In High Volume Automotive Manufacturing, even a single wrong or missing Component Assembly can trigger Costly Recalls, Warranty Claims, and Irreparable Reputation Damage.
SmartRun deployed an intelligent Vision Based Poka Yoke Solution, integrating Industrial Cameras, Real Time Image Processing, PLC Interlocks, and Centralized Validation Logging to transform assembly lines into Digitally Controlled, Error Proof Systems.
The solution was first validated as a Proof of Concept (POC) at a critical Disc Line Station, then successfully scaled across Cover Line 1, Disc Line 2, and Disc Line 3, achieving Zero Assembly Escapes at every implemented station while maintaining 100% Throughput with Zero Cycle Time Impact.
The primary goals of the Vision Based Poka Yoke Solution are to Eliminate Wrong and Missing Component Assemblies, Remove Dependency on Manual Inspection, and establish a Fully Automated, Audit Ready Quality Gate at every Critical Assembly Station.
A leading Automotive Clutch Manufacturer faced Quality Risks and Traceability Challenges due to Manual Inspections, Incorrect Component Assembly, Lack of Machine Interlocks, and Limited Digital Tracking, while requiring 100% Validation without impacting Production Cycle Time.
SmartRun deployed a Real Time Vision Based Validation System integrated with the PLC, enabling Automated Inspection, Machine Interlocks, Variant Wise Validation, Centralized Logging, and Scalable Deployment across multiple production lines.
Vision-Based Poka-Yoke is ideal for any industry where wrong or missing component assembly carries high quality, safety, or compliance risk. Primary industries include automotive (clutch, brakes, engine, gearbox assembly), electronics and PCB manufacturing, pharmaceuticals (blister pack and kit assembly), aerospace component assembly, and general discrete manufacturing. It is especially valuable at stations with high variant mix, repetitive manual tasks, or where a single escape can trigger a recall or customer line stoppage.
SmartRun's Vision-Based Poka-Yoke system uses variant-wise camera recipe management, where each product variant has its own pre-configured validation logic stored in the system. When the operator selects a product variant on the HMI, the correct camera recipe is automatically loaded and activated — no manual camera reconfiguration needed. This ensures the right components are validated against the right reference for every variant, even on high-mix assembly lines running multiple models in the same shift.
The solution supports IATF 16949 (automotive quality management), ISO 9001, customer-specific OEM poka-yoke and error-proofing requirements, and internal quality audit standards. The centralized OK/NOK logging with timestamps creates a ready-made digital audit trail that satisfies IATF clause requirements on monitoring and measurement, control of nonconforming outputs, and traceability — significantly reducing audit preparation effort and risk of non-conformance findings.
SmartRun follows a structured POC-first deployment model. In Phase 1, the solution is installed and validated at a single critical station — typically within 2 to 4 weeks — covering camera setup, image processing logic, PLC interlock integration, recipe configuration, and database logging. Once the POC is approved by the client with demonstrated zero-escape performance, Phase 2 scaling to additional stations and lines typically takes 2 to 6 weeks per station depending on variant complexity and existing PLC architecture. The entire approach is designed to minimise shopfloor disruption and deliver measurable results before full rollout commitment.
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