Mistake Proofing QC Ensures Good Parts to Honda
For a Tier 1 automotive manufacturer supplying to Honda, making sure that only “good” parts were shipped in the right quantity 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.
The supplier manufacturers only one part, but faced two key challenges in delivering the part to Honda:
Delivering only good parts to Honda
Delivering the right quantity of good parts to Honda
One key dimension is the singular factor that determines if a part is good or bad. The measurement is taken with a digital micrometer to validate a part has been produced to spec. A green light on the micrometer indicates a good part.
In both the old and new systems, this process is the same. However, under the old system, what happened next was completely under the operator’s control, who had to visualize the light indicator for each part and act accordingly:
A good part, indicated by a green light, was labeled and put in a tote
A bad part, indicated by a red light, did not receive a label, but was redirected to be reworked
Due to its repetitive nature, the process was prone to errors. Distractions and interruptions in the process also added to the probably of errors occurring which not only allowed out of spec parts to pass quality control, but also threw-off part counts.
ADI POWERPRINT Provides a Mistake Proof Process
POWERPRINT Solo provides a stand-alone, smart printing solution. In this case, the Honeywell PD43 smart printer was used. Smart printers run independently of a host computer and are programmable. These capabilities make smart printing ideal for line-side printing, where environments are not suitable for PCs.
For this supplier, the solution consisted of 2 stand-alone printers, providing checks and balances for the following printing processes:
Printer 1 is responsible for printing the item label. Through POWERPRINT Solo integration, the printer receives input from the digital micrometer and will only print an item label if the “green light” was given for that part. This poka-yoke mechanism ensures that a bad part is never labeled or put into a tote for shipment to Honda.
Printer 2 is responsible for printing the tote labels. Through POWERPRINT Solo program, the printer keeps count of the number of parts going into the tote by scanning the barcode on the part (which has previously been verified as “good” parts) and will only print the tote labels when the tote count is at the right quantity of parts.
Benefits of the POWERPRINT Solution
POWERPRINT eliminates the human element of deciding if a part is good or bad
Using a poka-yoke mechanism, POWERPRINT automates the printing of item labels and only prints the label for a part that is within specification
POWERPRINT keeps count of good parts and ensures totes are filled with the right quantity of parts