Method and system for reducing errors in a manufacturing process

A system for manufacturing an assembly within a plant on a conveyor line comprising:

• a non-segmented network including:
• a plurality of servers for storing data, said plurality of servers including a build data server for storing build data;
• at least one of a sensor and an operator for detecting an identity and a position of the assembly on the conveyor line, said conveyor line having a plurality of manufacturing zones and a plurality of stations within each of said plurality of manufacturing zones,
• a tracking controller electronically coupled to said plurality of servers for receiving data therefrom, said tracking controller for receiving said identity and said position of the assembly on the conveyor line from at least one of said sensor and said operator;
• at least one local I/O interface electronically coupled to said tracking controller and said build data server, said at least one local I/O interface receiving said data, said identity, and said position of the assembly from said controller, said at least one local I/O interface receiving said build data from said build data server for instructing said operator to perform an assembly task;
• and
• at least one I/O manufacturing tool electronically coupled to said at least one I/O interface, said at least one I/O manufacturing tool being utilized by said operator for performing said assembly task pursuant to said identity and said build data associated with the assembly, said at least one I/O manufacturing tool for detecting at least one of a successful build condition and an unsuccessful build condition;
• wherein said at least one local I/O interface comprises an embedded computer and a multi-colored stack light, said embedded computer having a touch screen and a plurality of non-moving parts, said multi-colored stack light electronically coupled to said embedded computer for indicating a build status to said operator.