Solutions for Automotive

Streamlining production, mistake-proofing processes, continuous improvement . . . all manufacturing organizations strive towards these goals. And nowhere is that more evident than in the Automotive Industry. Automotive assemblers are requiring more and more accuracy throughout the supply chain.


A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur. Developed in Japan in the 1960s by Dr. Shigeo Shingo, poka-yoke systems are still being used at Toyota more than 50 years later, not to mention manufacturers around the globe.

So how can ADI help eliminate mistakes in your operation? By example.

For a Tier 2 automotive supplier in Central Ohio, making sure these 3 things happened was critical for them to avoid charge-backs for non-compliance:

1) the right label was put on the right part

2) the right part was put in each tote

3) the right quantity of parts were put in each tote

ADI provided a POWERPRINT Enterprise solution which provided the following:

  • A label printing solution at line-side that automates production sequencing, ensuring the right label is put on the right part

  • A label printing solution that provides a poka-yoke mechanism that prevents labeling mistakes or identifies them as they occur

  • A label printing solution that ensures correct parts and correct counts in each tote

Watch the video to see how POWERPRINT automated a work cell, and helped to "mistake-proof" their process.

Video transcript . . . The POWERPRINT system you are observing shows three unique injection mold parts coming to an operator’s station. Each part is placed in a matching nest. The system is designed to print a unique barcode for each part and to use a scanner to make sure the right label is on the right part. After the part is labeled, it passes over a sensor. When the sensor is triggered, the part is counted into the quantity of parts needed for that tote. The system makes sure that each tote has the correct number of parts and that all parts are labeled correctly.

Case Study - Mistake Proofing Quality Control Ensures Good Parts to Honda

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For a Tier 1 automotive manufacturer supplying to Honda, making sure that only “good” parts were shipped was the end goal. However, the difference between a good part and a bad part was only thousandths of an inch, leaving the supplier little room for error.