GOVERNMENT POLYTECHNIC AMBAD

2022-23

DEPARTMENT OF MECHANICAL ENGINEERING

(INDUSTRIAL ENGINEERING AND QUALITY CONTROL)

MICRO-PROJECT REPORT ON

“Poka-Yoke Technique”.

FOR THE AWARD OF

DIPLOMA IN ENGINEERING & TECHNOLOGY

(MECHANICAL ENGINEERING- 3rd YEAR, SEM-VI)

UNDER THE GUIDANCE OF

Prof. V.V. Gaddmwar Sir

SUBMITTED BY

01. RUTIK VISHNU MULE

02. SAGAR HANUMANTHA BORUDE

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 CERTIFICATE

GOVERNMENT POLYTECHNIC AMBAD

DEPARTMENT OF MECHANICAL ENGINEERING

(INDUSTRIAL ENGINEERING AND QUALITY CONTROL)

(CODE:-22657)

This is to certify that the Micro- project entitled “Poka-Yoke

Technique”. Being submitted herewith for the award of DIPLOMA IN

ENGINEERING & TECHNOLOGY in MECHANICAL ENGINEERING of
MAHARASHTRA STATE BOARD & TECHNICAL EDUCATION (MSBTE)
is the result of micro-project work completed under our supervision and guidance by
Prof. V.V. Gaddmwar Sir

To the best of our knowledge and belief, the work embodied in this Micro-
project has not formed earlier the basis for the award of any degree or diploma of
this or any other Board or examining body.

Place: Ambad (Prof. V.V. Gaddmwar Sir)

Date: Micro-project Guide

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 DECLARATION

We, the undesired, hereby declare that the project entitled “Poka-Yoke
Technique” is written and submitted by us to Government Polytechnic Ambad
during Year 2022-23, Sixth Semester for partial fulfillment ofthe ‘Micro-project’
requirement of 'Final Year Micro-Project' subject under Maharashtra State
Board of Technical Education, Mumbai curriculum, under the guidance of Prof.
V.V. Gaddmwar Sir is our original work. The empirical findings inthis project are
based on the data collected in this project is collected from various sources.

Name of Student Enrollment No. Signature

01. RUTIK V. MULE 2011620436

2111620436
02. SAGAR H. BORUDE

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 ACKNOWLEDGEMENT
I have great pleasure to express my immense gratitude towards a dynamic
person and my project guide Prof. V.V. Gaddmwar Sir Department of mechanical
engineering, Government Polytechnic, Ambad for giving me an opportunity to
work on an interesting topic over one semester. The work presented here could
not have been accomplished without his most competent and inspiring guidance,
incessant encouragement, constructive criticism and constant motivation during
all phases of our group Micro- project work. I am greatly indebted to him.

I am very much thankful to DR. P. T. KALE, Head, Department of

Science & Humanities all HODs of various departments and DR. A. M.
AGARKAR, PRINCIPAL, Government Polytechnic, Ambad, for his
encouragement and providing me a motivating environment and project facilities
in the Institute to carry out experiments and complete this Micro- project work.

I would like to extend our thanks to all our professors, staff members and
all our friends who extended their co-operation to complete the project.

I am indeed indebted to my parents and other family members for their

immense help at all levels with moral, social & financial support, care and support
throughout my studies without which my work would not have seen light of the
day.

With warm regards,

Yours Sincerely,

Place: Ambad Rutik v. mule

Sagar borude

Date:

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 INDEX

Sr.No Name of points Page No.

1
01 Introduction

1
02 History

1-2
Definition
03

Functions of Poka-yoke 2-3

04

3-8
05 - Warning Poka-yoke

Types of Poka-yoke 8-12

06 devices

13
07 Conclusion

14
08 Reference

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 INTRODUCTION
1. Introduction
The world today is highly competitive and there is an expectation from any
Organisation or company to deliver reliable products that are characterized by
their high quality and zero defects at an acceptable for the customer price.
Different mechanisms and tools have been developed to achieve manufacturing
excellence and best possible operational performance, such as Six Sigma, JIDCO,
JIT, Poka-Yoke etc. This report will be focusing on the Poka-Yoke method as a
valuable strategy in improving the quality of an operations process.

