Complex assembly hides miss-builds
Many steps and part types. Miss, wrong part or reversed order is found late and can drive early-failure recall.
StoneDT
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StoneDT
Customer background
A precision-vehicle plant with climate-controlled shops. Complex assembly: pick, inspect, fit, torque and mark. Miss, wrong part or reversed order can cause early failure and recall.
Work relies on experience and team-lead sampling. Skill varies, training is long, skipped steps hide at the station. NG shows up at final test or the customer. Rework, scrap and recall are costly. The plant needed machine poka-yoke at the station.
Pain points Complex assembly hides miss-buildsMany steps and part types. Miss, wrong part or reversed order is found late and can drive early-failure recall.
Skill varies; training is longExperience plus sampling. Fatigue and skipped steps are hard to stop in time.
NG found too late, rework is costlyProblems appear at final test or the customer. Tear-down, scrap and recall are expensive. Stop them at the station.
SolutionMulti-camera SOP across pick, inspect, assemble, mark and complete: two-hand motion, part type, step order, screws and torque. Live step and compliance, 7×24, for high-mix low-volume lines.
Step-by-step guidance with forced correction on miss, wrong part or wrong order. Every unit keeps records and video. Dashboards show FPY, hot defects and operators. Find and rework online—NG never leaves the station, protecting the brand.