Implementation of Poka-Yoke Using Electronic Sensors

Siddharth Sharma
Department of Instrumentation and Control Engineering
Netaji Subhas Institute of Technology, Delhi University
siddharthsharma@nsitonline.in

Abstract: Poka-Yoke is a quality assurance technique developed by Toyota. Poka-Yoke has been very frequently used in
the manufacturing sector with the aim of removing defects in a product by preventing or correcting mistakes as early as
possible in the manufacturing/assembly line.
Electronic sensors can be used for Poka-Yoke in various manufacturing processes. This paper discusses how Poka-Yoke,
in general, is used for minimising defects during production and how various electronic sensors can be used for quality
control in the assembly line through poka-yoke techniques. Hence, a few Poka-Yoke techniques used in Bosch Chassis
Systems, Gurgaon, Haryana plant and a case study of Poka-Yoke implementation in the same have been discussed.

1. Introduction
Poka-Yoke (pronounced "POH-kah YOH-kay")
was invented by Shigeo Shingo in the 1960s.
Poka-yoke is Japanese for mistake-proofing.
Before Poka-yoke statistical sampling was largely
used for quality control in manufacturing. But
statistical sampling requires some products to go
untested to the customer, which would always
make some defects or mistakes to creep in.
Shingo writes about the importance of early error
detection, The causes of defects lie in worker
errors, and defects are the results of neglecting
those errors. It follows that mistakes will not turn
into defects if worker errors are discovered and
eliminated beforehand1. He continues that "Defects
arise because errors are made; the two have a
cause-and-effect relationship. ... Yet errors will not
turn into defects if feedback and action take place
at the error stage"2.
Shingo also cited an example that helps
understand how essential poka-yoke can be applied
in the early detection of defects. Suppose a worker
has to assemble a device that requires a spring to be
placed under the push buttons. Now if the worker
forgets to place a spring under any of the push
buttons the final assembled device would be
defective and if the defective product reaches the
customer, the defect would be found out only then
and replacing it would become a costly affair. All
this can be avoided by implementing a very simple
poka-yoke device. The assembly worker takes out
springs from the bin and places them on a small
dish. At the end of the assembly process of the
device if the dish has a spring in it, the worker
would know the device is defective and can rework
to remove these defects, with minimal additional
cost. An empty dish would be an indicator of a nodefect device.
To understand poka-yoke we need a new
attitude towards preventing errors. Instead of
1
2

Shingo 1986, p.50

Shingo, 1986, p. 82

teaching the workers to be more careful to

prevent mistakes, the following should be kept in
mind:
Make wrong actions more difficult.
Make it possible to reverse actions to
undo themor make it harder to do what
cannot be reversed.
Make it easier to discover the errors that
occur.
Make incorrect actions correct.3
Some everyday examples of Poka-Yoke devices
are:
A 3.5 Floppy Diskette cannot be inserted
unless inserted in the correct orientation.
The bevelled corner of the diskette pushes
a stop in the disk drive out of the way
allowing the diskette to be inserted. This
feature, along with the fact that the diskette
is not square, prohibits incorrect
orientation.
Circuit
breakers
prevent
electrical
overloads and the fires that result. When
the load becomes too great, the circuit is
broken.
Bathroom sinks also have a poka-yoke
device. The hole on the top of the sink
prevents the sink to overflow.
Light sensors are used in urinals that ensure
that the urinals are flushed.
2.

Types of Sensors Employed for Poka Yoke

Sensors represent a part of the interface
between the physical world and the world of
electrical devices, such as computers. The other
part of this interface is represented by actuators,
which convert electrical signals into physical
phenomena.
3

: The Design of Everyday Things, by D.A. Norman, 1988,

Doubleday

Sensors are used to detect defects as early as

possible in the manufacturing/assembling process.
Proximity sensors are used to check the presence or
absence of necessary components or to check the
proper orientation of components to be assembled
in the assembly line. Pressure sensors are used to
check the fluid pressure to be in the required range
and LVDTs are used to detect displacement
defects. Many other sensors like reed switches,
optical sensors are employed according to the
sensing needs in Poka-Yoke implementation.

