Defect prevention on order picking and manual assembly workbenches
Zero-Defect Assembly
Significant Productivity Boost
Reliable Multi-Variant Product Processing
Rapid Employee Onboarding
When installing components at manual workbenches, the supplied components are picked manually. In this process, it is almost inevitable that incorrect components may be selected and installed due to employee routine. As the complexity and variety of components increase, the likelihood of picking incorrect components also rises.
The benefits of the poka-yoke assistance system at a glance:
Zero defects in assembly
Productivity is increased considerably
Process reliability even with multiple product variants
New employees are trained and productive within a few minutes
Consistent quality regardless of the employee, no rectification or repair
No parts lists or instructions on paper
No searching for components
Short assembly times
Errors can easily be avoided with guided production solutions.
Typical sources of errors in manual assembly include picking incorrect components with a similar appearance or name, selecting and installing components in the wrong order, or simply omitting a component. A quality inspection conducted after production is not sufficient to prevent defects during assembly. Repairs or corrections are significantly more costly and time-consuming or, in the worst case, the customer receives incorrectly assembled products.
A poka-yoke assembly workbench offers a solution to these challenges. The poka-yoke principle is a Japanese concept that can be loosely translated as "error prevention." It is a method designed to prevent errors at their source, whether in production or logistics—before they even have a chance to occur and cause unforeseen costs.
Functionality Overview
The hinged doors are the main feature of a poka-yoke workbench. This means that poka-yoke also provides a physical barrier in addition to the visual aids of the classic pick-to-light system, ensuring that incorrect parts cannot be picked, even inadvertently. The employee is guided step by step to the correct component container by the opening of the flaps and the lighting up of the display. The materials required for the working step are picked, eliminating the need for a long search. Poka-yoke sensors/flaps are also used for material replenishment, as topping up components is another area susceptible to errors. For example, a QR code on a box of screws is scanned, and the system opens the correct compartment for replenishment. This ensures that the assembly worker is supplied with and installs the correct materials. The individual working steps can be shown on a display screen, with work instructions and error messages displayed visually using text and/or images.
1
The "Sho-Haisen" wiring principle allows for efficient attachment and replacement of all sensors using the same plug connector on the cable. The connections are intuitive, enabling quick and easy network installation. Additionally, the system offers simple configuration, programming, and maintenance processes.
2
The system offers a wide range of sensors and modules with various functions. It is customizable with variable width, color, and depth options. Additionally, the flap technology accommodates compartments of different sizes.
3
Special bridges connect assembly stations through CC-Link or CC-Link IE networks. The system can be integrated directly into the control system using special software. Additionally, it allows for a simple connection to the IT system.
4
New devices can be easily integrated into the overall system. New sequences can be stored using a remote control or teach mode. The system can also be perfectly adapted to meet retroactive requirements.
At Phoenix Mecano we don’t simply sell products and offer services. We constantly push for more: high-quality hardware and software products that can go further, process innovations that open up new opportunities, customized solutions that supercharge productivity. Here’s how we make much more possible for our customers:
When it comes to what’s possible, our engineers and designers can help you see beyond today’s limitations, to new potential.
Whether it’s supporting your new product designs or reimaging your assembly operations, our team is with you for the journey.
We come from a long Swiss and German engineering heritage and are proud of our culture for always seeking engineering excellence.
As technology transforms the manufacturing landscape, we bring you the deep expertise and industry leading partners that make innovation feel natural.
Our team brings many years of expertise working across sectors as diverse as Agriculture, Healthcare, Maritime and many more.
Our service led culture makes us the perfect partner whether you’re simply looking for a one-off product or a supply chain partner.
)
