A simple yet effective improvement was implemented to address recurring quality concerns. By focusing on error prevention and immediate corrective action, the team ensured that defective parts no longer slipped through the process, thereby strengthening overall quality standards.
Problem Description
At a production station, defective or NOK (Not OK) parts were unintentionally moving forward into the next cycle. This created a significant risk of defective components being assembled further down the line, leading to increased rework, scrap, and quality concerns. Operators had limited visibility when a defect occurred, which meant issues were often detected late in the process, adding unnecessary cost and reducing efficiency.
Solution
To address this challenge, a buzzer signal along with a light curtain system was introduced. Whenever a defective item is detected, the buzzer immediately alerts the operator and the cycle stops automatically. An interlock mechanism ensures that the next cycle cannot begin until the defective part is removed and placed in the rework bin through the light curtain. This improvement created a fail-safe process where defective parts are prevented from progressing further, thereby ensuring that only quality-approved items move forward.
