A Continuous Improvement ( Kaizen ) Driven Approach for Realistic Digital Transformation
Equation
5-1 ROI formula
Case Study 1 : Poka Yoke Empowered Worker
Despite smart manufacturing , manual work is still vital in manufacturing , especially for workstations with small batch quantities or complex processes . The Japanese Poka Yoke principle is a solution that aims at the systematic elimination of human errors , coupled with guided worker . Poka Yoke in this case study provides consistent worker guidance to eliminate mistakes by integrating on-site technology , visualization , and wide range of components for individualization . Poka Yoke has empowered workers eliminate human errors , and ensured high assembly quality 9 .
Issue specified : Low worker production efficiency and uncontrollable cost management
• Work speed and errors vary depending on workers
• Difficult to distinguish the worker mistake and the frequency it happens
Implementation : In this use case , we introduce a Guided Operator Solution for the worker assembly process and integrate it to the workstation to have an error-free workstation (
Figure 5-1 ). In the Guided Operator Solution , a controller is installed on-site in a small control cabinet , which is the intelligent , individually configurable and expandable heart of the solution that controls the picking and assembly sequences . Apart from the controller ,
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November 2021