Figure 2: NPN and PNP Sensor Output for 24VDC Input

Sensors are also available in Normally

Open(N.O.) and Normally Closed(N.C.) types.

Figure 1 (a) and (b): The above figures show how optical
sensors can be used for mistake-proofing. The optical sensor
turns on (1(b)) only when it detects the hand of the worker in the
washer bin, thus removing the possibility of the worker
forgetting to pick up a washer because the machine would not
actuate until the optical sensor is switched on by the workers
hand. This is an example of how sensors can effectively avoid
human error.

Sensors are broadly classified into two types

depending on whether they require external energy
input for functioning or not Active and Passive.
Passive sensors are those for whose functioning we
need to provide an external current or voltage
input. The passive sensors used in the assembly
plant were Proximity sensors, pressure switches,
photo-electric sensors, limit switches, Linear
Variable Differential Transformers (LVDT), etc.

Since the sensors give standard output values

(5VDC, 12VDC, etc), this amount of voltage is not
enough is not enough to activate a circuit that
functions on 250VDC, say. To solve this voltage
problem control relays are used to switch on an
external circuit of any voltage rating using the
24VDC/0VDC or any other standard values that are
obtained from the sensor.
A control relay is an electro-mechanical device
which activates one or more switches according to
the current flowing through a coil not connected to
the switches. A relay basically consists of an
electromagnet with two possible states such that
when sufficient current flows through the coil, the
core of the coil attracts a ferromagnetic armature
which mechanically operates switches. A spring is
designed to snap the contacts between the two
states and so that there should not be a certain value
of current at which the contacts remain in an
intermediate state.

We keep our focus towards 3-wire sensors,

although other types of sensors are available too. In
three-wire proximity sensors there are two further
classifications based on the type of output the
sensors give: NPN proximity sensor and PNP
proximity sensor.
NPN sensor consists of a NPN output transistor
and is used where the load is connected to the
positive terminal of the power source. A PNP
sensor consists of PNP output transistor and is used
where the load is connected to the negative
terminal of the power source. A PNP sensor is
called a source sensor and a NPN sensor is called a
current sinking sensor. The sensors used in the
manufacturing sector for Poka-Yoke work on
standard values of input like 5VDC, 12VDC or
24V DC. The PNP sensors gave an output of 24V
through the black wire and the NPN sensors gave a
zero volt output. The brown and blue wires are
positive and negative respectively. Three-wire
sensors consist of black, brown and blue wires
where black is the output wire, brown and blue are
positive and negative respectively. The PNP
sensors give a positive output (standard values
5VDC, 12VDC, 24VDC, etc) whereas the NPN
sensors give a negative output (zero VDC).

Figure 3: Basic Circuit Diagram for a Control Relay

Correct selection of relays should be made

before using them in a particular operation.
Considerations like speed of operation, sensitivity
and hysteresis should be kept in mind. Typical
contact relays operate in the 5ms to 20ms range,
but relays with speed of operation as fast as 100us
(micro-seconds) are also available. Reed relays
which are actuated by low currents and switch fast
are suitable for controlling small currents.
2.1 Pressure Sensors/Switches
A pressure switch is a form of switch that
makes electrical contact when a certain
set pressure has been reached on its input. This is
used to provide on/off switching from
a pneumatic or hydraulic source. The switch may

be designed to make contact either on pressure rise

or on pressure fall.
The pressure sensor consists of a resistive
sensor circuit which obeys Ohms Law and
Kirchhoffs Rules for circuit analysis. The pressure
switch also employs Wheatstone bridge in its
functioning. A Wheatstone bridge is used as an
improvement to the simple voltage divider. It
consists of a simple voltage divider, combined with
a second voltage divider called reference divider. It
consists of fixed resistances and is used so as to
make a reference voltage that is same as the voltage
of the sense voltage divider at some nominal value
of sense resistance. The output of the sense divider
and the reference divider are the same when the
sense resistance is at its starting value. The resistors
used in the pressure sensors circuit are
piezoresistors i.e. the value of their resistance
changes with the application of pressure. Changes
in the sense resistance lead to creation of a
differential voltage. A differential amplifier is used
to produce the difference between the two voltages
and amplify the result.4

