Error-Proofing

[[Er...]]

My boss has tasked me with "Error-Proofing" (reduce human error) several of our programs.

The problem is that the parts look similar to the untrained eye and operators are running the incorrect program causing collisions and numerous broken styli. One good thing is that the parts are unique enough that it would be possible to do a "seeking" point to verify that the correct program has been selected.

What i'd like to do but don't know how.

if "seeking point" is taken then
continue running the selected program
else
return to CMM safe position, end program and, display "incorrect program" .jpg on PC Monitor.

Is this something that can be done via PCM?

Any and all help would be most appreciated.

[[Cl...]]

What I would do is, Have a Poke Yoke fixture dedicated to each part designed in such a way as to only allow
the part it is designed for to be loaded in it, Also, we laser etch the fixture with the part number its used for.

[[Er...]]

The problem isn’t the operators misleading the part; it’s the operator selecting the incorrect program. A new fixture wouldn’t fix my problem.

[[Ro...]]

There is a "missing Bore" command, i've never used it personally but i have seen it in use, the probe moves into the hole very slowly and if the hole is missing (broken drill bit) then the probe makes contact with the side of the part and the program skips that feature. no more broken probe.
I think what you're looking to do is have the program sense the part (If statements and variables) and if the diameter of feature X is 1.000 inches then adjust the other dims to this size, and call it part number Part1.0. if the diameter of feature X is 1.100 inches then adjust the other dims to this size, and call it part number Part1.1

but at some point you need the operators to have personal responsibility, which can be difficult in auto or similar manufacturing situations.

maybe a barcode scanner to open program?

[[Ma...]]

I do something similar. In this case, I check a plane to make sure it is in the correct angle (both in A1 and A2) to the fixture if not move off and let me reorient the part. The stepRS command is the move off command.


getActual("Error Proof Plane Measure").z
A1 = abs(deg(getActual("Error Proof Plane").a1) - 17.9)
A2 = abs(deg(getActual("Error Proof Plane").a2))

if A1 > 0.5 then
stepRS(0,150,50,())
message(" PART IS LOADED INCORRECTLY ",cr()," RELOAD PART AND RESET TRAFFIC LIGHT ")
cncBreak()
endif

if A2 > 0.5 then
stepRS(0,150,50,())
message(" PART IS LOADED INCORRECTLY ",cr()," RELOAD PART AND RESET TRAFFIC LIGHT ")
cncBreak()
endif

[[Br...]]

Eric,

I've attached a PDF of PCM code for a "Clamp State Check". It fires every time the inspection is run, to see if the clamp handle was found. If not, it displays a message explaining why the program will stop and short instructions on how to proceed. I'm sure with a little tinkering you can make it find something unique on your part types to prevent unwanted collisions.

Clamp State Check.pdf

[[Er...]]

Thanks Brad! That's exactly what i was looking for!