2. History
Poka-Yoke is a concept that originated in the 1960s in Japan by Shigeo Shingo,
who was working at Toyota as an industrial engineer. The original terminology
Baka-Yoke, meaning ‘fool-proofing’, was deemed too disrespectful and
dishonourable and was altered eventually to Poka-Yoke, which translates to
‘mistake-proofing’. The basic idea behind the phrasing, was 11that it is not
sufficient and acceptable by any means the manufacturing of a product with even
the smallest traces of defect or nonconformity. Poka-yoke is utilized as a
prevention mechanism which has the focal point of identification and
elimination of anything that might cause a degree of variance in the
manufacturing process, as this could potentially lead to defects. The cost-
effective solutions provided by Poka-yoke are directed at the source of the
defects and are not only easy to comprehend but also quite simple to implement.
In turn, this leads the quality management system (QMS) of any company to
attain higher levels of performance. Therefore, Poka-yoke is considered to be a
good method and integral factor for the continuous improvement strategy in
many top Japanese as well as international companies. [1, 2]

3. Definition
A systematic literature review of the Poka-yoke method revealed that over 50
diverse definitions exist, as the majority of researchers approached the theoretical
aspect of Poka- yoke from different angles and had a slight contrasting
understanding of its general applications. There is no official acceptable uniform
definition of Poka-yoke, which makes studying or comparing results from articles
rather complicated. A list of some of the definitions used for Poka-yoke is
provided in Table 1.

Tab. 1: Various interpretations of Poka-yoke.

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Author Definition
Hinckley and Barkan Poka-yoke utilizes devices in order to
prevent errors during the manufacturing
process that could lead to defective products.
It then shuts down the process and after
identifying the root cause of the problem,
eliminates it.
Robinson Poka-yoke is a simple mechanism that applies
a warning or control device, which enables
the detection, prevention and correction of
defects at their source, so that clients get the
highest quality product possible.

Stewart and Melnyk Poka-yoke is an approach focusing on quality

improvement, a systemic technique or a
simple unique device that impedes a defect
from reappearing after it was eliminated. If
operators adhere to the correct steps and
proper procedures, then
the outcome will be a defect free product.
Pakdil et al. Poka-yoke is a straightforward and cost-
effective device operated during the
manufacturing process with the aim to
prevent defective products.
Vidor and Saurin Poka-yoke can be described as a device or
even a system that is able to detect as well as
prevent nonconformities and abnormalities
that negatively impact the quality of a
product.

4. Functions of Poka-yoke
Advanced manufacturing technologies can only lead to minimization of potential
errors, because human mistakes are still common in the production environment
and potentially have a positive impact on the cost expenses. The implementation
of Poka-yoke in completely eliminating any kind of mistakes is still not very
widespread and a lot of managers are not even familiar with this term. [3]

Poka-yoke can either detect defection after it has taken place or predict an error
that is about to transpire. This rather innovative technique commences with the
examination of possible problems, followed by identification of any parts in
regard to dimension, shape, size and weight and ends with the analysis of
potential deviation from the nominal processes. According to the functionality of
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 the procedure occurring, there are three various types of Poka-yoke: [1]

5. Control Poka-yoke
The Poka-yoke device as control method can be described as regulatory in
working and is integrated with the process equipment. This makes it impossible
to manufacture a product with nonconformity characteristics, as it will simply not
progress to the next stage of the production line. This type of Poke-yoke also
provides assurances that any product will be without any types of defects. [2]

6. Warning Poka-yoke
This Poka-yoke technique is alerting an operator at the production sector through
buzzer sounds or lamp flashes that there is a defect in the manufacturing
procedure. This requires urgent interference from a worker and a correction of
the process that is causing the errors, so that the next products in line will appear
defect free. This method does not provide certainty that the products will be of
the highest quality due to the reliance on the human factor. If the warning from
the Poke-yoke device is ignored or not noticed on time, then it is the irresponsible
conduct of the operator liable for the mistakes that occur in the production line.
[2]

Out of the three types of Poka-yoke mentioned above, the control one is the best
and most effective device in terms of the corrective approach towards a defect as
it leads to an immediate shutdown of the production line until all errors are
eliminated. Three different types of control Poka-yoke exist: [9]

- Contact method
The Poka-yoke device is able to identify specific abnormal characteristics
regarding the shape or dimension of a product. [9]

- Fixed-value method
This technique is used when there is a constant repeat of the same activity, giving
operators an opportunity to determine the performance of this activity and it
ascertains that a certain number of movements is generated. [9]

- Motion-step method
This method is utilized when various activities are taking place in sequence and
it regulates that the fixed motions of the production process are followed properly.
[9]

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 7. Types of Poka-yoke devices
Errors during the operation process, as can be seen in Figure 1, can occur at any
given time point. The process starts with activity 1 and ends with the finished
product at operation m. During this procedure, each activity is potentially
susceptible to product failure or causing defects to the finalized product. The first
error can happen at point A1, which is the beginning of operation and additional
mistakes could appear anywhere between the activities A1 and An. There is a
possibility of errors developing at the point areas A, B and C or even during
product handling within different work operations. It is also poignant to note that
each operational step must be carried out in accordance with the formalized
design solution. [3]

