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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

    全方位、堅固的雷射距離感測器提供卓越的性能，並能夠檢測小於1毫米的距離變化。

    • 提供數位訊號、類比（0至10 V或4至20 mA）、透明物件和IO-Link型號
    • 可靠的感應工作距離：從25 mm到610 mm
    • 可以偵測各種目標顏色、材料和表面的距離變化
    • 雙重教導模式（反射光強度+距離變化）是防錯應用的理想選擇，不需要反射鏡就可偵測透明物件
    • 符合FDA食品級認證的不鏽鋼堅固外殼, 環境防護等級達到IP69K
    iVu color vision sensor
    iVu Series

    Vision Sensor

    iVu和iVu顏色圖像感測器用於監測部件的類型、尺寸、方向、形狀、位置以及顏色或顏色變化。 

    • 一體式的設計包含了視覺感測器、控制器、鏡頭以及燈源。
    • 使用Vision Manager PC軟體、機載觸控式螢幕或遠程觸控式螢幕可在幾分鐘內完成配置
    • 多樣的灰階及色彩工具可同時進行多點檢測
    • 輕薄、堅固、IP67級外殼配有集成式環形燈，顏色可變為紅色、藍色、綠色、白色、紅外或紫外線
    • 可更換鏡頭，配有C型支架，可最大限度地提高應用靈活性
    • EtherNet/IP™、 Modbus/TCP、PROFINET®、PCCC、 和串列RS-232
    iVu color vision sensor
    PTL110 pick-to-light device

    PTL110 Series

    Scalable, Versatile Pick-to-Light Devices

    PTL110 多功能拾取指示燈，提供觸控按鈕，光學式感測器， 以及三位數的顯示螢幕，將多個裝置串接後可以建構一個功能強大的拾取指示系統。 具備反應快速以及多種安裝選項的特性，PTL110 系列提供了拾取料件，組裝以及相關的應用一個快速，高生產力，以及高品質的解決方案。 

    • 提供光學式以及觸控按鈕觸發的型號。
    • 部分型號 具備三位數的顯示螢幕，可以顯示計數的數量或提供其他的指示。 
    • M12 快速接頭可以快速安全的將多個裝置安裝起來，無須額外的線材。
    • 指示燈提供 14 色以及多種動畫模式，可以區分不同的狀況。
    • 透過 PICK-IQ™功能，實用的Modbus 序列通訊，使用 Common ID 可以減少多裝置輪詢所造成的延遲。
    • 可以搭配DXM700 無線控制器，應用在購物車或是移動取料設備上。
    See More Error-Proofing Applications
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