Case Studies – FA

Case 1 : Smart Cards Replacing Paper Labels

Before

 

In order to improve traceability customer had been using printed barcode labels for recognizing individual products during production but faced the following problems:

  • Discarding the labels after use posed a burden on the environment.
  • Removing the labels from the finished products required additional labour.
  • Labels could not be removed cleanly, damaging the products.

After

 
  • Due to repeated use, running costs were successfully lowered.
  • Clients were able to stop using paper and show consideration for the environment as an ecologically conscious business.
  • Because labels were no longer directly affixed to products, the products would no longer be damaged.

Solution

  • Using Smart Cards for process management from parts’ picking to assembly and packaging of the finished product ensures traceability.
  • Smart Cards are also used to manage the restocking of supply parts.
Hardware Used

Case 2 : Using Smart Cards to the Maximum

Before

 
  • Paper consumption was huge and made a larger environmental load
  • Lot of labour and time were spent for manual digitization and storing a large amount of paper documentation.

After

 

NO paper documents were needed, reducing the environmental load

  • By digitizing check lists, time consumed for searching pages, printing, manual data input and paper storage were reduced.
  • Environmental paper based load was eliminated (20 sheets x 400 units = 8000 sheets/day at the time of full operation) .
  • Smart Cards can be Rewritable as many times as required.
  • Using the Smart Card Cases for attaching smart cards made attaching and detaching easy.
  • Larger display of next process made it easy to see the status of delayed item.
  • Switching display for each process made it easy to understand.

Solution

  • Using Smart Cards for process management from parts’ picking to assembly and packaging of the finished product ensures traceability.
  • Smart Cards are also used to manage the restocking of supply parts.
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Hardware Used

Case 3 : Batch Assorting Made Easy

Before

 
  • Several different types of mats are batched before shipping to each customer.
  • Batching the products and matching those to their customers took a long time because the assorting was done manually and according to paper lists.
  • With paper lists as the only control, there is a high risk of assorting errors.

After

 

Our system successfully simplified data management and shortened the work time

  • Using our PTL system assorting of products was easier.
  • The systematization made it easier for data management.
  • The task of putting products into the racks illuminated by PTL lamps led to shorter work time and fewer assorting errors.

Solution

  • A scanner scans the barcode attached to each product and lights up the corresponding PTL modules on the rack.
  • The operator then puts the products in the PTL illuminated places.
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Hardware Used

Case 4 : Preventing Mistakes in Assembly

Before

 

Customer looking for a system to prevent missing of parts and wrong assembly of functional parts that might affect human lives.

  • Lot of work delays and mistakes were occurring daily.
  • Training workers also took time and efforts.

After

 
  • Reduced lot of working hours due to work delays and shipping errors, as well as reduced worker training time.
  • Contributed to a solution for preventing missing parts and wrong assembly of functional parts that might affect human lives for automobile parts
  • Enabled anyone to perform work without mistakes via the Pick to Light system and drastically reduced work delays
  • Reduced working mistakes via the Projection Picking System PPS and by displaying warning information via photographs and text, reduced distribution position mistakes.
  • Because it is no longer necessary to have lists and remember locations, worker man hours were reduced and the burden on staff decreased as well. Reduction of man hours for operator training from 2 weeks to 3 days, saving 7 workdays and approx. Rs.500,000 per year.

Solution

Applied use of Pick-to-Light (PTL) system & Projection Picking System (PPS)

  • First scan the shipping instruction QR code. Respective PTL gets illuminated displaying the quantity to be picked up.
  • After picking up the quantity displayed move it to the next processing location.
  • Using the Projection Picking System🄬 (PPS) displaying the work instructions for parts with designated locations. Illuminating work locations so that the operator can perform the work according to the instructions.
  • Once the work has been completed, transfer the materials to the assembly line.
Hardware Used

Case 5 : Error-Proofing with PPS

Before

 
  • Multiple types of screws were picked based on lists, leading to inefficiencies in preparation times.
  • Screw picking depended on experienced operators.
  • The large quantity of screw types led to working mistakes.

After

 

Enabling easy working without wait times

  • By picking small quantities of many types of screws with the Projection Picking System PPS and large quantities of few types of screws with automated screw dispensers, it became possible to quickly supply screws to the assembly line.
  • Working with the Projection Picking System PPS and screw dispensers enabled anyone to swiftly and easily do working.
  • An error-proofing feature (Pokayoke) using image recognition via cameras and automated screw dispensers overwhelmingly decreased picking mistakes

Solution

  • Barcodes of bins having screws for distribution are scanned via a scanner.
  • After scanning, the Projection Picking System PPS automatically illuminates the drawer positions on the picking locations.
  • Operators pick the quantities of screws from illuminated drawers and as shown on screen.
  • If any wrong drawer is opened, the operator is warned via sound and light. (error-proofing feature (Pokayoke) via image recognition by camera)
  • After the picking from the drawers has been completed, automated screw dispenser picking instructions are shown on screen.
  • The operator dispenses screws from the automated screw dispenser to complete the task.
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Hardware Used

Case 6 : Increase Speed and Efficiency

Before

 
  • Company A needed to streamline picking work to meet their needs to shorten lead time to delivery.
  • Picking errors were excessive due to the high number of similar product groups.
  • To deal with extremely high turnover, the company urgently needed to make picking process easy for anybody.

