Global Renowned Precision Manufacturer Improves Product Quality with HOP AI Poka-Yoke

10 October 2022

With over 25 years of experience in semiconductor precision manufacturing, this global leader of precision machining in critical components such as reticle box, wafer handing, substrate shipping box, is now adapting AI vision into it’s production quality control protocol.

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Results

19% Increase in UPH

In just six months, the average assembly cycle time (CT) at this station cut down from 3.5 minutes to 2.8 minutes, shaving almost 20% of the overall work time. Therefore increasing the UPH by 19%.

AI data-driven process optimization helped achieve this efficiency boost. HOP collected and analyzed extensive operation times, integrating key production metrics such as product serial numbers, machine numbers, OK/NG status, errors and reasons. This aids managers in planning and decision-making. Additionally, AI-tagged problem videos help accurately identify bottlenecks…

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AI enhanced quality control protocol. Step 1: SOP optimization.

| The engineering department: “[This] blindspots never occur to us when designing the SOP”

Industrial Engineers (IE) have discovered that when the SOP is executed on the production line, there is often a gap between the planned and actual performance. This discrepancy arises from new employees being unfamiliar with the operations and lacking mature skills, as well as seasoned workers having ingrained habits. Even if the IE provides the same SOP, the performance of each operator can vary significantly, leading to inconsistencies in assembly quality and difficulties in management.

Introducing HOP with full AI vision support

Before the project began, PowerArena engaged in multiple discussions with the plant manager and IE engineers to establish a more detailed and comprehensive SOP. Standardizing the operational procedures to train and enhance AI models recognition. Accelerating production by reevaluate the processes from a human factors. The ever much sophisticated work step AI recognition includes recognition of tools that can be…

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