Poka Yoke

Methods used by Padmini for Poke-yoke

A method that uses sensor or other devices for catching errors that may pass by operators or assemblers.

1. Control Approach
   • Shuts down the process when an error occurs.
   • Keeps the "suspect" part in place when an operation is incomplete.
2. Warning Approach
   • Signals the operator to stop the process and correct the problem.

Some of the Mistake-proofing Devices used by padmini

• Guide Pins
• Blinking lights and alarms
• Limit switches
• Proximity switches
• Counters
• Checklists
• Photo sensors
• Trip switches
• Fixtures to orient parts
• Kitting of parts

Poke yoke systems

Padmini uses all Poka-yoke systems that need all three primary methods:

1. Contact
2. Counting
3. Motion-Sequence

• Each method can be used in a control system or a warning system.
• Each method uses a different process prevention approach for dealing with irregularities.

Poke Yoke systems in Padmini

Classification based on fail-safe method

• Physical detection and control (contact methods)
  » Identify items by their physical characteristics
• Sequencing (motion-step methods)
  » Indicate, discourage or prevent deviation from process steps
• Grouping and counting
  » Assure correct groupings, ordering, and the use of all and only the correct components
• Information enhancement
  » Prevent failed or incomplete communications as well as enhance existing communications