Abstract
Built-In-Quality (BIQ) is a vital component of Lean manufacturing. Basic BIQ levels ensure that the defect does not leave the plant, while advanced levels ensure that defects do not leave the team or station. At the highest BIQ level the possibility of making an error is eliminated. This paper presents operational principals and architecture of an innovative error proofing system for a manufacturing plant to achieve a level that prevents defect leaving the station and area. This system is standard, programable & scalable to identify, annunciate and stop defects from moving to the next station. In this study the General Assembly shop of an Automotive manufacturing unit was selected to demonstrate the benefits of this error proofing system. Although the system has capabilities to error proof various operations for simplicity purposed error proofing of torque applications was focused. This paper shows that automated error proofing systems require need to interface with plant floor devices, operators, conveyor controllers as well as various IT systems. We show that the error proofing system could detect defects and hold the vehicles from being shipped in 100% of the cases. This methodology offers an excellent solution for ensuring Built-In-Quality improvement with minimal investment.