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.
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