Fig. 1: Simplified work process containing various operations that need to be

realized in order to deliver the finished product. [3]

Different types of Poka-yoke devices can prevent errors from transpiring at

various stages of the operations process and deliver products without any kind of
defect and of high quality. There are six particular devices that need to be
mentioned: [3]

I. Passive device
The Passive device Poka-Yoke (PPY) utilizes visual effects such as light and
sounds that act as a warning about high probability of an error during the operation
procedure. It does not prevent mistakes from occurring, but simply indicates
which operational stages are dysfunctional and should be bypassed. [3]

II. Active preventive

The Active Preventive Poka-Yoke (APPY) addresses the issue of errors
prevention, by being active from the start of the operation process until the end,
when a defect free product is materialized. [3]

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III. Active, for detection
The Active Detection Poka-Yoke (ADPY) is an electro-mechanical device that
aims to identify abnormalities on products and requires corrective adjustments
for those that do not abide by high quality standards. This of course impairs the
operations process and is reflected in requiring more materials, additional time
and labor. [3]

IV. Hybrid active, preventive

The Hybrid Active Preventive Poka-Yoke (HAPPY) is a combination of I and II
and can be considered the best and optimal variation of the Poka-yoke system
regarding investigating errors. The cost of implementing this rather complicated
device is higher in comparison to the above-mentioned devices but is
complemented by successfully preventing defects and improving worker
efficiency with the help of audio-visual signals. [3]

V. Hybrid active, detection

The Hybrid Active Detection Poka-Yoke (HADPY) is a combination of I and III
and is regarded as a desirable device for the operation procedure. It merges audio-
visual signals with an active preventive mechanical mechanism that leads to better
efficiency in all stages of the work process and guarantees zero errors. The
training of operators on this device is simple and does not require high expenses.
[3]

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 8. Methodology of Poka-yoke
The theoretical analysis of the Poka-yoke method can be summarized in six steps:
[1]

I. Identification of the problem

All the complaints from clients internally and externally are compiled and
classified in terms of the number of complaints filed, the quantity of the defects,
defects in materials and any other data associated with mistakes during
production. These results will be key in the development and eventually
implementation of a Poka-yoke method for the specific problem a company is
facing. [1]

II. Observation at workstation

A detailed analytical study will be completed on-site and the reasons for causing
the problem in the manufacturing process will be investigated with the aid of a
fishbone diagram. The causes could be related to the machine, the production
method, employees or even the material used. This will provide a better
understanding of the defects, variations from the normal procedure and any
possible imperfections. [1]

III. Brainstorming for idea

The third stage of the methodology includes a brainstorming session, where all
employees provide a solution to the current problem being studied based on their
unique skillset and creativity. [1]

IV. Select best idea

The best idea is chosen from the brainstorming discussion depending on certain
criteria’s such as associated cost, implementation time of the solution, number of
required changes in the system, complexity etc. [1]

V. Implementation plan
A plan is development concerning implementing and installing the selected
solution. This step also encompasses the necessary material requirements as well
as the processing of the material and the manufacturing procedure. [1]

VI. Monitoring and sign off

The final phase incorporates the inspection of products from any defects and the
performance of the specific Poka-yoke system is under review. [1]

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9. Conclusion
The purpose of implementing Poka-yoke is to minimize or at best eliminate
human errors during the manufacturing procedure, so that a defect product of low
quality does not reach customers hands. The main idea behind this system is to
be able to prevent any causes that might lead to mistakes in the operation process
by constant monitoring all production stages. This requires synergy with workers,
that can apply corrective measures when Poka-yoke identifies the possibility of
defects. [10]

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 10. References

GOOGLE
[1] R. Kumar et al, Poka-Yoke technique, methodology & design, Indian Journal of
Engineering, Vol. 13, Issue 33, 2016.
[2]. S. Anderson, “Poka-Yoke: Mistake-Proofing as a Preventive Action”, The
Informed Outlook Reprint, Vol. 7, No. 3, 2002.
M. Lazarevic et al, A systematic literature review of Poka-yoke and novel approach to
theoretical aspects, Journal of Mechanical Engineering, 2019.
[3] Hinckley et al., Selecting the best defect reduction methodology, Quality and Reliability
Engineering International, Vol. 12, No. 6, p. 411–420, 1996.
[4] Robinson H., Using Poka-Yoke techniques for early defect detection, In Sixth International
Conference on Software Testing Analysis and Review (STAR 1997), p. 1-12, 1997.

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