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In order to obtain a new project contract, TG-Missouri Corp. needed to effectively mistake-proof its assembly processes within a month and demonstrate dramatic improvements in quality control. The Perryville, MO company, a third-tier automotive parts supplier, makes injection-molded products including body side moldings, interior dash components, and air bag systems. Omron was selected to design and install a poka-yoke system based on pick-to-light sensors.
The Omron Solution
The popular Japanese mistake-proofing method known as “poka-yoke” gives an assembler the opportunity to correct an error in parts picking at the least expensive point in the process. Omron’s latest approach is the F3W-E pick-to-light sensor mounted on each bin, which counts the number of times an assembler reaches into the bin for a part.
When multiple bins are used, the next part to pick can be indicated to the assembler as a reminder after an interruption. In addition to making sure the correct number of parts have been removed from each bin, the sensor can provide a training function, used in conjunction with an operator interface terminal such as Omron’s NS-Series. By showing the order of parts to pull, how many, and where to place each one, the system can keep track of proper and improper actions like a video game. The assembler can be trained quickly to build several kinds of parts with a high level of accuracy. Errors can be fixed at the source with little additional time or resources, leading to an overall cost savings at the end of the process.
Omron’s Services Group delivered, installed, and trained staff to operate a custom quality control system using pick-to-light sensors.
“Operators love the new poka-yoke system,” says TG-Missouri machine engineer George Davies. “I am sure we have reduced defects.” Engineering manager Kevin Poat explained, “Even with someone over their shoulder, operators still make mistakes....From seeing the final numbers, it proves this project is effective.”
Orchestrating Fast Turnaround Behind the Scenes
Omron responded quickly, designing, building, testing, and installing the first poka-yoke system just three weeks after the initial sales call. Here’s how:
Omron’s field application engineers had past experience designing poka-yoke systems for automotive suppliers and electronic assembly fabricators.- Omron’s manufacturing group in St. Charles, IL built the custom control panels for the project.
- Omron field service technicians assisted with field installation, service, and the start-up effort.
- Omron Electronics LLC customer service expedited parts delivery to meet the tight schedule set by TG-Missouri Corp.
- The local distributor, Richard Greene Co., was brought in to provide expertise in sensor selection and ongoing local system support.
“I hadn’t dealt with the Services side of Omron before this project,” said David Buxton, a TG-Missouri machine engineer. “They were good and I was very impressed with the Omron programmer. He was flexible and able to react to changes easily.”