DDLC for Autonomous Manufacturing Workstations

Banbury Sulfur Poka-Yoke

ポカヨケ - Intelligent Sulfur Detection & Error Prevention

Machine vision ensures precise sulfur addition for zero-defect tire production

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See Banbury Sulfur Poka-Yoke in Action

Explore how DDLC's machine vision detects sulfur presence and controls the conveyor

Interactive Demonstration

Sulfur Detected

Conveyor Moving

No Alerts

Scanning...

Conveyor Moving

No Alerts

Sulfur Added

Resumed

Alert Cleared

✓ Normal Operation

The camera detects the yellow sulfur bag on top of the rubber. The system confirms proper setup, keeps the conveyor running, and allows the material to proceed to the Banbury mixer. Quality is assured.

✗ Error Detected - Sulfur Missing

Computer vision detects rubber without sulfur. The system immediately stops the conveyor, prevents defective material from entering the mixer, and alerts the operator. A defective batch has been prevented.

↻ Recovery Process

After the operator adds the sulfur bag, the camera instantly detects it. The system automatically clears the alert and resumes the conveyor. Production continues with quality maintained.

Before & After Banbury Sulfur Poka-Yoke

See the transformation in sulfur detection and quality control

Without Sulfur Poka-Yoke

Operators manually verify sulfur addition
Human fatigue leads to occasional misses
Defective batches enter the mixer
Quality issues discovered later
Costly material waste and rework
Inconsistent product quality
No objective process records
Reactive problem solving

With DDLC Sulfur Poka-Yoke

Automatic 24/7 vision monitoring
100% consistent detection, no fatigue
Defects prevented before mixing
Instant detection and prevention
Zero defective batches produced
Guaranteed quality consistency
Complete digital traceability
Proactive quality assurance