[Jadhav, 4(1): January,2014] ISSN: 2277-9655 Scientific Journal Impact Factor: 3.449 (ISRA), Impact Factor: 2.114 http: // www.ijesrt.com© International Journal of Engineering Sciences & Research Technology [123] IJESRT INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY POKA -YOKE SYSTEM FOR OUTPUT SHAFT ASSEMBLY OF TWO WHEELER Hemant L. Jadhav * , Kirankumar R. Urgunde, Amol J. Pawar Department of Electronics & Telecommunication, ICEEM, Aurangabad, Maharashtra, India Abstract It is not possible to eliminate all the mistakes people make. People are not mistake proofed by their nature. But organization can avoid these mistakes from reaching the customer, which is known as a defect in this case. Mistakes can be stopped as soon as they happen at least. Poka-yoke is very simple concept in nature. The basic concept of this is avoiding the problems by correcting the process. Poka-yoke is a quality assurance technique developed by Japanese manufacturing engineer Shigeo Shingo. The aim of Poka-yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. So what is mistake proofing? The use of process or design features to prevent errors or their negative impact. Also known as Poka yoke, Japanese slang for “avoiding inadvertent errors” which was formalized by Shigeo Shingo. A method that uses sensor or other devices for catching errors that may pass by operators or assemblers. Shigeo Shingo defines Poka Yoke as: Poka – “Inadvertent Mistake That Anyone Can Make” [2] and Yoke – “To Prevent or Proof” [1]. Poka -Yoke performs two key operations of ZDQ (Zero Defect Quality) i.e. identifying the defect immediately ( Point of Origin Inspection) & quick feedback for corrective action. Poka-yoke detects an error, gives a warning, and can shuts down the process. KEYWORDS: Poka –Yoke, Output shaft assembly, PLC, ZQC. INTRODUCTION It is very important to avoid a mistake becoming a defect. But meanwhile it is very important to find out why there are mistakes in the system. According to my knowledge some systems lead people to do mistakes. So many data passing processes, so many contact points, unnecessary documentations and processes makes the systems complicated. Complicated systems can make mistakes easily. Poka-yoke is a quality assurance technique developed by Shigeo Shingo. The aim of Poka-yoke is to eliminate defects in a product by preventing or correcting mistakes in the early phase. Poka-yoke has been used most frequently in manufacturing environments. Japanese industrial engineer Shigeo Shingo developed Poka - yoke [1] (to avoid (yokeru) [2] inadvertent errors (poka) along with "source inspection" as a means for achieving Zero Quality Control (ZQC). Shingo introduced these ideas in his book Zero Quality Control: Source Inspection and the Poka-yoke System. People are human and cannot be expected to do everything like a machine, exactly the same each time. A simple distraction can lead to a part of their work being done wrong. It is also not necessarily their fault, as poorly-designed processes that require a great deal of attention can contribute severely to problems. The basic principles of Poka-yoke advocate designing or developing tools, techniques and processes such that it is impossible or very difficult for people to make mistakes. It is a simple principle that can lead to massive savings. One simple example of Poka-yoke is having an automatic stoppage of machinery when oil levels go down. So people will not operate machinery with lower oil levels. This will make sure your system is operating smoothly. Another very good example for this kind of mistake proofing process can be found in computers. Every plug has a socket exactly matched with it. No other device can be plugged into this. So even if you want to do a mistake you can’t. LITERATURE SURVEY 2.1 Historical Background of ‘Poka-yoke’: ‘Poka-Yoke’ techniques are now widely prevalent amongst manufacturers all over the world and across industry verticals. While majority of ‘Poka-Yoke’ systems are based on basic mechanical jigs and fixtures, there is increasing popularity for more versatile and instantly reconfigurable machine vision based ‘Poka-Yoke’ systems which are:  Mistake-proofing systems  Does not rely on operators catching mistakes  Inexpensive