Reducing operator intervention

It is human to error therefore we should do as little as possible. Implementing CNC machine tools and robots anywhere that it is feasible is a sound engineering and business decision. Keypunch errors, calculator errors, momentary lapses of dyslexia are just a few of the blunders we face as humans all the time. Machines and computers just do as they are told over and over again. Limiting the amount of data and input an operator deals with daily will greatly reduce manufacturing errors.

Various error checks can be implemented using the NC controls to check for human occurrence errors. A couple of examples have been written about in this blog: “Using the offset range setting as an error check” and "Preempting a common "C" axis error". Preventative checks are limited only to your imagination and ingenuity and you will also discover that these ideas also serve as time savers too.

Don’t wait until an unfortunate occurrence happens to put your thinking cap on. Try and catch these problems preemptively and share your ideas with the world. A few examples are to follow.

Measuring probes can be used for all kinds of location and fixture type checks. Simple macro programs can be written to automatically set work and fixture offsets by finding their location. It is also possible to probe for an identifying feature on machining fixtures to tell the machine which one is loaded on the machine. Then use these identifiers to look up all kinds off related data and offset variables in tables automatically. 

The use of bar code and scanners is a very efficient way to stop keypunch errors and is the best time saver you will ever invest in. They can be used in every process related to industry from inventory and materials through manufacturing and out the door from shipping. Don’t over look this efficient invention for diverting human errors. 

Humans and computers analyze data in different ways and something that is simple to conceive as humans require unimaginable amount of processing power for a computer… and visa versa.  Always implement a checker in visual type processes. Another set of eyes is the best possible way to catch another person at one of those inadvertent times when we overlook details. In this situation the only answer is to increase human intervention.