We need a changeover check for our FR5 cover-loading nest. Two inserts look nearly alike, and their labels disappear underneath once fitted. One also seems able to go in backwards. A photo in the training sheet won't help if nobody can see what they've installed.
Can the wrong insert fully seat and clamp, or does it only look as though it will? I'd get tooling to check both cases before writing a confirmation box that asks an operator to promise the impossible.
Then you've got two faults to deal with: wrong identity and wrong seating. A readable label helps identity; it won't stop the clamp making a backwards insert look finished.
Keep the ID visible after fitting as well. I've seen beautifully legible labels become invisible at exactly the moment someone needed to check them. Your training sheet can then show the view the operator actually gets.
Have you included the right family with an older insert revision in the discussion? I ask because a family match could still leave the wrong pocket geometry if the design has changed.
Also try choosing the recipe first and changing the insert afterward. That catches a check which only ran when the screen was opened, not when the hardware changed.
Priya, yes, and don't make the operator navigate away and back just to persuade the screen to notice. That is the sort of extra ritual that gets taught as normal.
Mina, there is an older cover insert in stores with the same family marking. Tooling has put it in the comparison. Priya, changing the insert after recipe selection is now a test case.
Good to have found it while the checks are still being designed. Will stores retain a clear list of which revisions are allowed with each recipe? Otherwise the next spare issue may reopen the same problem.
Stores and controls are building that list together. The new locating feature stops reversed seating in the bench sample, but the family and revision checks still need testing.
Try the actual changeover with whoever does it on the other shift once the checks are ready. Especially the old-revision case. Easy to get a perfect result when everyone in the room already knows which insert is wrong.