1. Non-contact detection, eliminating damage

to sensor head and target.
2. Long service life due to non-contact output.
3. Stable
detection
even
in
harsh
environments exposed to water or oil
splash.
4. High response speed.
Proximity sensors are basically of four types:

Inductive
Capacitive
Magnetic
Photoelectric
Table I5
Targets and Range of Various Sensors

SENSOR
Limit Switch

TARGET
Any

Reed Switch

Magnetic
Materials
Opaque
Materials

Digital pressure switches are also widely

applied for pressure sensing operations. These are
micro-processor based and consist of various
modes like hysteresis mode and window
comparator mode, they also have the provisions to
store the pressure data and copy the desired
pressure settings into other pressure switches.
These have very easy operation and can be
operated even by semi-skilled labour.

Photo-electric

2.2 Proximity Sensors

These are the type of sensors that detect objects
without physical contact with the objects that are
lying in proximity to the sensors. The working
principle of these involves a high frequency
oscillator that creates field in close surroundings of
the sensing surface. The presence of object changes
the output state of the sensor and thus the object is
sensed according to the change in the output state.
The operating distance of the sensors depends on
the actuators shape and size and strictly linked to
the nature of material of the object. These have
great use in applications where small defects (in
order of a few millimetres) have to be measured.

Ultrasonic

Figure 5: Proximity Sensor Configuration

Features of proximity sensors are:

4

Wilson, Jon S. (2005). Sensor Technology Handbook. pp 6-7

Inductive

Conducting
Materials

Capacitive

Most
solids
and liquids
Non-porous
large objects

RANGE
0 (Contact
Required)
20 mm
0.1m 50 m
Also Depends
on Shape of
target
Ferrous: 50mm
Non Ferrous:
less than
50mm
30mm
30mm 10m

2.2.1
Inductive Proximity Sensors
Inductive proximity sensors consist of a coil
and an oscillator that creates an electromagnetic
field in close surroundings of the sensing surface.
The presence of metallic object (actuator) in the
operating area causes a dampening of the
oscillation amplitude. The rise or fall of such
oscillation is identified by a threshold circuit that
changes the output of the sensor. These are based
on the principles of eddy currents and are used for
metallic objects or other conducting objects in
which eddy currents can be induced. These sensors
make use of inductance measurement circuits6 to
measure the changes in inductance in the operating
area.
2.2.2
Capacitive Proximity Sensors
Capacitive proximity sensors used for detection
of non-metallic objects (liquid, plastic, wooden
materials and so on). Capacitive proximity sensors
use the variation of capacitance between the sensor
and the object being detected. The main difference
5

Industrial Automation by D.W. Pessen, Wiley Interscience

between inductive and capacitive proximity sensors

is that capacitive type proximity sensors create an
electrostatic field near the sensing surface, not
electromagnetic field as in case of induction type
sensors. Capacitance measuring circuits 6 are
employed for measuring changes in capacitance in
the operating area.
The sensing surface of a capacitive sensor is
formed by two concentrically shaped metal
electrodes of an unwound capacitor. When an
object nears the sensing surface it enters the
electrostatic field of the electrodes and changes the
capacitance in an oscillator circuit. As a result, the
oscillator begins oscillating. The trigger circuit
reads the oscillators amplitude and when it reaches
a specific level the output state of the sensor
changes. As the target moves away from the sensor
the oscillators amplitude decreases, switching the
sensor output back to its original state.
2.3 Magnetic Proximity Sensor
Magnetic (Reed Switch) proximity sensor is
actuated by permanent magnets. Operating
principle is based on the use of reed contacts whose
thin plates are hermetically sealed in a glass bulb
with inert gas. The presence of magnetic field
makes the thin plates flex and touch each other
causing an electrical contact. The plate surface has
been treated with special material particularly
suitable for low current or high inductive currents.

The above pictures show the riveting machine.

