Fewer errors in assembly through process optimization
Why process optimization in assembly is essential.
In the world of mechatronic assembly is all about precision, reliability and speed. Every action an operator performs can potentially lead to an error. And that’s exactly why production process optimization is such an important part of our work at BS&i Mechatronics.
By optimizing assembly processes, we ensure fewer errors, shorter lead times and higher and predictable product quality. We do this with smart techniques such as Lean assembly processes, Poka Yoke and insights from the Human Reliability Analysis (HRA).
The link between operations and errors in assembly
Numerous studies have shown a direct relationship between the number of operations in an assembly process and the likelihood of errors. For example, shows Human Reliability Analysis shows that even well-trained operators make an average of 1 error per 100 operations. With more complex tasks or under pressure, that error rate can rise rapidly.
| Type of action | Average error probability |
|---|---|
| Much practiced, simple assembly operation | 1 in 1,000 |
| Standard manual assembly step | 1 in 100 |
| New or aborted task | 1 in 10 |
| Decision under stress or time pressure | 1 in 2 to 1 in 5 |
In short, the fewer steps needed in the assembly process, the less chance of errors. We apply this knowledge daily in our production environment.
Lean assembly process: fewer operations, more quality
At BS&i Mechatronics, we apply the principles of the Lean assembly process apply. This means:
- Eliminate unnecessary actions
- Standardizing processes
- Deploy smart tools and resources
- Applying visual control and Poka Yoke techniques
This approach fits seamlessly with the philosophy of Shigeo Shingo, who developed Poka Yoke as a method for preventing errors already at the source.
Mechatronic assembly with an eye for people
Although technology plays a major role in our processes, we believe that good assembly starts with people. Our employees are highly skilled technically, but even the best craftsmen benefit from a well-designed work process. Learn more about the role of our people on our page on organizational understanding.
By designing our workstations intelligently and structuring tasks logically, we maximally support our people in delivering consistent quality. For insights into human performance and ergonomics, we often work with models from, for example The Measure of Man and Woman.
Smart assembly as the basis for production process optimization
Our experience shows that effective production process optimization begins with looking critically at each assembly step:
- Is this action really necessary?
- Can this be automated or secured?
- How can we make the process more fault-tolerant?
We often make such an analysis as early as the engineering phase, for example in design for assembly of customer orders.
Ready for error-free assembly?
At BS&i Mechatronics, we don’t just supply assembly – we think with you about the entire process. From initial design to final product, with an eye for quality, efficiency and reliability. For example, take a look at our test solutions that contribute to error-free delivery.
Want to know more about our approach in mechatronic assembly or production process optimization?
Contact us or schedule a no-obligation meeting.
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