Verify the right parts, the right torque, and the right order on every build.
FlexIPS combines step-gated work instructions, machine vision, screwdriver torque capture, and beamer guidance into one assembly verification station. The line cannot advance until each check passes, and every step is recorded to FlexDashboard for traceability.
step-gated assembly: the line cannot advance until each check passes
torque, parts, and orientation captured against every serial
typical station cycle for a full assembly and verification sequence
Step
4 / 6
Points
6/12
Verdict
SCAN
One station verifies the complete build state before it ships.
An assembly can pass a visual glance while still carrying hidden issues: a fastener torqued low, a gasket unseated, a connector not fully locked, or a harness clip in the wrong nest. FlexIPS verifies parts, torque, orientation, and sequence, and gates the build so a wrong step cannot advance.
Fasteners & Torque
- Bolt and screw presence, count, and position at every seat
- Screwdriver torque value captured and compared to target per fastener
- Torque-angle window verification for critical joints
- Torque sequence enforced before the station can release
Parts & Placement
- Gasket, seal, and O-ring seated and continuous
- Sensor, magnet plug, and vent cap presence and orientation
- Filter cover and breather installed in the correct position
- Correct part variant confirmed against the work order
Connectors & Routing
- Harness connector fully mated and locked
- Harness clips present and routed along the reference path
- Connector pin bent / missing detection before mating
- Cable routing checked clear of pinch and heat zones
Bolts
5 / 5
Torque
in window
Connectors
mated
Routing
ref OK
From transmission cases to torque, beamer guidance, and FlexDashboard.
Assembly verification is not one check; it is a family of them. FlexIPS handles the full range on a single station, all tied to the same serial and traceability record.
Transmission Case
Verify bolt pattern, torque sequence, gasket, sensor, magnet plug, vent cap, and harness clip on every case.
Screwdriver Torque
Capture torque and angle from DC nutrunners per step and gate the build on target windows.
Beamer Guidance
Project the exact part position and torque order onto the fixture so the operator builds it right first time.
Connector Mating
Confirm connectors fully seated and locked, and catch bent or missing pins before the join.
Part & Variant
Read 1D/2D codes to load the correct recipe and confirm the right part is in the right station.
Routing & Clips
Check harness clips and cable routing against the reference path to avoid pinches and abrasion.
Presence / Absence
Confirm clips, caps, washers, and fasteners are present, and that nothing foreign was left behind.
Orientation
Verify parts are oriented correctly: magnet polarity, connector key, gasket notch, and label face.
FlexDashboard
Search any serial to see its steps, torque values, images, and verdict in seconds for audits.
M8 - FL
target 23.0 Nm · angle 52°
23.4 Nm
OK
M8 - FR
target 23.0 Nm · angle 49°
22.9 Nm
OK
Center
target 18.0 Nm · angle 41°
17.8 Nm
OK
M8 - RL
target 23.0 Nm · angle 30°
19.1 Nm
LOW - REWORK
Every fastener torqued to spec, and proven.
FlexIPS talks to your DC screwdrivers and torque tools. The target value, tolerance window, and torque-angle curve are captured per step and tied to the serial. If a fastener falls outside the window, the station locks and the operator is told exactly which seat to rework.
- Capture torque value and angle from each nutrunner per step
- Gate the build on target torque and angle windows
- Enforce the correct torque sequence before release
- Rework guidance names the exact fastener that failed
Projected
Part outline and order
Confirmed
3 / 8 placed
Next
Torque M8 (FR)
Show the operator the exact part position, projected on the fixture.
A FlexProjector beams the next part position, orientation, and torque order directly onto the assembly. The operator places parts into the projected outline, the camera confirms placement, and the step advances. New operators reach quality speed without memorizing the sequence.
- Project part outline, orientation, and torque order live
- Camera confirms placement before the step advances
- Removes reliance on paper instructions and tribal knowledge
- Swap variants: the projection updates with the recipe
1 · Barcode and variant
TC-K9 · loaded
2 · Gasket seated
image · 0.97
3 · Sensor mated
locked · 0.95
4 · Torque M8 x4
23.4 · 22.9 · 22.7 · 23.1 Nm
5 · Harness clip and routing
path OK · 0.93
6 · Label / 2D read
TC-44120-B07
Search any serial. See every step, torque value, and verdict.
Every assembly is recorded as a complete, searchable history in FlexDashboard. When a return or audit arrives, search the serial and instantly see the work order, each step result, the torque values, inspection images, the operator, and the final verdict, all exportable and audit-ready.
- Search a serial to pull up its full step-by-step assembly record
- Torque values, images, and verdict on one timeline
- Filter by station, operator, variant, or pass/fail
- Export evidence for audits, returns, and containment
Every step enforced, every action recorded.
Step-Gated Work Instructions
Digital instructions advance only when the camera, scanner, or torque tool confirms the step, eliminating skipped steps and wrong-order builds.
Evidence Per Step
A calibrated image is captured for every critical step, so the quality team can prove what was present, seated, torqued, and accepted on each serial.
Torque and Angle Capture
Torque value and angle are recorded from the screwdriver per fastener and compared against the target window before the build can continue.
Projected Part Guidance
FlexProjector beams the next part position and torque order onto the fixture, so operators place and tighten in the correct sequence every time.
