • 提供具备光学传感器和触摸传感器功能的型号。
    • 选配的 3 位字母/数字显示可用于指示部件计数或提供其他指令。
    • M12 连接器支持快速、安全地安装多个设备，无需额外布线。
    • 指示器提供十四种颜色和多种动画功能，以此区分多种情况。
    • 由 PICK-IQ™ 提供支持，这是一种专用的 Modbus 兼容串行总线协议，它使用通用 ID 来减少轮询多个设备所产生的典型延迟。
    • 可与 DXM700 无线控制器配对，以便在推车和移动拾取站中部署。
    See More Error-Proofing Applications