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

A global leader in the semiconductor industry with over 25 years of extensive manufacturing history, this company specializes in precision machining and provides critical components for the high-tech sector, including reticle box, wafer handing, substrate shipping box, and similar products. The manufacturer is dedicated to integrating smart manufacturing into its global production network. Through substantial investments in automation equipment, data analytics tools, and artificial intelligence technologies, they have transformed traditional production lines into more efficient, flexible, and intelligent manufacturing systems.

For the reticle pod assembly workstation, the company has implemented the PowerArena HOP (human operation platform) to help review manual processing steps and further optimize production processes. 

| Engineer from the Engineering Department: “We overlooked the blind spots in SOP design.“

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 AI Vision, Advancing AI SOP

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 once again was not only for training and recognizing the AI models but also to help the production line reevaluate the processes from a human factors engineering perspective, thereby increasing the potential for accelerated production. The more detailed SOP includes specifications for the placement of materials and tools, the distances between them, and considerations for the different operating habits of left-handed and right-handed workers.

|  Engineering Department Manager: “Why was it possible before, but not now?”

The IE shared that in the past, when supervisors questioned the legitimacy of improvement projects, the IE lacked data and video evidence to support their case. When abnormalities occurred, operators typically “made up for the errors with time,” but since these extra efforts were not recorded continuously, the additional time spent could not be traced.

AI Data + Video: Evidence for Production Line Optimization

Cameras are deployed at workstations to enable real-time AI visual analysis. HOP accurately identifies cycle time (CT) and records all 20 steps of assembling reticle pod covers, collecting production time data continuously. This replaces time-consuming manual measurements, eliminates human errors, and frees up management resources, allowing IE to handle other tasks without being burdened by these essential measurements.

With video records, IE possesses concrete evidence of “waste” occurrences, invaluable when demonstrating anomalies to line managers, production engineers, or operators. The combination of data and video allows IE to address supervisors’ concerns and justify the need for changes.

During rework or improvement processes, video records ensure progress and effectiveness are traceable, and the causes of anomalies are always identifiable. IE can pinpoint error sources precisely and propose concrete solutions, ensuring the improvement plans are executed effectively.

At this assembly station, managers found that experienced operators tend to rely on old habits, while new employees often make mistakes or forget steps. Variations in manual operations are hard to prevent, but deviating from the SOP can lead to defects.

AI Real-Time Alerts for Immediate Corrections

HOP provides real-time AI alerts to serve as the first line of defense. If an operator pauses too long, an alert sound reminds them, and an anomaly message is sent to managers for immediate attention.

HOP can also filter problematic video clips, reducing the need for manual review of extensive production footage, saving valuable time. By marking problem areas with AI alerts, IE can easily trace and understand the root causes of errors, allowing them to focus on addressing the underlying issues leading to anomalies.

Operators at this station sometimes need to temporarily support other production lines. When they return, they may forget previous steps. The time spent re-learning becomes a hidden cost, slowing overall production efficiency.

Digital Prompts for Enhanced Operations

If operators forget the steps after pausing, they can check a nearby screen with HOP’s digital prompts to confirm the next action, ensuring correct continuation of assembly.

If the station’s monthly output increases and operators from other lines are brought in to help, the digital SOP aids in quickly familiarizing them with assembly tasks.

This is especially useful for expanding new lines and training new employees. Previously, assembly training took about half a day. With HOP’s assistance, training time can be reduced to under two hours, allowing new employees to integrate into the production line faster, improving overall quality and efficiency.