Manual workstations are indispensable, because automation is not always profitable with small batch quantities or complex processes. Such workstations are preferred at the Martinshof Werkstatt Bremen, a sheltered workshop for a mixed workforce including people with handicaps, as they are ideally suited for integrating persons with physical or cognitive handicaps into working life.

Handke Industrie-Technik, a long-standing supplier to Werkstatt Bremen of manual workstations, and a premium solution partner of Mitsubishi Electric, recognized the unique opportunity. Together with Mitsubishi Electric, Handke developed a Poka Yoke solution for adapted working. The prototype of the error-free workstation convinced the customer and was installed in the production line. Since May of 2018, a total of four identical zero-error workstations are in use for automotive parts production.

The Japanese Poka Yoke principle, which aims at the systematic elimination of human errors, coupled with Mitsubishi Electric's Guided Operator Solutions, ensures high quality for Martinshof´s customers, which include well-known automakers in the region. “Poka Yoke has empowered our workers,” said Miriam Berger, in-charge, Production Planning, Martinshof Werkstatt Bremen. “We use automation to avoid mistakes that previously occurred in the production process. Everyone must be able to work smoothly together,” continued Bremen.

The MELSEC iQ-F series PLC, installed on-site in a small control cabinet, is the intelligent, individually configurable, and expandable heart of the solution that controls the picking and assembly sequences. Apart from Mitsubishi Electric's own components, the system can also handle third-party sensors and actuators. In this case this included the digital torque wrench and a system for industrial image processing. The connection of a barcode printer is being implemented, and thanks to existing conventional interfaces, this can be done easily by the PLC. 

For more information: www.mitsubishielectric.com/fa