In many production environments, human error remains a leading cause of defects, rework, and quality loss. Even well-trained operators make mistakes when work instructions are unclear or outdated, processes rely on memory, or manual data entry allows skipped steps. As a result, quality issues are detected too late, leading to scrap, delays, and higher costs that impact overall customer satisfaction.
No-fault-forward is a production philosophy designed to prevent errors before they happen.
Instead of detecting faults at the end of the process, each step is verified before the next can begin — ensuring that only “fault-free” work moves forward.
It’s built on a few core ideas:
Ansomat offers an extensive suite of tools and devices connected to its Operator Guidance platform to support with no-fault-forward procedures. This helps with every step in the process to think what’s required to reduce operator mistakes to the maximum. Common technologies used for error-proofing include:
Machine vision
Real-time location systems
Monitor operators and eliminate human error
Even the most skilled operators can make mistakes, often with costly consequences. Vision systems drastically enhance operational accuracy by continuously monitoring manual actions using computer algorithms.
Identify human errors at the point of origin
The earlier an error is caught, the lower its impact. Vision systems detect flaws at their origin, whether in base materials, component misplacements, or assembly mistakes, preventing issues from propagating downstream.
Give real-time feedback on potential mistakes
Advanced, AI-powered vision systems can provide real-time feedback on the cause of a detected error. This enables operators to understand what went wrong, take corrective action immediately, and resume production without delay.
Position tracking with high accuracy
Real-time location system (RTLS) can deliver position tracking with up to 1.5 mm accuracy. It’s an expandable, factory-wide solution, simply add more anchors to extend coverage across larger areas. The system tracks tools and actions in full 3D space, capturing movements in all orientations. Because measurements are taken from the bit of the tool, accuracy is maintained regardless of whether the operator is right- or left-handed.
Reliable performance in challenging areas
Unlike camera-based vision systems restricted by their field of view, RTLS maintains precision even in hard-to-reach or obstructed zones. Its coverage can be effortlessly expanded by deploying additional anchors, ensuring consistent performance throughout the entire facility.
Beyond tracking: intelligent action validation
RTLS goes beyond simple position tracking, it can automatically validate actions without the need for extra sensors or manual confirmation. Activities such as completed picks, verified assemblies, or operator movements can be detected and recorded in real time. This transforms RTLS into a comprehensive, factory-wide platform that supports safety monitoring, asset tracking and a wide range of other industrial applications.
| Aspect | ❌ Before (Without NFF system) | ✅ After (With No-Fault-Forward system) | Typical improvement |
| Process flow control | Manual: operators can skip or perform steps out of sequence | Automated: next step allowed only after correct completion of current one | 100% step validation |
| Error prevention | Reactive: errors found during inspection or testing | Proactive: system prevents errors in real time | ⬇️ 80–95% assembly errors |
| Rework & scrap | High: mistakes discovered late in process | Minimal: errors caught immediately | ⬇️ 50–80% rework/scrap |
| Quality consistency | Dependent on operator skill & attention | Enforced process compliance across all operators | ⬆️ 20–40% consistency |
| Training requirements | High: operators need extensive training to remember process details | Lower: system guides each step interactively | ⬇️ 30–50% training time |
| Cycle time | Variable: mistakes and corrections increase time | Stable: fewer interruptions and predictable flow | ⬇️ 10–25% cycle time |
| Data capture | Manual: operators record results or skip data | Automatic: all steps and validations digitally logged | ⬇️ 90% data errors |
| Traceability | Limited: hard to prove each step was done correctly | Full: each operation verified and time-stamped | ⬆️ to 100% traceability |
| Quality escapes (Defects leaving station) | Common: incomplete or incorrect assemblies move forward | Eliminated: faults detected and stopped at source | ⬇️ 100% escapes |
| Operator confidence & accountability | Variable: fear of making mistakes | High: guided workflow builds confidence | ⬆️ operator satisfaction |
| Customer quality perception | Inconsistent: occasional field failures | Consistently high: fewer defects reach customers | ⬆️ brand reliability |