Error Proofing in automation relates to the ability of a system to either prevent an error in a process or detect it before further operations are performed.
- Example Preventative Method: Part present proximity switch.
- Example Detection Method: Pressure test on an AC system.
Error proofing can be performed on every manufactured part, or can be used to monitor critical components of a process.
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The REAL Cost of Quality
Corporations can consume 6 to 24% of their production budget on scrap, rework, repair, warranty. Quality focused Corporations like Toyota consume only 3%. (Source Benchmarking Study)
Six Sigma 80/20 rule: 80% of process defects arise from 20% of the process issues. Control these few issues, and reduce scrap by 80%
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“Error Proofing” Applications Using iRVision
- Small Camera mounted in the tooling on or off the robot.
- Visual check of features
- Adds quality control value to customer at low cost
- Unique Advantage with FANUC
- Processing hardware and software is built into the robot
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10 Common Error Proofing Applications
| Presence / Absence |
holes, fasteners, washers, o-rings, labels, markings |
| Orientation Check |
are the parts right side up |
| Alignment Check |
are the parts rotated properly, pre or post assembly |
| Clearance Check |
is the tool or part clear for an operation |
| Size / Fit Check |
is the hole the right size and in the correct position, are components the proper length |
| Product Integrity |
cap or lid on properly, package properly sealed |
| Part Identification |
feature matching, correct label |
| Kitting and Counting |
Are the correct products in the container, is the correct amount of product present (volume or number), are there threads in a hole |
| Connectivity Check |
no breaks in a bead of sealant |
| Manual Process Validation |
did the operator load all the correct parts into the tool |
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Application Examples
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Assembly Validation
Identify that all critical components have been assembled and are in the correct location.
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Package Validation
Many Applications in the Food Packaging Industry require validation of packaging. |
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Pre-Package Validation
Validate the ase / box packaging prior to filling. |
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Marking Verification
Question - Has the part been marked?
Precise part locating is not required
Part Geometry Locates where label should be.
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Label Verification
Identify that the product label is present.
Label does not have to maintain exact shape |
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Orientation CheckIdentify if product is mis-oriented. Identify if the parts are in the correct orientation. |
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Over Flash Detection
Even very fine details like plason a part or process can be error proofed. |
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Hole Present
Identify that all pierced and laser cut holes are present
Check that holes are approximately the correct size |
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Stud, and Threaded Weld Nut Process Check
- Check if weld nuts are present
- Check if studs are present
- Check if Threads are there. (Thread Count, Pitch Check)
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Measurement
Are all the pieces the correct length +/- a tolerance. |
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