Error Proofing ensures part quality at each stage of the process

There is a new concept in manufacturing that is sweeping through the U.S. manufacturing community. The concept is Error Proofing and it is as significant as the adoption of the first PLCs thirty years ago. Error proofing is application driven. It does not depend on a specific new technology, but on application expertise on the part of manufacturing engineers in charge of product quality. The idea is to use sensors to confirm that each step in the process is not only being performed, but being performed correctly.

An error proofing program consists of sensor-driven quality checks custom designed for each manufacturing process step that prevent a part from being made incorrectly. Using this process, sensors no longer merely report that an assembly step is complete or that a production pallet is in a certain location. Now they verify that a part is being man-ufactured or assembled correctly at each stage of the process – and prevent the process from continuing if it is not. Using error proofing, a finished product is automatically within specification and ready for the customer. No need for further quality checks.

For example, a production step calls for two color coded pieces to be attached to each other. Rather than have an operator load two different loads of pieces of the same color into the process and a sensor report they were attached correctly, two color-sensitive sensors are used at the attachment point to verify that the two pieces are in fact the correct color.

Error proofing can also protect expensive production equipment, automatically identify production subassemblies, and protect operators from dangerous conditions on the line. A good error proofing program will increase productivity, increase product quality, decrease costs and scrap, and increasing a company's chances to prosper in today's highly competitive manufacturing environment.

Balluff Inc.
Florence, KY
balluff@balluff.com