The circuit shown in the diagram below is used to
check any defect in the hook bend of the handbrake
lever and prevent riveting of a defective part, thus
preventing a defective part reaching the
customer.The reed switch is attached to a
pneumatic cylinder. The reed switch turns on only
when the width gauge that is mechanically coupled
with the pneumatic cylinder completely enters the
hook, thus detecting the presence of correct hook
bend of the lever. If incorrect bend is there then the
width gauge would be obstructed by the wrong size
of the hook and cylinder would not switch on the
reed switch. Further, on- delay and off-delay
timers are used to control the operation of the
machine automatically and this prevents any error
or mistake that could have been made by the
machines operator.
Timers that are used are :
ON-DELAY TIMER- This type of timer delays
the switching on of the circuit when the coil is
energized. When the coil is de-energized the circuit
switches off immediately without any delay.
OFF-DELAY TIMER: This is the type of timer
in which the circuit switches on immediately when
the coil is energized, but when the coil is deenergized, it delays the switching off of the circuit
according to the time set by the operator.

2.4 Photoelectric Sensors

Photoelectric sensors based on the principle of
reflection of optical beams. These consist of an
emitter and a receiver for sensing purposes. The
emitter emits the optical beam, and the change in
density received at the receiver, due to the
obstruction in the beams path by the object, is used
to detect the distance or other characteristics of the
object.
3. Case Study
The following example shows how a panel for
Poka yoke using electronic sensors was designed
and implemented on a riveting machine in the drum
brake house of Bosch Chassis Systems, Gurgaon
Plant.

Figure 6: The Riveting Machine at Bosch Chassis Systems,

Manesar Plant. Reed switches check the correct bend in the
handbrake lever.
6

Wilson, Jon S. (2005). Sensor Technology Handbook. p 8.

Figure 6: The above panel was setup on the riveting

machine in the drum brake house. Reed switch (magnetic
sensor) and timers were employed for Poka-Yoke.

When the reed switch senses the presence of the

correct model of component on the riveting
machine, TR1 is turned on, which delays the
switching on of the main punch cylinder (riveting)
by 10 seconds and stays turned on for 20 seconds.
TR2, which is an off delay timer also gets activated
simultaneously with TR1. TR2 delays the turning
off of the lever profile checking cylinder circuit by
30 seconds.So , when TR1 is turned on, the main
punch cylinder gets actuated after a 10 second
delay and turns off after another 10 seconds. After
ten more seconds (total of 30 seconds), TR2
switches the lever profile checking cylinder circuit
off and the operation of the riveting machine gets
completed successfully and both cylinders return to
their normal position.

Figure 7: Left: The hook on the handbrake lever is sensed

by the reed switch
Right: The lever profile checking cylinder in the riveting
machine.

This way poka-yoke can be implemented to

reduce the scope for human mistakes by making
use of sensors. When this poka-yoke was not
present on this machine, a defect of hook bend was
reported by Maruti Suzuki India Ltd., Gurgaon
which is a cutsomer of Bosch Chassis Systems on
25 May, 2011 when they received a defective part.
Implementation of this poka-yoke prevents this
situation from occuring when a defect in a
particular part is reported by the customer itself in
which case the customer demands the supplier to
test all other parts for defects. This requires a lot of
effort and often adversely disturbs the production
of the manufacturing plant. So, by employing a
simple technique during assembly a lot of effort,
money and time is saved.
Another addition that was made to the riveting
machine was that a proximity switch was provided
in the circuit, before the start push-button. The
proximity switch was so installed that it only
switched on when there was a component kept on
the machine. This ensured that the machine did not
run if the worker forgot to keep the component on
the machine. This also made the machines
functioning safer for the operator.
4. Conclusion
Thus Electronic Sensors can be used for
effective mistake proofing in manufacturing
plants and can drastically reduce the rejection rate
of production thereby reducing the cost of
production and enhancing customer satisfaction
and confidence.

5. Acknowledgment
The author would like to thank Mr. Brijesh
Singh, Maintenance Department, Bosch Chassis
Systems, Gurgaon Plant. He continually maintained
a level of excitement in his teachings and all
involvements
in
this
project.
Further
acknowledgment to Mr. Rajat Tandon, Plant
Manager, Bosch Chassis Systems, Gurgaon Plant
for taking keen interest in the project and providing
vital laboratory and infrastructure facilities that
have given this paper a certain level of practical
outlook.
6.

References

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