I've got two nest inserts on my desk for an FR5 inspection station. Same outside shape, different relief underneath the sensor cover. Either insert will bolt down either way round.
The screen asks the operator to select a part family. I can't sign that off as an insert check. Am I missing an obvious mechanical answer?
Make the wrong orientation physically difficult to install, if the tooling permits it. Selecting a family on a screen establishes what somebody intended, not what they fitted.
Only what its geometry distinguishes. If both inserts accept the same pin in the same orientation, you still haven't identified which insert is present.
Then give identity its own check. The recipe should agree with the installed insert, and the response to an absent or unreadable identity needs defining too.
Do your inserts stay with one part family? We had removable labels on teaching fixtures. Someone swapped a label to tidy the cupboard and the label check happily approved the wrong fixture.
That's a good failure case for the design review. Reading a tag proves which tag was read. How it stays associated with the insert matters just as much as the reader.
Plan how a replacement insert gets accepted as well. Our fleet tooling had a tidy normal workflow, then a spare arrived without its identity configured and nobody on shift knew who could authorise it. Downtime came from that missing handover.
And don't let the replacement process become the everyday way to dismiss a mismatch. The normal screen should explain what's mismatched and keep the automatic job pending.
Good catch. Demo screen retains the last family after the fixture is removed. I've added removal and a swapped label to our test list. The inserts will each stay with one family.
Yep, I described that badly. It still shows the old 'verified' state too. Toolmaker is revising the locator; software review is tomorrow. Thanks for giving me a specific failure to demonstrate.