Zero Defects. Zero Escapes. Intelligent Error-Proofing with SmartRun.
In high-volume automotive manufacturing, even a single wrong assembly can lead to costly recalls, warranty claims, and reputation damage. A leading automotive clutch manufacturer faced recurring risks of wrong or missing component assembly at critical stations.
SmartRun implemented a Vision-Based Poka-Yoke Solution integrated with PLC interlocks and centralized validation logging — transforming their assembly lines into digitally controlled, error-proof systems.
The Business Challenges
The client was experiencing quality and traceability challenges at critical clutch assembly stations:
- Repeated risk of wrong or missing component assembly
- Heavy dependency on manual inspection, leading to human errors
- Previous vendors failed to deliver a stable Vision + PLC interlock system
- No automatic machine blocking on wrong assembly — risk of quality escape
- High variant complexity requiring dynamic validation logic
- No centralized digital logging for audit and traceability
- Expectation: 100% validation with zero cycle time impact
Solution Provided
SmartRun deployed an intelligent, real-time validation system tightly integrated with the assembly line PLC.
- Implemented Vision-Based Poka-Yoke POC at critical disc line machine
- Integrated industrial camera with real-time image processing and validation logic
- Enabled PLC-level machine interlock — cycle start only on Vision OK
- Configured variant-wise camera recipe auto-synchronization with HMI
- Logged station-wise OK/NOK results into centralized SmartRun database
- After successful POC validation, scaled deployment across Cover Line 1, Disc Line 2, and Disc Line 3
Value Delivered
The implementation delivered measurable and strategic impact:
- Achieved zero assembly escape at implemented stations
- Significantly reduced operator-dependent validation risk
- Prevented wrong assembly before defect creation — true error-proofing
- Enabled audit-ready digital validation logs
- Strengthened process control at bottleneck stations
- Successfully delivered a solution where previous vendors failed to meet expectations
