Honda MPR Compliance

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Our Poka Yoke solutions integrate PLCs, weigh scales, vision, OCR and USB cameras to control the part counting, packing and  labeling processes. Vision sensors and cameras can validate parts for correctness, provide accurate counts, and adherence to packing requirements. They can detect suspect parts and trigger a conveyor to divert them. Touch-screen PCs display real-time status information of WIP, production totals, packing and labeling operations. 

Serialized WIP /internal labels are printed on-demand, enabling WIP units to be uniquely tracked, provide visibility and ensure the WIP unit proceeds in the correct sequence from the first operation to the last. Traceability records are created automatically to enable each WIP unit to be easily traced back to its raw components, and forward to the finished part. 

Serialized container labels are automatically printed at line-side, triggered by input from a PLC, Weigh Scale, Vision Sensor and/or USB Camera when the pack count or dunnage is correct. Cameras can provide video to confirm that packing requirements were met in case of customer inquiry. Label data is supplied by the host ERP/ EDI system. Back /forward Traceability records are automatically created by SPEDE. These Poka Yoke solutions prevent labeling errors and enable Honda MPR compliance.

Individual parts and containers of parts can be serialized at line-side. 2D serial numbers on parts can be read by vision sensors as the parts are counted and packed. Part serial numbers are linked to the container serial number in which they are packed. The container serial is linked to production details including machine, run date, lot, shift, etc., providing detailed traceability.

At a re-pack station, there won't be a PLC to validate the correctness of parts being packed into a container. Instead, a vision sensor can confirm each part is correct, alert the operator if an error is being made, and optionally trigger the conveyor to automatically divert the wrong part. When a pack count of good parts is reached, a serialized container label will print automatically. 

Error-proof processes in Re-work are critical for quality control and reliable traceability. A vision sensor can count the parts leaving production, while identifying good vs. scrap. By interfacing to a conveyor, good parts can be diverted for packing and labeling; scrap parts diverted for re-work. The re-work parts are controlled via serial number on the Part /Container. Serial numbers provide accurate traceability.