FAIL Routing to FlexCheck
Failed steps route to FlexCheck with the captured image, reference overlay, defect label, and the action the operator should take.
Line-Paced Cycle
Barcode read, guidance, torque capture, vision checks, and PLC verdict complete in a single line-paced cycle and never become the bottleneck.
Not just pass/fail. A complete build history for every serial.
Assembly teams need more than a green light. They need proof: when a return arrives, when an audit is run, or when a defect mode appears. FlexIPS stores every step result, torque value, image, and verdict in one searchable record tied to the serial.
Serial-linked proof
Barcode, variant, each step result, torque values, images, verdict, operator, and timestamp stay tied to the assembly serial.
Faster root cause
When a defect escapes, search the serial to see exactly which step, fastener, or part was involved, with no folder diving.
Audit-ready history
Every assembly ships with a complete, exportable record proving the build was completed and verified correctly.
M8 Bolt RL: torque low
19.1 Nm captured vs 23.0 Nm target
Harness clip missing
Front-right nest: not detected
When a step fails, the operator sees exactly where and why.
FlexIPS inspects every step as the operator builds. If a part, torque value, or feature fails, the assembly is routed to FlexCheck, where the captured image is overlaid on the golden reference at adjustable opacity. Failed regions are marked, labeled, and paired with the action to take: rework, check, or controlled override.
- Every step is verified by camera, scanner, or torque tool before it advances
- Failed points are highlighted directly on the captured image
- Overlay the captured build on the reference at adjustable opacity
- Clear action label per failure: REWORK, CHECK, or OVERRIDE PASS
- Every decision is logged against the serial for traceability
From barcode to traced verdict in one paced cycle.
Step 1
Identify
Read the case barcode and load the correct variant work-instruction and torque sequence.
Step 2
Build
Step through assembly with beamer guidance marking the exact part position before each fastener is tightened.
Step 3
Torque
Capture screwdriver torque values and confirm fasteners hit target and angle windows per step.
Step 4
Release
Verify all features, release PASS to the line, or route FAIL to FlexCheck with the failed step.
Drops into your assembly line.
FlexIPS bridges IT and OT without middleware, from screwdrivers and PLC handshakes to MES genealogy records.
Screwdrivers & Tools
Connect DC nutrunners and torque tools to capture torque and angle per step, gate the build on target windows, and tie every value to the serial.
MES & Traceability
Serial, variant, every step result, torque values, images, and verdict are written directly to your MES or SQL store, with full genealogy tied to each assembly shipped.
PLC & Station I/O
Trigger on part-present, handshake with the station, and return pass/fail to the line PLC with 24V logic. Station-lock on critical faults is included.
Common questions from assembly and quality teams.
Step-gated build verification with torque capture, vision checks, and projector guidance, answered for production, quality, and IT teams.
What is assembly verification?
Assembly verification is a step-gated process that confirms every aspect of a build is correct before the unit can advance. FlexIPS verifies the correct parts and variant, part presence and orientation, fastener count and position, screwdriver torque and angle per step, connector mating, harness clip and routing, and enforces the correct build sequence end-to-end. The station only releases when every step passes, eliminating the missing-part and wrong-sequence escapes that cause field failures.
How does torque verification work?
FlexIPS connects directly to DC nutrunners and torque tools. The target value and tolerance window are defined per step; the captured torque and angle are compared to the window and tied to the serial. A fastener that lands outside the window locks the station and names the exact seat to rework, so no under- or over-torqued joint can leave the station.
What is beamer (projector) guidance?
A FlexProjector beams the next part position, orientation, and torque order directly onto the fixture as a light spot. The camera confirms placement, the step advances, and operators build it correctly the first time without paper instructions. Combined with vision verification and torque capture, it is a full poka-yoke: the operator is guided to the right place, the action is verified, and the next step only unlocks on a confirmed pass.
Can it enforce the correct build sequence?
Yes. Each step is gated: the station cannot advance to the next step until the current one passes its vision and torque checks. This prevents skipped steps, out-of-order operations, and the partial builds that drive most assembly escapes.
What happens when an assembly fails a step?
The station returns a FAIL verdict and routes the unit to FlexCheck. The failed step is highlighted on the captured image with the reference overlay and a clear action label: rework, check, or controlled override. The operator sees exactly what went wrong and where, and the decision is logged against the serial for traceability.
Can I search a past assembly in FlexDashboard?
Yes. Search any serial to see its work order, every step result, torque values, inspection images, operator, and final verdict. Filter by station, operator, variant, or pass/fail and export the evidence for audits, PPAP, or customer complaints in seconds.
Does it support high-mix, multi-variant assembly?
Yes. The build sequence, part list, and torque targets are stored per variant and load automatically from the barcode, serial, or MES record. One station can run many variants without manual changeover, with each variant verified against its own recipe.
How is assembly verification integrated with the line?
FlexIPS bridges IT and OT without middleware. It triggers on part-present, handshakes with the line PLC over 24V I/O, captures torque from the screwdriver controller, and writes serial, step results, torque, images, and verdict to MES, SQL, OPC UA, or REST. Station-lock on any failed step prevents escapes at the source.
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Test FlexIPS on your assembly station
Send a sample assembly, work instruction, or torque sequence and we will map a tailored demo around your variant, quality gates, FlexCheck flow, and traceability requirements.