After

 

Picking efficiency improved and sharply reduced shipping errors, which helped stabilize quality

  • Our system makes it possible for a simple explanation to enable even the least experienced workers to perform the work quickly and correctly. The foreman’s training workload also decreased sharply.
  • Work performance on terminals visualize when, by whom, and how picking work is performed. On the rare occasions when errors occur, it is now easy to trace work performance on the floor.

Solution

  • A pick to light system based on a software package that enables picking by installing a Pick to Light system on shelves that hold parts.
  • The software is easy for users to maintain.
  • The system also makes it easy for users to configure the light modules.
Hardware Used

Case 7 : Shorten the Lead Time

Before

 
  • This company needed to shorten lead time to delivery for a multitude of orders from users.
  • The company also needed to arrange parts quickly and reliably for post-process assembly.

After

 

Sharply reduced errors in arrangement for the assembly process

  • Our system successfully shortened lead time by improving picking efficiency, enabling anyone to perform picking work easily and quickly.
  • Our system sharply reduced errors in tray arrangement for the assembly process, ensuring consistent product quality.

Solution

  • A pick to light system based on a software package.
  • When the list is scanned by a scanner, lamps in the corresponding locations light up; the mechanism makes it easy to instruct operators, allowing anyone to perform picking work easily and quickly.
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Hardware Used

Case 8 : Manage Work History

Before

 
  • Company A was unable to manage assembly-line part picking performance in numerical terms.
  • Lines reset for new parts frequently stopped due to picking delays caused by operators’ unfamiliarity with the new configurations.
  • There were cases where it was not possible to use the correct electric screwdrivers for tightening.

After

 

Access to line work history leads to fewer picking errors

  • Before Company A introduced our system, operators had to read written instructions as they picked. Under our system, operators pick and batch parts illuminated by light modules, so line work progresses smoothly even with inexperienced operators because new line settings for new parts pose no extra burden.
  • Pairing with external equipment via 1-Point Digital I/O Interface AW2902, made it possible to use the correct electric screwdrivers according to the work sequence, and also to maintain histories in numerical terms.

Solution

  • We created a Pick to Light System which enables the assembly of the correct parts using the correct tools in the correct order.
  • When the base of a product moves on to the next procedure, the light module of the shelf that holds the part to be attached to the base lights up.
  • The operator still picks the part and uses an electric screwdriver to attach it, but the electric screwdriver is linked to the system via 1-Point Digital I/O Interface AW2902, so the work history now shows whether the correct screwdriver was used.
  • This reduces picking errors and makes it possible to manage work histories in numerical terms in real time.
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Hardware Used

Case 9 : Increase Operator Efficiency

Before

 
  • The company manufactures small quantities of a diverse array of products, and the many procedural patterns result in a long training period.
  • The production involves many parts that are placed around the cells, constricting workspace.

After

 
  • Since the videos, pictures and comments are displayed, the need to memorize procedures is eliminated. Hence the average training period was reduced from seven days to two days.
  • The torque screwdriver signal and the error-proofing function of the Projection Picking System (PPS) are linked. This prevents operators from picking the wrong parts and forgetting to insert screws.
  • Operations were improved so shelves dedicated to each model are switched out. This resulted in a 70% decrease in the space required for parts around cells.

Solution

  • AIOI Systems constructs a working area and a frame with a projector and camera. The operator places pull-out shelves on a cart, and places the cart behind the frame.
  • The operator uses the PPS to read the manufacturing instructions and barcodes on the shelves, checks the shelves, and then starts working.
  • The operator picks parts from the openings projected by the Projection Picking System (PPS).
  • If the operator pulls out the wrong shelf, the system detects the AR marker on the side of the shelf, and alerts the operator by illuminating the entire shelf in red light and sounding an error alarm (error-proofing function of the Projection Picking System (PPS)).
  • The top of the display area features large displays of videos, pictures, and comments that illustrate the work procedure. The operator follows the procedure as per the display.
  • Power is supplied to the torque screwdrivers during the screw tightening process. When a screw is tightened in the position indicated by the Projection Picking System (PPS), the system receives a “complete” signal from the torque screwdriver, and subtracts one from the number of remaining screws.
  • The operator continues to follow the procedures on display until the model is complete.
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Hardware Used

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