One kind of error is superior to all others: The one that never happens. The Piston Automotive’s error proofing and testing strategies and procedures are oriented towards attaining the highest possible levels of quality at all points in the manufacturing process. Our goal: to ensure that no defective parts emerge at the end of an assembly line.
Prevention is the first stage of the Piston Automotive error-proofing methodology. At the process design stage, we work to create an environment in which it is physically impossible for an operator to build a part incorrectly.
As a safeguard, we introduce sophisticated detection and inspection systems in each workstation to immediately recognize problems should they occur, and to trigger immediate corrective measures. Contact and non-contact measurement systems, torque systems, barcode scanners, in-station fixed vision systems and part presence sensors along with many other tools and techniques provide multiple layers of error proofing to ensure defect-free production.
In-house designed and developed end of line and in-process robotic vision systems using robot mounted high-speed, high-definition camera systems enable automated sensing of part presence, orientation, dimension, color, texture and other factors to facilitate error-free assembly while providing visual feedback to the team members on all error conditions. In addition, end of line and in process electrical testing and leak testing is integrated throughout the assembly process as required.
Collection, Reporting and Traceability of all assembly process data has been standardized throughout the company. Piston serializes 100% of the modules built, all critical process information is captured and stored for the life of program and can be accessed for root cause analysis or system capability. This data ranges from time stamp of all operations, component traceability requirements, torque and measurement information, test data and all vision inspection images captured in the assembly process.