According to a recent study, human errors alone cause an extraordinary 23% of unplanned downtime in manufacturing. Mistake-proofing - also referred to as Poka-Yoke - is a Japanese ideology describing any method used to detect and prevent errors that cause defects.
Below are the top 5 mistake-proofing techniques in a plant floor error-proofing software that will help manufacturers achieve first time quality in a complex and ever-changing environment.
Interactive assembly instructions and operator guidance are tied to every work step and provide continuous feedback to the operator, based on their skill level. As an example, managers would have the ability to display smaller step progression for an operator with one week on the line, versus only critical checkpoints for a five-year veteran. The same principle applies to a new product or process on the line compared to an existing, well-known process. The key word here is “interactive”, ensuring operator engagement and mistake-proofing error checks at every critical point in the assembly process. These checks prevent an error from happening or catch the error within a few seconds of its occurrence. This method greatly reduces the amount of overall production downtime.
Controlling an operator’s access and checking their certification level and checking their certification level before allowing them to perform specific assembly tasks is a must for accountability and compliance. Operator engagement in an increasingly dynamic manufacturing environment is one of the key challenges manufacturers face.
Ensuring operator accountability is the first step towards mistake-proofing by driving engagement and ultimately reducing downtime.
Many manufacturers are already seeing the benefits of mistake-proofing by using software in their processes – reduced production downtime, savings in rework, repair and recall costs, protection of brand reputation, and more. Contact our experts to schedule an appointment or learn more about error-proofing by Atlas Copco.
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