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Poka Yoke Concepts in Design Automation Renukaprasad Belgur.

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Presentation on theme: "Poka Yoke Concepts in Design Automation Renukaprasad Belgur."— Presentation transcript:

1 Poka Yoke Concepts in Design Automation Renukaprasad Belgur

2 Inadvertent Mistakes - Poka Prevention - Yoke

3 Poka Yoke - Fail Safe fail-safingmistake-proofing POH-kah YOH-keh - means "fail-safing" or "mistake-proofing Poka – Inadvertent mistake Yoke – Prevention Shigeo Shingo Concept by Shigeo Shingo (1909 ~ 1990) – Worlds leading expert on Mfg Practices – Shingo Prize – Lean Mfg Practices A methodology to Detect & Prevent causes of Defects ZQC – (Zero Quality Control) Most mistakes – committed by workers / errors in the production systems Feedback control and action system at the error stage fail-safingmistake-proofing POH-kah YOH-keh - means "fail-safing" or "mistake-proofing Poka – Inadvertent mistake Yoke – Prevention Shigeo Shingo Concept by Shigeo Shingo (1909 ~ 1990) – Worlds leading expert on Mfg Practices – Shingo Prize – Lean Mfg Practices A methodology to Detect & Prevent causes of Defects ZQC – (Zero Quality Control) Most mistakes – committed by workers / errors in the production systems Feedback control and action system at the error stage Hi-Tech Gears Limited – Manesar, Haryana

4 Replacement Elimination Mitigation Facilitation Detection 3 4 Poka Yoke Principles Mitigation Minimizing the effect of Error. - Protection, Safety Devices Elimination Eliminate the possibility of Errors. Redesign of the Process or Product s – No need to inspect Facilitation Make work easier to perform such as color coding, combining steps,.. Replacement Substitute a more Reliable Process for the existing one. - Use of Robots or Automation Detection Detect error before further processing. Software interlocks which notifies an Operator for wrong inputs.

5 Design Principles - Fundamental 1. Basic Functionality 2.Safety 3.Poka Yoke (Mistake Proofing) 4.Ergonomic Design 5.Simplicity 6.Flexibility 7.Robustness & Reliabile 8.Ease of Use 9.Ease of Maintainability ….. 1. Basic Functionality 2.Safety 3.Poka Yoke (Mistake Proofing) 4.Ergonomic Design 5.Simplicity 6.Flexibility 7.Robustness & Reliabile 8.Ease of Use 9.Ease of Maintainability …..

6 Design Principles - Examples

7 Design Principles – Innovative

8 Road Crossing Solution

9 Poka Yoke Design - Examples

10 Poka Yoke Solutions - Examples

11 – Examples Circular Saw - Safety

12 – Examples Missing Parts Missing Parts Forgetting to assemble a part – Screws, Washers, labels, etc., Misassembled Parts Misassembled Parts Misassembly – loose parts, upside down, not aligned – Ex: Brackets (Reverse), seals not aligned, screws (Loose), Labels (Upside Down) Incorrect Processing Incorrect Processing Disposing of a part rejected at test to the wrong pile Incorrect Parts Incorrect Parts Retrieving and assembling the wrong part from a model mix selection – seals, labels, brackets, cses… Missing Parts Missing Parts Forgetting to assemble a part – Screws, Washers, labels, etc., Misassembled Parts Misassembled Parts Misassembly – loose parts, upside down, not aligned – Ex: Brackets (Reverse), seals not aligned, screws (Loose), Labels (Upside Down) Incorrect Processing Incorrect Processing Disposing of a part rejected at test to the wrong pile Incorrect Parts Incorrect Parts Retrieving and assembling the wrong part from a model mix selection – seals, labels, brackets, cses…

13 Fail Safe Assembly - Turbochargers FailSafe Concept of FailSafe – Prevention & Detection Devices Guided Part Picking Verification of the picked part Verification of the Assembly Interlocking of checking systems Elimination Elimination – Eliminating the chance of error Facilitation Facilitation – Guidance Methods to minimise error Mitigation Mitigation – Lessen the effect of the error Flagging Flagging – Methods for capturing all defects prior to shipment Replacem ent Eliminati on Miti gatio n Facili tatio n Detecti on 3 4

14 TurboCharger - Assembly Line

15 Assembly Line - Electrical Switchgear

16 Assembly Line – Yesteryears

17 Engine Assy Line – Workstations

18 Engine Assy – Engraving Station Inspn.

19 Typical Schematic - Engine Assembly Line 110 Work Stations 110 Work Stations 3000 I/Os 14 HMIs 14 HMIs 80 Profinet Nodes 80 Profinet Nodes 80 ASI Nodes 80 ASI Nodes 4 Barcode Printer 4 Barcode Printer 12Vision System 12Vision System 5 Servo Systems 5 Servo Systems 11 Nut runner stations 11 Nut runner stations 1Engraving unit 1Engraving unit 110 Work Stations 110 Work Stations 3000 I/Os 14 HMIs 14 HMIs 80 Profinet Nodes 80 Profinet Nodes 80 ASI Nodes 80 ASI Nodes 4 Barcode Printer 4 Barcode Printer 12Vision System 12Vision System 5 Servo Systems 5 Servo Systems 11 Nut runner stations 11 Nut runner stations 1Engraving unit 1Engraving unit

20 Poka-Yoke – RH, LH Axle Bearing Inspn PLC Ethernet Network Detecting RH, LH & Counting Lower Brg Balls Light Camera 1 Counting Upper Brg Balls Camera 2 Upper bearing counting result OK Not OK

21 Data Carrier, 32kB RF350T Read/Wright Head RF310R Read/Wright Head RF310R Data Carrier, 2 kB RF360T RFID Controller RF180C Profinet Ethernet S7-300 PLC Profinet RFID Controller RF170C RFID – Typical Configuration

22 Fail Safe Devices – Poka Yoke Light Guided pick Devices Presence of Thread Sensors Presence of Component Sensors Vision System – Shape, Dimension, Orientation, etc., Laser Distance Sensors – Resolution >2microns Auxiliary equipment interlocks Software interlocks – Proceed to next station lock Component Check - Go – No Go Gauges with sensor Torque Sensors – Nut tightening Balancing check – Assembly Check Manual angular alignments – Checking using encoders

23 Laser Sensors Application Areas Reference & Diff thickness measurements Distance Measurements Positioning Profile measurements Level Measurements Material deformity measurements

24 Intelligent Systems – for Assembly

25 Pick Light Sensors

26 Fail Safe – Poka Yoke Approach 100% On-time delivery irrespective of variants Flexibility in Assembly line Consistency in Output with high Quality Best in class Ergonomics (man material movement) High Safety Standard Compliance Zero accidents, less fatigue, maxi efficiency Built in Sequential disciplined work approach - HMI No missing Parts / Parts pick sensing Vision check failsafe through Camera Quick changeover (< 1 min) Part Identification Integration of each station – Ethernet Data Acquisition, transfer, storage & analysis

27 Presentation material - © Avasarala Technologies Limited


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