What is HOP? Top 5 benefits of HOP.

20 November 2024

What is HOP?

HOP, Human Operation Platform, is PowerArena’s AI-powered smart manufacturing solution. Focusing on labor-intensive production lines, PowerArena HOP 24/7 records and analyzes production video footage, provides real-time insights into worker activities and identifies critical line abnormalities. It offers managers production line information with “video” and “data”.

Why you need HOP?

Tracking Production Data is Challenging

Tracking human activity, like work time and tasks, is challenging compared to IoT-monitored machine production. Traditionally, engineers or managers use stopwatches and manual data entry at each station, which is time-consuming. Data collection and analysis are frequently incomplete and biased.

HOP’s AI vision technology operates 24/7, precisely capturing key production line data such as cycle time, process time, and idle time. It continuously records and analyzes manual operations on the line.

HOP provides comprehensive and objective production data. This is a crucial starting point for production line optimization.

Root Cause Tracing is Time-Consuming and Costly

In manual production lines, tracing process anomalies is lengthy and expensive. Without a comprehensive management system, minor human errors are often neglected. When product quality issues arise, managers struggle to identify the exact time, location, or personnel responsible for the issues. If problems linger, defects may keep recurring.

HOP tracks manual operations and identifies anomalies within complex production processes. It records each issue’s time, workstation, and cause in real-time. Production history with “video” and “data” allows managers to pinpoint root causes via video playback quickly and allows them to see the exact conditions when the issue occurs.

HOP helps resolve issues quickly, saves time and labor costs on investigation, and prevents problems from spreading.

Managing Human Operation is Challenges

On labor-intensive production lines, human factors are uncertainty—errors, fatigue, and lack of experience are common. With traditional methods, managers can’t ensure that every worker follows each SOP. Failure to follow SOPs may lead to poor product quality.

HOP enables real-time Poka Yoke in-process. Managers set up the SOPs, such as component placement or screw tightening sequence. If workers deviate from these standards, the platform instantly detects errors. This prevents defects from moving to the next workstation. There is less need to depend on quality control for issue detection.

HOP strengthens process quality control to ensure SOP follows and improve yield rate.

Top 5 benefits of HOP

1. Continuous Data Collection for Complete Production History

All stages of the production process are recorded.

Production history for each product is established by video record and AI vision analysis.

A complete production history enables traceability and improves process transparency. Objective data analysis builds data trust within the organization and with clients.

2. Data-Driven Decisions for Better Management Efficiency

“Data” is the source of all insights and improvements.

Transforming unstructured video data into structured analytical reports, production decisions are supported by objective information.

Consistent and clear production data helps management eliminate blind spots, identify causes of low quality and inefficiency, and confidently optimize production plans.

3. Precise Issue Tracking for Rapid Root Cause Identification

Traceability of production history is important in quality management.

When defects or efficiency issues occur, managers with “production history” can quickly trace the process, pinpoint the time and location, and eliminate the root cause to stop problems from escalating.

4. AI Poka Yoke for In-Process Error Prevention

Effective in-process Poka Yoke can eliminate many quality control tasks.

AI vision is like an SOP assistance, which makes sure that workers follow standard production SOPs during the process.

When AI detects errors, the workstation immediately stops and alerts management. Staff can view platform reports to understand the cause of the issue in real time and decide whether to resume production or stop it and solve the root causes.

5. Consistent Performance Facilitating for New Facility

Replicating successful production line to cross locations is difficult.

The scalability and flexibility of AI vision technology allow new facilities to follow the successful SOP of existing plants as companies expand globally to maintain the same production quality.

Fundamental model provides rapid deployment of quality management without extensive retraining, ensuring that the new plant can quickly achieve operational efficiency.

Results of Implementing HOP

EMS

 

Semiconductor

 

EV

 

👁️‍🗨️ Explore Now. More HOP application cases.

HOP Solutions

Digital Transformation and Smart Factories Start Here!

Digital Station

We’ve digitalized human operations on production lines for full traceability. With real-time updates on employee status and production issues every minute, managers can easily track progress and stay on top of production without being on the floor.

Demo & Pricing: Unlock your production history. Elevate your manufacturing.

AI Line Balancing

It helps track key production line data. Once production goals are set, the system automatically monitors cycle time, process time, idle time, and more, providing data to optimize production plans and drive efficient manufacturing.

Try Now: Get a customized plan. Enhance your factory today!

AI Poka Yoke

System uses process knowledge and worker experience to help managers eliminate human errors in production. Once SOPs are set, platform starts to track worker behaviors and capture more production details. No need to change the current workflow. All the defects are caught.

Chat with Experts: Stop the errors in process. Eliminate many QC tasks.