Error Proofing By Guidance

Like W. Edwards Deming, we believe operators demonstrate pride of craftsmanship when the obstacles to quality are removed. Our Error Proofing By Guidance approach removes many of those obstacles. Our goal is to help your team do the great job they want to do.

Deming also said that 93% of errors come outside the system.  Even on the best of days, there are plenty of distractions on an assembly line or in an assembly cell. Our Error Proofing By Guidance has been carefully crafted to guide the operator where it is most needed. We have designed our systems to account for just about everything that might happen in an assembly process where torque is involved. 

Working together, the Global 400 and the GIM 400 (Global I/O Multiplier) organize up to 16 torque tools, 8 holding tools, light/socket trays, light stacks, serial printers,  And, you can set it to provide as much operator guidance as you would like. For example, the GIM 400 can guide workers to select the correct tool and modify their behavior when they have not chosen the right tool. It can even guide them to put the tool back in the appropriate place before being able to proceed. 

Exacta Series Digital Torque WrenchOur intelligent tools also provide operator guidance. The Exacta 2 wrenches have a screen that changes color as the operator delivers more torque. As the operator nears the desired torque value the display turns yellow. The display turns green when the desired torque is achieved. If the operator continued pulling and took the fastener past the top torque value the screen turns red to denote over torque. 

The SLTC FM 2.4 GHz A3 click wrenches combined with the Global Series process monitors/controllers have successfully converted torque value to time. This provides Error Proofing by Behavior Modification as well as Error Proofing By Guidance. 

If the operator does not reach torque, the wrench does not click. The Global Series unit does not advance the count or even recognize that work was attempted until the predetermined torque value is reached.

If the operator reaches torque and continues to provide additional force the wrench recognizes that andSLTC FM 2.4 GHz click wrench provides visual feedback. provides visual feedback by illuminating the raised Fresnel LED on top of the radio housing on the wrench. The wrench also sends a message to the Global Series Monitor and the Global Series Monitor provides visual and auditory feedback telling the operator that the fastener does not meet the required torque values.

We give you both flexibility and control over the error-proofing. For example, you determine whether or not the process monitor advances the batch count when a fastener is non-compliant. You can shape our system to your needs rather than our system dictating what you can and cannot do.


Even our calibration and test equipment provide built-in Error Proofing.  

When a test transducer is pulled to 120% or more of the rated capacity, the Fail-Safe Engineering protocol immediately takes over. This protocol tells the operator that the transducer has been pulled beyond tool capacity to the point that it should be checked for accuracy. It also guides the operator to the next steps. And, if the operator makes a mistake, the system guides the operator to issue resolution. 


Error Proofing From A Different Angle: Definition of error proofing and some observations by W. Edwards Deming.

Finding The Balance: In error proofing "one size fits no one."  To find what fits in your organization, start with the fundamental question of "How much responsibility for error proofing should be given to the tool and how much should be operator responsibility?" This section provides more on this concept.

Six Error Proofing Scenarios: Error proofing solutions all have trade-offs. You can have control or you can have flexibility. Rarely do you get both. This page looks at error-proofing extremes as well as the middle ground. 

How Much Are You Investing In Errors? If your current error proofing system or approach still leaves you with errors you are investing in errors, not error proofing. Error proofing is about quality and it is also very much about dollars and common sense. This page digs into that.

Understanding The Common Centerline: Not having a common centerline is one invisible place where your error-proofing approach can introduce errors instead of eliminating them. If you want to know how to calculate a common centerline and why it is important this page is for you.

There is more about error proofing in our tool pages.


  Sturtevant Richmont tools are proudly made by highly capable union hands.