Error proofing & poka-yoke assembly station

GUIDED ASSEMBLY STATION

Combining Sorion’s software and hardware products in a fully integrated guided assembly station allows manufacturers to avoid costly rework, increase productivity and maximise quality on their production line.

The solution is field proven and is already enabling manufacturers from a variety of industries to actively improve their quality processes whilst also reducing their operating costs.

CAPABILITIES

At the heart of the system is Sorion’ Sextans error proofing software for product assembly processes. Running on a touchscreen PC, Sextans controls the kitting and assembly process, data acquisition and result management.

Typical deployments for the Guided Assembly Stations include the automotive industry, manufacturing and technology sectors.

FEATURES

  • Controlled process with no faults forward
  • Pick to light system to ensure selection of correct parts
  • Integration with factory equipment, tools, test equipment, vision systems etc.

Error Proofing

Full traceability of all parts

Increased accuracy and quality of operations

OPERATOR GUIDANCE

Digital work instructions (running on touchscreen PCs) guide operators step by step through complex tasks.

TRACEABILITY

Data for each completed step is recorded for a digital history of the entire production process.

Orion manufacturing traceability

NO FAULTS FORWARD

Sequenced production operations and integrity checks help eliminate errors in product assembly.

Guided assembly software

INDEPENDENCE

Easy to configure to exact requirements, without the need for hard coding.

CAPABILITIES

User Access Control

Prevents unauthorised operation with permissions and user roles

Part verification

Barcode scanning or RFID reader to identify product components

Pick to Light

Ensures quick and precise selection of parts

DC Tooling

The correct tool and tightening program is selected dynamically

Factory Interfaces

Full integration with customer build control systems to receive build specifications

Assembly Jigs/Fixtures

Providing Poka Yoke functions

Image Capture

Capture and store images for quality control and complete traceability

Digital I/O

Easy connectivity of external I/O devices

At the heart of the system is Sorion’ Sextans error proofing software for product assembly processes. Running on a touchscreen PC, Sextans controls the kitting and assembly process, data acquisition and result management.

Typical deployments for the Guided Assembly Station include the automotive industry, manufacturing and technology sectors.

Example projects

KAB Seating operator guidance
Guided assembly stations for seat assembly
Gardner Denver operator guidance
Process control solution for a compressor manufacturing facility
Assembly stations at Grupo Antolin

What our customers say:

By incorporating the use of a Pick to light system and assembly fixtures designed by Sorion across four workstations, we have been able to streamline our build and test process to achieve an output of 1 x assembly every 15 minutes. The system as a whole has been crucial to achieve the weekly demands from our customer and without it our output would be dramatically reduced.
Tier 1 Automotive Supplier
Due to the safety critical nature of the assembly it was important to maintain a high level of quality in the part. The Pick to Light system has been crucial to eliminating field failures attributed to build/process errors. Traceability is also key and the use of a barcode scanning system within the Sorion workstations  has allowed us to track child part information and generate a birth certificate for every assembly including part, build and operator data. The data stored in Orion is key to us being able to give our customer confidence in the quality of parts as we can share this data quickly and easily with them.
Manufacturer of Automotive Components
The Sorion team installed a complete production control solution at our manufacturing facility. The system has greatly improved the quality of the assembly processes and it was instrumental in helping us to achieve IATF (International Automotive Task Force) 16949 certification.
Gardner Denver

Get a quote

If you would like a quote for a bespoke guided assembly system, please give as much information as you can and we will get back to you.

Complete the contact form or call our team on 0121 454 8966.