Error Proofing

Ensuring product quality is a never ending process. Ineffective processes, human errors, equipment failures and material defects can adversely affect product quality and production efficiency. Early identification of mistakes, the conditions that give rise to them and correcting those conditions is fundamental to error-proofing and promotes a Lean manufacturing environment. Banner’s expertise in a broad range of sensing technologies allows us to offer problem-solving solutions that help manufacturers overcome these challenges, increase efficiency, improve quality, and reduce expenses and downtime. 

Narrow Results

Clear All Filters

+- Sensor Type

  • (22)
  • (17)
  • (3)
  • (2)

+- Industries

  • (1)
  • (18)
  • (8)
  • (2)
  • (2)
  • (1)
  • (2)
  • (4)
  • (6)
selected filters
  1. logo with r symbol

    The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

  2. Combined Inspections Used to Meet Quality Standards

    Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.

  3. Operator Guidance Solution

    A Henshaw customer manufactures drivetrain and powertrain systems for the automotive industry. The company had experienced productivity losses due to errors in the assembly of transmission valve bodies. Henshaw was tasked with developing a system that would reduce errors and improve the assembly process.

  4. Run Bar Provides Operator Guidance

    A leading machine manufacturer builds workstations designed for accurate, timely and cost-effective battery cell assembly. A value added component of the workstations is an operator guidance device that does three jobs: enables assembly processes to start and stop, indicates parts to be picked and installed, and completely stops line operation if emergencies occur. When it became too costly for the OEM to construct and mount these devices themselves, they turned to Banner to craft an all-inclusive solution. To honor the time line requirements of their customer—a major tier two battery supplier—the OEM needed the solution in eight weeks.

  5. Wireless Call for Parts

    A system of Banner’s TL70 wireless modular tower lights and K50 touch buttons provides an efficient, easy way to communicate a call for more parts with a forklift driver. When a workstation is almost out of cartons, the operator touches the ergonomic K50 touch button which changes the status on the connected TL70 wireless tower light to red.

  6. Cap Orientation Verification

    Banner’s Q4X laser sensor, made of 316L grade stainless steel, is very suitable for pharmaceutical environments and other aseptic filling areas. The Q4X has a sensing range of 25 to 300 mm, precise beam spot size and can effectively detect the orientation of caps as they exit a feeder bowl. If any caps are upside down, the Q4X will detect a height difference and reject the cap.

  7. Engine Block Positioning

    Banner’s L-GAGE LH Laser Displacement Sensor is ideal for applications where exact positioning of a part is crucial. The L-GAGE LH Series consistently looks at dark targets on micron levels. Banner’s laser displacement sensor is extremely accurate for precise positioning applications, including engine block positioning. The sensor can take measurements on virtually any surface, such as cast iron or aluminum alloys, which are often used for the manufacturing of engine blocks.

  8. High-Speed Tablet Counting With DF-G2

    Banner’s DF-G2 small object detection fiber amplifier is ideal for small object detection and counting applications. The DF-G2 amplifier has a fast response speed and can detect extremely small sizes, such as 3 mm tablets or pills. When the tablets fall into bottles, it fires an output to the DF-G2 fiber amplifier, which keeps count of tablets.

  9. Kitting Operation with Gloves

    Banner’s fixed-field K50 indicator detects gloved hands , sensing when operators select the correct parts during the kitting process. The K50 indicator’s logic function is then able to notify the operator that he/she picked correctly by changing from green to yellow—additional colors can be selected to suite to the manufacturer’s preference. The K50’s ability to detect black gloves is especially important for lean manufacturing processes where workers typically wear dark gloves.

  10. Counting Gel-Caps in Pharmaceutical Bottling Applications

    To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

  11. Pick-to-Light Kitting Support

    Banner’s K50 Optical Pick-to-Light series is a compact, self-contained, three color indicator with integral sensor. Green typically indicates which part to pick, and when the internal sensor detects the hand, the indicator changes to yellow to confirm the task is complete. An optional third message is to display red for a mispick.

  12. Order Fulfillment

    The system controller issues an instruction to pick an item from a particular location. The controller turns on the PVA’s job lights at the specified location. The job lights go off when an item from that location is removed. If multiple items are required from one location, the job light stays on until the correct number of items are removed. The bright light of the EZ-LIGHT PVA pick-to-light sensor makes it possible to see which part to pick from a distance, saving time.

