Real-Time Quality Control System
Poka Yoke Smart Error-Proofing
Poka Yoke Hardware by Opus One is an advanced sensor-based error-proofing system designed to detect product defects instantly during the production process. Integrated with an industrial IoT node and controller kit, the solution captures quality deviations in real time and transmits them directly to the Opus One Manufacturing Execution System (MES) for visibility, traceability, and corrective action. Built for Industry 4.0 manufacturing environments, the system can be easily retrofitted on legacy machines, transforming traditional quality checks into automated, intelligent quality control. By detecting defects at the source, manufacturers can significantly reduce rework, scrap, and quality-related production losses.
Zero Defect Manufacturing Starts at the Source
Real-Time Visibility
Faster Response
Higher Productivity
100,000
Offline Storage capacity
600/minute
Capture Signals
Edge Computing
Faster on-site processing
24×7
Live Production Monitoring
Pain points in the industry
Why Poka Yoke Error-Proofing Matters
for Plant Heads?
Quality issues that are detected late in the production cycle can lead to serious operational and financial challenges, such as:
Higher Cost of Poor Quality (COPQ)
Describe your module here…
KEY FEATURES
Key Features
Core Capabilities of the Poka Yoke Hardware
The Opus One Poka Yoke Hardware prevents defects at the point of production, improving First Pass Yield (FPY) and ensuring consistent manufacturing quality.
Sensor-Based Quality Detection
The system uses industrial sensors to validate production processes and detect defects instantly.
- Presence or absence validation
- Assembly verification checks
- Process confirmation monitoring
- Position or completion detection
- Real-time defect signal capture
Detection logic can be configured according to workstation requirements and product specifications.
Industrial IoT Node & Controller
The solution includes an industrial-grade IoT node and controller unit designed for reliable shopfloor deployment.
- Secure sensor signal acquisition
- Local validation logic processing
- Reliable industrial data transmission
- Seamless integration with Opus One MES
- Stable performance in high-speed production environments
Rugged and reliable kit deployment.
Industrial IoT Node & Controller
The system ensures that defects are detected and acted upon immediately.
- Buzzer notification on defect detection
- Immediate operator workstation alerts
- Prevention of continued defective production
- Faster corrective action and process correction
This ensures rapid response and improved process control.
MES-Based Quality Intelligence
All defect events and rejection data are digitally captured within the MES platform.
- Timestamped rejection logs
- Machine-wise and station-level defect tracking
- Shift-wise rejection counts
- Defect trend analysis
- Root cause data logging
This converts quality incidents into actionable manufacturing analytics.
Retrofittable & Industry 4.0 Ready
The Poka Yoke hardware is designed to support gradual digital transformation in manufacturing plants.
- Compatible with legacy machines
- Minimal wiring modifications
- Support for multiple sensor types
- Scalable architecture across production lines
- Fully integrated with the Opus One MES ecosystem
This allows manufacturers to adopt Industry 4.0 quality control without large infrastructure investments
Universal Compatibility
Built for Every Machine,
Ready for Every Industry
Our Wi-Fi OEE Monitoring System seamlessly integrates with virtually anymanufacturing equipment. From legacy machines to modern industrial robots, OpusOne adapts to your factory floor.
- CNC Machines
- VMC / VFC Machines
- Press Machines
- Injection Moulding Machines
- Industrial Robots
- Looms & Textile Equipment
- Assembly Lines
- Packaging Machines
Reliable Hardware, Industrial-Grade Performance
Purpose-built for demanding factory environments with enterprise-grade components and seamless connectivity options.
Display
Industrial Features
- Industrial-grade durability
- IP54 rated enclosure
- Anti-glare display
- Wide operating temperature
- LED status indicators
QR Code
Industrial Features
- IP54 rated enclosure
Wi-Fi
Industrial Features
- Industrial-grade durability
- IP54 rated enclosure
- Anti-glare display
Easy Installation
Plug. Play. Scale.
Real results that impact your bottom line within months, not years
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Unbox & Mount
Secure the OpusOne device near your machine using the included mounting bracket. No special tools required.
- Wall or panel mount options
- VESA compatible bracket
- Adjustable viewing angle
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Connect to Wi-Fi
Power on the device and connect to your factory Wi-Fi network through the intuitive setup wizard.
- Simple on-screen setup
- WPA2/WPA3 security
- Automatic reconnection
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Configure I/O
Connect sensor wires from your machine to the digital I/O terminals for automatic production counting.
- 3 digital inputs available
- 3 digital outputs available
- RS485 for PLC integration
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Start Monitoring
Access your real-time dashboard from any device. Your factory data is now visible 24/7.
- Web-based portal access
- Mobile responsive design
- Instant data visibility
System Requirements
Power Supply
12-24V DC, 2A min
Wi-Fi Network
2.4GHz or 5GHz
Signal Source
24VDC sensor output
Mounting Space
200 x 150 x 50 mm
Need Help with Installation?
Our technical team provides remote or on-site installation support to ensure your system is up and running smoothly.
Value & ROI
Measurable Gains.
Rapid Payback.
Real results that impact your bottom line within months, not years
5-20%
Productivity Gains
Optimized workflows and better resource utilization
Better
On-Time Delivery
Meet customer commitments consistently
Production
Smarter Production Outcomes
Consistent performance with fewer delays.
Lower
Scrap & Rework
Early defect detection reduces waste
10-30%
Reduced Downtime
Faster response to issues means less production loss
Quick ROI
3–9 Month ROI
Lower downtime. Faster returns.
Installation & Setup – Data Collection Analysis – Decision Making
Implementation of Decision
making & Improvement
observations
ROI Realization
Software & Data Flow
How Your Data Gets From OEE to Opus One Platform
Understand how OpusOne captures, transmits, and processes your production data todeliver actionable insights in real-time.
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Machine Signals
Digital I/O captures production events, cycle times, and machine states in real-time.
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Wi-Fi Transmission
Data is securely transmitted over your factory Wi-Fi network using encrypted protocols.
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Cloud Processing
Our servers process and analyze data, calculating OEE metrics and generating insights.
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Dashboard Access
View real-time dashboards and reports from any device, anywhere, anytime.
Sample Reports
Data-Driven Insights at Your Fingertips
Generate comprehensive reports automatically. From daily OEE summaries to detailed
downtime analysis, get the data you need to drive continuous improvement.
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Sample Report
Machine: RACB14
Request a demo
Ready to simplify your factory operations?
Manufacturing teams rely on real-time visibility to stay in control.
Trusted by growing teams worldwide
faq
Got questions? We’ve got
answers
Real results that impact your bottom line
within months, not years
What industries can benefit from OpusOne?
OpusOne caters to a wide range of industries including automotive, aerospace, consumer goods, and pharmaceuticals, enhancing their manufacturing processes with digital solutions.
How does OpusOne improve productivity?
By integrating automation and real-time data analytics, OpusOne helps identify bottlenecks, optimize processes, and increase overall operational efficiency.
What is the timeline for implementation?
The implementation timeline varies based on the complexity of your existing systems, but our team ensures a smooth and efficient transition.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Still have questions?
