A lean strategy in human mistake prevention
Typical applications
Mitsubishi Electric's Guided Operator Solutions offer a wide array of ergonomically designed terminals and can be deployed in many industry areas that include; automotive, logistics, semiconductor and life science sectors.
Picking
Picking is a key area where production efficiency can be improved and where product quality can be enhanced. Guided Operator Solutions significantly reduce overall man-hours, eliminate mistakes in parts picking, and also reduce operator fatigue.
Parts replenishment
Parts replenishment is another area where mistakes can occur, and these can have knock-on effects in quality control in assembly. Guided Operator Solutions identify exactly where parts need to be replenished and ensure that correct parts are added to the bin.
Production cell
The ‘cell production’ model for assembly is becoming common at plants focused on ‘high mix, low volume’ production, with a single operator responsible for the complete assembly of a product. Guided Operator Solutions can eliminate mistakes at source reducing the risk of re-work on the product.
Kitting
Kitting out a tray with components for a subsequent manufacturing process requires an operator to pick a number of parts from a number of different bins, following detailed work instructions for components and quantities. Guided Operator Solutions ensure the right components are added to the kit box in the right quantities, saving time and reducing mistakes.
Tangible benefits
Mitsubishi Electric’s Guided Operator Solutions not only significantly reduce the risk of quality issues occurring in manufacturing processes, but they also can be deployed in a diverse range of industry sectors where the benefits can be identified by both managers and operators.
Before implementing Guided Operator Solutions
- Time to read part list and instructions
- Operator must search for parts
- Slow assembly time
- Potential for incorrect parts assembly
- Extensive operator training required
After implementing Guided Operator Solutions
- No parts list or instructions
- No need to search for parts
- Faster assembly time
- Increased assembly quality
- Reduced operator training requirements
With the Mitsubishi Electric Guided Operator Solutions in place, the automation system guides the worker to the correct parts bin by simply lighting an indicator next to the correct picking location, or by opening a shutter and requiring an operator acknowledgement of the successful pick of the correct part. Picking becomes not only inherently more reliable and mistake-free but also much faster, so both quality and overall productivity improve.
Poka Yoke = mistake prevention
Poka Yoke is a method of eliminating mistakes in a manufacturing or logistics operation at source before they can occur. Based on the principles of Poka Yoke, a Japanese term that translates as ‘mistake prevention’, Mitsubishi Electric have developed their integrated Guided Operator Solutions.