  13. Pick Sequence Indication and Pick Verification

    A pair of EZ-LIGHT PVA pick-to-light sensors are mounted to a rack on either side of a bin. In response to a signal from a process controller, the PVA illuminates to show the assembler which part to pick next. When the assembler's hand enters and leaves the bin, the controller recognizes that the part is picked and lights up the PVA for the next bin in the pick sequence.

  14. Part Removal Verification in Automotive Assembly

    In an automotive assembly plant, temporary pins—called grenade pins—are used to attach some parts temporarily. To make sure the grenade pins are removed, the inspection station includes a container for the pins that is equipped with an EZ-LIGHT PVA pick-to-light sensor.

  15. Bin Coverage for Bin Picking Applications

    The PVL provides 100% reliability over a large area and can be mounted directly to the racking profile. The PVL can also be mounted in a vertical or horizontal orientation to suite application needs. This versatility allows for a quick set up and quick and efficient processes.

  16. Small Parts Counting

    Banner's DF-G1 Series amplifier provides a simple setup and calibration for small part counting applications. Once the amplifier is setup, the easy-to-read digital dual display allows for simple operation because it shows the signal level and threshold simultaneously.

  17. Pick-to-Light Solutions

    Several technologies and solutions are available for bin-picking applications for error-proofing processes. Light arrays prompt the operator for part selection with integral job lights, then reliably sense retrieval of the part, using an array of visible red or infrared sensing beams located in front of the bin.

  18. Call For Parts

    Installing a signal to parts bins is a simple solution to keeping parts bins stocked and the assembly line productive. The EZ-LIGHT K80 Call Light is a large illuminated signal the operator turns on before parts are depleted. The K80 flashes red to signal stocking personnel to replenish bin supplies. In flexible manufacturing environments, operator stations and work cells must allow for quick changes to assembly and manufacturing lines.

  19. High-Speed Soybean Counting

    To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

  20. Electronic Marking Verification

    The solution uses an iVu Series sensor configured for a Match inspection. A reference "good" identifier is taught into the sensor. In service on the production line, the sensor detects when a component does not have the correct identifier, and sends a fail output to the line, and the part is rejected.

  21. Counting Dropping Parts with an LX Sensor

    Banner Engineering's LX series part-sensing light screen generates a multi-beam infrared pattern that can detect any item passing through the beams, enabling exceptional sensitivity to small objects. As small parts drop from the feeder bowl into the plastic bag, the LX sensor detects each part and triggers the line to advance when the bag contains the specified number of parts.

  22. Adhesive Bead Detection

    The D10 Expert sensor, with the fiber optic sensing tip positioned near where the robot applies the adhesive, verifies that adhesive is applied to the IC chips. Opposed pairs of VS2 sensors detect when the level of filled wafer trays exceeds a preset height.

  23. Rubber Washer Detection on Engine Block

    Banner’s Q4X versatile laser sensor is ideal for presence/absence detection even in challenging applications with small height changes such as confirming a small black target is present on a shiny metal part. The washers should be present in the cast aluminum engine block, and if the Q4X detects a slight height difference, even as small as 1 mm, it will send a signal to alert operators a rubber washer is missing or there are multiple washers present. The Q4X can detect duplicate rubber washers with its unique windowing capability while in foreground suppression mode.

  24. Error-Proofing Assembly Applications

    Banner’s K50 Series of single-point pick-to-light sensors are a simple, easy-to-use error-proofing solution in assembly applications. In this application, the job light is Green while the job input is active, indicating the correct bin for the next pick. The presence of the assembler’s hand initiates an output change of state, turning the job light red. The job light above the next pick location will then turn Green.

  25. Package Inspection Using Diffuse-Mode Laser Sensors

    A WORLD-BEAM QS18LD diffuse-mode laser sensor can be used to accurately inspect each package as it passes on a conveyor. The sensor emits a visible Class 1 laser sensing beam, focused on the piece of tape used to seal the package. When the top of the box is closed and sealed correctly, the tape will return the sensing beam back to the receiver.

  26. Incorrect Pick Signal

    The EZ-LIGHT K50 sensor lights above a bin to show the assembler which part to pick. If the assembler reaches into a different bin, that bin's EZ-LIGHT K50 sensor lights up in the designated warning color—in this example, red— to indicate the error.

  27. Part Pick Verification from a Wide Bin

    The EZ-LIGHT K50 sensor in retroreflective mode indicates that the next part in the assembly sequence is the sunroof. When the operator selects the sunroof from its wide bin, the K50 detects the pick.

