Design and deployment of an interlocking system for enhancing manufacturing process stability

Abstract

Despite the use of Operation Work Standards (OWS) in industrial manufacturing, human processes frequently result in failures such as product functionality issues, missing components, and improper packaging. An improved Interlocking System has been designed to address these recurrent difficulties. This system successfully leads workers and assures the sequential execution of tasks, lowering the risk of failure dramatically. The Interlocking System works in tandem with the Traceability system to automate the production of QR codes. Hardware upgrades, data collecting capabilities, and compatibility with numerous production lines are also included. The Interlocking System has shown remarkable accuracy, efficiency, and success in lowering the Risk Priority Number (RPN) score and resolving early challenges via rigorous testing and trials in a case study in a Viet Nam’s manufacturer. As a result, not only has this unique approach increased consumer confidence, but it has also improved the factory's reputation. Manual operation failures have been reduced, resulting in higher product quality, faster delivery, and higher overall customer satisfaction.