Digital instructions


Producing the correct quality directly, 'zero faults", is important for resource-efficient production in manufacturing industry, where production is often governed by customer orders. This results in a production flow that contains a wide range of variants. It such a situation it can be difficult to consistently do the right thing.

Incorrect assembly and missed steps in the work process could result in major costs. There could be a need to adjust or rework the products or maybe even scrap them. At worst, incorrect products could reach the customer, which is not only expensive but could damage the good name of the company. A basic prerequisite for achieving a high, even level of quality is the use of a standardised working method – all operators carry out the same steps in the work process in the same way and in the same order.


Poka Yoke Client makes paperless production

Working in collaboration with a number of major customers, Binar has formulated Poka Yoke Client, a support system that guides the operator to follow standardized work flow (SOB). The operator receives help from assembly instructions presented in both image and text form. The system is designed in such a way that an experienced operator does not need to cope with restrictive control procedures in his or her work. An inexperienced operator, however, receives the support and help required to consistently do the right thing.


Quality-enhancing benefits

  • Standardized working methods that are performed in a predetermined order.

  • Each step that is pointed out by the FMEA analyzis, is acknowledged by the operator (non-contact).

  • Clear instructions that can be issued in several languages.

  • Changes in instructions can be introduced at all stations at the same time and have a direct impact without any delay.

  • Create a sense of security for operators with a growing range of variants.

  • A production environment with increasingly shorter production series.

  • One-piece production with a large degree of manual work can be carried out while still retaining a high level of quality.  

  • Can be combined with peripheral equipment, such as a torque wrench, hand tools, processing machinery, robots etc. 



Examples of quality-assured assembly

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 The operator begins the task of registering his/her personal ID card. Information about each individual product and who is responsible for the assembly is stored and can be used in subsequent processes. By doing so the process can be traced backwards if, despite everything, a fault should rise. When an assembly sequence is completed, a barcode label is printed out with the same information. The operator begins by registering his/her personal ID card. The image also shows the 'ball' – a lamp sensor that indicates a stage in the work process without item picking.




 The items that are to be picked in each stage of construction are indicated with the aid of photocells with built-in indicator lights (lamp sensor LP115), which is located in the item rack. The lamp sensor above the item that is to be picked is green. When the operator picks the item, the photocell is activated by the operator moving his/her hand. By doing so, the system receives acknowledgement that the correct item has been picked.



Display with instructions

After acknowledged Pick to Light, the display shows instructions for how to asseble the parts that has been picked. The stages in the process that is to be carried out are described with both guidance text and instructive images. A step does not always need to include picking items. It could, for example, involve preheating a cogwheel in an oven. Steps such as these are indicated using a joint light sensor known as the 'ball'. As with other light sensors, the 'ball' is turned on to indicate the step in the process and when the operator activates the photocell (acknowledges), the working instructions in question are shown on the display.



Poka Yoke solutions

In a manufacturing process in which the TPS (Toyota Production System) concept is applied, a key element is the inclusion of different items of Poka Yoke equipment for error-proofing. Workstations using Binar's Poka Yoke Client are a good example of such equipment. For example, the station's electric tightener is introduced into the assembly sequence in such a way that it can only be used at the right moment. When a joint is tightened, angle and torque information is sent back to the system for verification. Each step in the work process must be verified in order to move on to the next stage.


Easy to create work sequences

The whole system is administered using the Poka Yoke Manager software. The software could very well be used on a PC in the product technicians' office. Here the product technicians can easily create or change the work sequences. No programming or external assistance is required. The work takes place independently of current production. When a work sequence has been tested and is ready, it is introduced at the designated work stations. The instructions are built up using PDF files that are placed in the work sequence. The work sequences are then linked to actual workstations and can be activated or deactivated as necessary. All workstations are configured via Poka Yoke Manager. Different workstations are built up, which are then linked to actual workstations. If several workstations look the same, they can be allocated the same station type. All information is stored centrally and can be accessed via the network.

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System overview


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