poka yoke concepts in design automation renukaprasad belgur
TRANSCRIPT
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Poka Yoke Concepts in Design Automation
Renukaprasad Belgur
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Inadvertent Mistakes - PokaPrevention - Yoke
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Poka Yoke - Fail Safe
POH-kah YOH-keh - means "fail-safing" or "mistake-proofing”
“Poka” – Inadvertent mistake
“Yoke” – Prevention
Concept by Shigeo Shingo (1909 ~ 1990) – World’s 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
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Replacement
Elimination
Miti
gatio
n
21
5
Facilitation
Detection
3
4
Poka Yoke Principles
MitigationMinimizing the effect
of Error. - Protection,
Safety Devices
EliminationEliminate the
possibility of Errors.
Redesign of the Process or Product s
–
No need to inspect
FacilitationMake work easier to perform such as color coding, combining steps,..
ReplacementSubstitute a more Reliable Process for the existing one. - Use of Robots or Automation
DetectionDetect error before further processing. Software interlocks
which notifies an Operator for wrong inputs.
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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 …..
Prod
uct s
& S
ervi
ces
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Design Principles - Examples
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Design Principles – Innovative
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Road Crossing Solution
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Poka Yoke Design - Examples
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Poka Yoke Solutions - Examples
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Errors@Work – Examples
Circular Saw - Safety
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Errors@Work – Examples
• Missing Parts Forgetting to assemble a part – Screws, Washers, labels, etc.,
• Misassembled PartsMisassembly – loose parts, upside down, not aligned – Ex:
Brackets (Reverse), seals not aligned, screws (Loose), Labels (Upside Down)
• Incorrect ProcessingDisposing of a part rejected at test to the wrong pile
• Incorrect PartsRetrieving and assembling the wrong part from a model mix selection – seals, labels, brackets, cses…
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Fail Safe Assembly - Turbochargers
Concept of FailSafe – Prevention & Detection DevicesGuided Part PickingVerification of the picked partVerification of the AssemblyInterlocking of checking systems
Elimination – Eliminating the chance of error Facilitation – Guidance Methods to minimise error Mitigation – Lessen the effect of the error Flagging – Methods for capturing all defects prior to shipment Replacement
Eliminati
on
Miti
g
ation
21
5 Facilitation
Detection
3
4
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TurboCharger - Assembly Line
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Assembly Line - Electrical Switchgear
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Assembly Line – Yesteryears
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Engine Assy Line – Workstations
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Engine Assy – Engraving Station Inspn.
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Typical Schematic - Engine Assembly Line
110 Work Stations3000 I/O’s 14 HMI’s 80 Profinet Nodes 80 ASI Nodes 4 Barcode Printer 12 Vision System 5 Servo Systems 11 Nut runner stations 1 Engraving unit
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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
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Data Carrier, 32kBRF350T
Read/Wright HeadRF310R
Read/Wright HeadRF310R
Data Carrier, 2 kBRF360T
RFID ControllerRF180C
Profinet
Ethernet
S7-300 PLC
Profinet
RFID ControllerRF170C
RFID – Typical Configuration
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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
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Laser Sensors
Application Areas
• Reference & Diff thickness measurements• Distance Measurements• Positioning• Profile measurements• Level Measurements• Material deformity measurements
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Intelligent Systems – for Assembly
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Pick Light Sensors
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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