Error Proofing

Error Proofing

Ensuring product quality is a never ending process. Ineffective processes, human errors, equipment failures and material defects can adversely affect product quality and production efficiency. Early identification of mistakes, the conditions that give rise to them and correcting those conditions is fundamental to error-proofing and promotes a Lean manufacturing environment. Banner’s expertise in a broad range of sensing technologies allows us to offer problem-solving solutions that help manufacturers overcome these challenges, increase efficiency, improve quality, and reduce expenses and downtime.

Detecting Refrigerated Breakfast Rolls on a Multi-Lane Conveyor

    • Detection of pressurized cans on multi-lane conveyor
    • Dark labels with multiple color transitions
    • Blue LED sensor detects dark colors better than traditional red LEDs

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Adhesive Detection on PCB Assembly During the Assembly Process

    • Real-time detection of glue on printed circuit boards
    • Very small space for sensor installation
    • Recognize minimal changes in distance to confirm the presence of adhesives
    • VS8 is small and sits atop the glue dispenser, pointing down at the PCB

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Detailed Inspection on a Sortation Conveyor

    • Confirm presence/absence of items on trays on sortation conveyor
    • Smart camera with high attention to detail
    • Works fast to keep throughput high

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Fine Detail Inspection of Mobile Electronic Devices

    • Error proofing during mobile equipment assembly in a cleanroom
    • Very small electronic components on a printed circuit board
    • 5-megapixel imager captures fine details at close range

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Track Vials Through an Automated Clinical Laboratory

    • Detection of pucks, regardless of color
    • Compact and easy-to-use
    • The fixed field Q12 can be set to ignore anything beyond a programmed range

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Error Proofing for Integrated Circuit Chips Loaded into Pocket Tape

• Confirm presence and orientation of IC chips

• Sensor performs multiple functions at once

• Cost savings and versatility

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Accurate Label Inspection [Success Story]

The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

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Combined Inspections Used to Meet Quality Standards [Success Story]

Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.

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Operator Guidance Solution [Success Story]

A Henshaw customer manufactures drivetrain and powertrain systems for the automotive industry. The company had experienced productivity losses due to errors in the assembly of transmission valve bodies. Henshaw was tasked with developing a system that would reduce errors and improve the assembly process.

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Run Bar Provides Operator Guidance [Success Story]

A leading machine manufacturer builds workstations designed for accurate, timely and cost-effective battery cell assembly. A value added component of the workstations is an operator guidance device that does three jobs: enables assembly processes to start and stop, indicates parts to be picked and installed, and completely stops line operation if emergencies occur. When it became too costly for the OEM to construct and mount these devices themselves, they turned to Banner to craft an all-inclusive solution. To honor the time line requirements of their customer—a major tier two battery supplier—the OEM needed the solution in eight weeks.

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Wireless Call for Parts

A system of Banner’s TL70 wireless modular tower lights and K50 touch buttons provides an efficient, easy way to communicate a call for more parts with a forklift driver. When a workstation is almost out of cartons, the operator touches the ergonomic K50 touch button which changes the status on the connected TL70 wireless tower light to red.

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Cap Orientation Verification

Banner’s Q4X laser sensor, made of 316L grade stainless steel, is very suitable for pharmaceutical environments and other aseptic filling areas. The Q4X has a sensing range of 25 to 300 mm, precise beam spot size and can effectively detect the orientation of caps as they exit a feeder bowl. If any caps are upside down, the Q4X will detect a height difference and reject the cap.

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Engine Block Positioning

Banner’s L-GAGE LH Laser Displacement Sensor is ideal for applications where exact positioning of a part is crucial. The L-GAGE LH Series consistently looks at dark targets on micron levels. Banner’s laser displacement sensor is extremely accurate for precise positioning applications, including engine block positioning. The sensor can take measurements on virtually any surface, such as cast iron or aluminum alloys, which are often used for the manufacturing of engine blocks.

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High-Speed Tablet Counting With DF-G2

Banner’s DF-G2 small object detection fiber amplifier is ideal for small object detection and counting applications. The DF-G2 amplifier has a fast response speed and can detect extremely small sizes, such as 3 mm tablets or pills. When the tablets fall into bottles, it fires an output to the DF-G2 fiber amplifier, which keeps count of tablets.

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Kitting Operation with Gloves

Banner’s fixed-field K50 indicator detects gloved hands , sensing when operators select the correct parts during the kitting process. The K50 indicator’s logic function is then able to notify the operator that he/she picked correctly by changing from green to yellow—additional colors can be selected to suite to the manufacturer’s preference. The K50’s ability to detect black gloves is especially important for lean manufacturing processes where workers typically wear dark gloves.

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