Following on from our previous blog about how to set up an automated, repeatable, and consistent screwdriving process, in this post we’ll explain how to mistake-proof your assembly line.
Mistake-proofing, Poke-Yoke, or fail-safing are terms used to describe an automated method that makes it impossible for an error to occur during the manufacturing process. The methodology originated from Shigeo Shingo while working at Toyota, but it’s a standard process analysis tool used in many manufacturing environments today.
In screwdriving applications for aircraft assemblies, error-proofing requires manufacturers to verify that each driving operation achieved the specified clamp load. Driving to the right depth with the correct torque and angle will ensure that each joint operates as designed.
To ensure the proper seating of each screw, a process controller will execute the operation according to your precise specifications. The driver and torque transducer uses WEBER’s C30S process controller to drive the screw to the correct position using an analog depth sensor, at the required angle and within the precise torque requirements.
A 3D screwdriving process controller from WEBER will:
Precise process control is how you can error-proof your automated screwdriving tasks. The system will alert when the angle over-ran its specification, where the torque was over or under during driving, and monitor the depth of the screw where these events occurred. Because it interfaces with your PLC, you can incorporate in-line process validation and stop the line when an issue arises.
To demonstrate compliance, you should gather the required process data and performance parameters for each screwdriving procedure. This data provides proof that the joint achieved the required torque, angle, and depth as per the specification.
Because you are stopping any defective components or assemblies from coming off the line, you can also track your overall performance and continue making corrective adjustments to the process for improved quality. Integration with your MES and QMS systems allows you to document each screwdriving process and deliver these quality records to your customers to easily demonstrate compliance.
With automated screwdriving solutions from WEBER, you can eliminate errors from your production line and increase profitability. We can help you calculate the ROI available from screwdriving automation in this eBook to see how decreasing labor dependency will establish a more resilient manufacturing operation.
WEBER makes automation (and error detection) easy with our intelligent process controllers. You can speed up production without increasing product liability risks, and verify that each fastener or screw achieved the required clamp load. If any errors do occur, you can analyze the performance data to find the root cause of the problem and take corrective actions quickly.
With an automated screwdriving system from WEBER, you can rest assured that each joint coming off your assembly line meets the required specification parameters.
Download our latest eBook here if you want to learn more about our automation solutions and screwdriving systems.