  28. Part Pick Verification for Order Fulfillment

    In an order fulfillment operation for a candy distributor, bins are equipped with EZ-LIGHT K50 sensors connected to a process controller programmed with the order. Based on the order, the K50 illuminates to show which items to pick. When the worker places a hand into the bin, the indicator detects the presence of the hand, and the controller triggers the K50 on the next bin to pick.

  29. Part Pick Verification for Large Bins

    To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor is placed on the top rail of a shelf, looking down on the shelf opening. The PVD is interfaced with a process controller that is programmed to illuminate the PVD on the bin to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD on the next bin to pick.

  30. Part Pick Verification for a Camera Lens

    Each bin has an EZ-LIGHT VTB Verification Touch Button connected to a process controller programmed with each order manifest. The VTB's LED base glows to indicate which lens to select to fulfill an order. After selecting the lens, the worker places a finger in the touch zone of the VTB to verify the pick. The worker does not have to apply any pressure to, reducing the risk of repetitive motion injury.

  31. Part Pick Indication for Small Bins

    To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor with a 400 mm range is interfaced with a process controller programmed with the correct assembly sequence. The controller makes the PVDs light up in the correct order, to show the assembler which part to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD of the next bin in the pick sequence to light up.

  32. Part Loaded Indicator

    Before the EZ-LIGHT K50L indicator light was installed, the operator would place a part on the machine and then step out of the work area to check the stack light to see if the part was loaded properly. If not, the operator had to repeat the set-and-check process before initiating the machine's action on the part. Since the K50L was installed inside the workstation, using a simple Y splice, the operator can tell immediately if the part is correctly placed.

  33. Part Kitting

    After the operator selects a washer or shim from a bin, the operator places the washer on the corresponding illuminated EZ-LIGHT indicator on a rolling cart.

  34. Order Fulfillment: Wide Shelf

    Each wide shelf is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor in retroreflective mode, which has a range of up to 2 m. The PVD lights up on the bin from which the worker should select the map to ship.

  35. Bin Picking for Order Fulfillment

    In a book packing warehouse, the rack above each carton of books is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor. A worker fills orders by selecting the quantity of each book specified on the packing slip. To make it easier for the worker to find the cartons from which to pick books, the PVDs above those cartons are illuminated. The PVD detects the workers hand in the carton to verify that the title was picked.

  36. Long Bin Pick-to-Light

    The EZ-LIGHT PVA pick-to-light sensors provide a reliable error-proofing solution for various operation systems. The light indicate to assemblers which items to pick and in which order to pick them.

  37. Part Detection for Error-Proofing

    To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. In this application, the operator removes a cap and drops it through a funnel. The cap is then detected by the Small Object Counter, which verifies that the cap has been removed so the assembly process can continue.

  38. Cap Sorter Detection

    Banner’s R55F fiber optic sensors have the capability to detect the presence of caps regardless of their color or size – a clear advantage in an industry that has a wide variety of bottle caps and frequent line changes. In this type of application, the fiber optic sensors are used to recognize long pauses between the caps which would then signal a jam to the operators of the machine. The fibers are compact and can be easily mounted in confined and typically inaccessible spaces.

  39. Assembly Error-Proofing

    Banner’s Q4X analog sensor can give operators real-time measurement feedback to verify the part is present and correctly positioned before moving to the next operation. In this application it is crucial that both flanges around the weld nut are properly seated in order to fit correctly in the final assembly. The Q4X’s analog measurement can determine if both flanges are properly seated.

  40. Pick Indication and Verification

    Push-button EZ-LIGHT K50 pick-to-light sensors on a rack of parts light up to indicate which parts to pick. After picking a part, the worker pushes the button on the indicator light to verify that the pick is complete.

  41. Wireless Call for Parts

    Each production operator is equipped with a toggle switch and a Wireless Q45 Sensor with a dry contact input. The gateway is connected to a large lane status display board with multiple K50 EZ-LIGHTs. When a production operator needs supplies, the operator toggles the switch connected to the Wireless Q45. The corresponding K50 EZ-LIGHT light on the display board lights up, signaling to forklift drivers where they are needed.

  42. Reducing Production Errors with a Pick-to-Light System

    A supplier of door panels to a global car manufacturer wanted to implement a pick-to-light system to reduce errors and the lost time that results from picking the wrong part during assembly.

  43. Improving Production with Pick-to-Light Systems

    A Banner wireless solution is a simple way to optimize inventory, reduce errors, and minimize waste. Each SureCross Performance Node with I/O Mapping can be equipped with up to six EZ-LIGHT operator indicator lights. The SureCross Gateway is conveniently located at a central location where maintenance personnel and management can monitor the parts consumption throughout the site.