NAGARE™ AI shows each assembly step at the station and confirms it on camera, one step at a time. US plants stop missed steps and wrong parts before either one leaves the station.
In the United States, a missed step at one station can surface weeks later as a field recall or a costly warranty return. Without standardized work that someone checks, each shift builds its own version of the job.
NAGARE™, Jidoka's closed-loop process system, runs digital work instructions at US assembly stations and puts the next step on a station display. It tracks parts and hand actions only, with no facial recognition.
See it running on your line
Tell our engineers where errors bite today and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers your build sequence and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers your torque-critical steps and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers about your manual stations and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers which steps get missed and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertOperator guidance runs on the cameras you already have at your stations. No pilot line, no new hardware to install. We have mapped this deployment before, which is what makes it fast now.
We walk your stations, confirm camera coverage, and scope the steps and variants for verification.
The model trains on your actual steps, parts, and variants, not a generic action library. Training uses 120 minutes of footage.
Guidance runs alongside your current process first, then is confirmed accurate before it goes live on your line. Deployment takes 4 weeks, with ROI payback in 6–12 months.
Bring your highest-scrap station and your trickiest variant. We will scope a pilot on your line.
Comparison
When errors are caught
At assembly or at the customer
End-of-line, after the errors
During the step, in real time
What it sees
Whatever the checker notices
Components, fixed positions only
Components and operator actions
New line or new variant setup
Retraining, weeks
Reprogramming, weeks
New variants configured in minutes
Hardware
Hand tools and checklists
Fixtures, jigs, proprietary sensors
Runs on your existing cameras
Traceability
Paper logs, if kept
Pass or fail report per unit
Video-backed record for every unit
First-Time-Right
Hope
Inspection after the fact
Right the first time, every shift
APA Engineering uses NAGARE™ to verify sequence and quantity at every step of its export kitting. Any step skipped or done out of order triggers audio and visual alerts on the spot, and export kits now ship without errors.
High-speed biscuit inspection with automated quality control:
Labelled bottle inspection with AI vision system and modular hardware:
Poka-yoke means mistake proofing. Such a step either makes an error impossible or catches it the instant it happens. The idea comes from Shigeo Shingo's work at Toyota, and NAGARE™ applies it with cameras that watch the work itself.
Poka-yoke stops a mistake at its source. Jidoka, a founding pillar of Toyota's production system, halts work when something abnormal happens, and the andon is how a line signals that stop. NAGARE™ covers both ideas from one camera feed.
Yes. When NAGARE™ flags an error, it can light the station's andon, sound an alert, or signal the PLC to hold the line.
Yes. First pass yield counts units built right the first time, and digital work instructions lift it by catching operator errors while they are still quick to fix.
No. NAGARE™ checks the process during each step, and inspectors still sign off the finished product. With fewer errors reaching them, inspectors can spend their time on checks that need judgment.
The cost of poor quality typically runs 15 to 20% of sales revenue (ASQ), and human error drives 23% of unplanned manufacturing downtime (Vanson Bourne). Correcting errors at the station, before they escape, attacks both numbers: Jidoka deployments have delivered $140k savings in inspection and COPQ, 20% higher productivity, and 30% reduction in downtime, with new operators reaching standard work faster through guided steps.
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