Research Of Quality Management Poka-Yoke Method And Poka-Yoka Device

Under the furious automobile market competition, the profit space of component manufacturing company becomes smaller and smaller. In order to keep the continuous increase of their profits and meet customer satisfactionin condition of operation costing increasing, manufacturers start to pay more and more attention on enhancing the manufacturing quality of products, and reduce the errors when manufacturing. Poka-Yoke method is just asuitablemethod for preventing manufacturing errors and enhancing the first passing rate. Besides, as vehicle model is diversified, manufacturers need to adapt to the conditionof different kinds of products, shorter lifecycle, less manufacturing cost and higher quality requirements. As the design is the source of product quality, inappropriate design may bring error chance to manufacturing process.In order to make better use of error proofing, in this paper, thePoka-Yokemethod is studied including the type of error proofing devices and the design principle. It summarizes the effect and the application range of Poka-Yoke method, illustrates the implementation steps and the matters that need attention in the process of implementation.Through the enterprise quality management FMEA analysis, the sequence number RPN of the risk about various quality management activities error can be determined. And then study quality management mistakesaccording to the risk ranking from the previous, make effective improvement measures.Combined with E-glass assembly process (including mixed assembly) BBAC F18 program, three Poka-Yoke methods were designed including E-glass detection (SICK30 wheelbase screen), tube detection (OMRON laser ranging) and shell detection (IFM M12 proximity switch).When using the mistake proofing devices every step can be confirmed by the equipment, it can effectively prevents the scrap caused by the workers, and greatly improves the assembly efficiency.