Smart Export Packing Verification and Poka-Yoke System
Problem Overview
Export packing is currently vulnerable to manual errors such as interchange of LH and RH parts, placement of an incorrect component in the packing box, and excess or short quantity during packing. These errors may not be detected immediately and can result in rework, dispatch delays, customer complaints and traceability issues. The challenge is to develop an intelligent packing verification system that confirms part identity, LH/RH orientation where applicable, correct component-to-box matching and required quantity before a box is released for dispatch.
Industrial Context & Background
Smart Manufacturing / Poka-Yoke / Computer Vision / Traceability
Technical Requirements
1) Verify part identity using QR/barcode/vision or suitable method
2) Distinguish LH and RH parts where applicable
3) Validate component against packing order
4) Count actual quantity and compare with required quantity
5) Provide immediate OK/NG indication and block release for mismatch
6) Store verification result with box/part/date-time traceability
Suggested Technology Stack: Computer Vision; QR/Barcode/RFID; Counting Sensors; Database; Poka-Yoke Logic; Edge/PLC Integration
Expected Solution & Prototype
1) 100% verification of selected packing boxes before release
2) Wrong LH/RH placement detection rate quantified
3) Wrong-component-to-box detection rate quantified
4) Excess/short quantity detection accuracy measured
5) Packing verification cycle time per box measured
6) Packing error escapes compared with the current process quantified
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