In Jan 2018 BCW Manufacturing Group welcome the implementation of two Poka- yoke assembly benches into the cross member cell. These benches have been developed by BCW to provide an error proofed manufacturing process for all products built on the cell. Poka-yoke has ensured they match customer expectations and allows delivery of the same quality to all customers consistently.
For one particular customer BCW can only send a maximum of 4 defective components every three months, albeit paperwork or machining, out of a quantity of 70,000. Poka-yoke is a Japanese term that means “mistake-proofing”. A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. BCW invested within the Poka-yoke to ensure we are protected from errors moving forward with several million pounds riding on quality and delivery perfection.
In July Blessed Trinity RC College, Year 10 Business Studies students, were invited to BCW Manufacturing Group to put their learning into practice and witness firsthand how BCW operates which included a tour around the business and the different divisions. The students visited both BCW Precision and BCW Treatments however BCW Engineering set them a task to name the Poke Yoke Benches. They were requested to come up with a concept and explain why they had selected to name the benches their chosen names.
All entries were submitted and a decision was made and Steve and Bettie were the chosen ones!
BCW wishes to congratulate the winners and thank them for their innovative ideas, they were pleased with all entries and were impressed with the detail. Gordon Cassie, HR Director said, “We thought the idea of using acronyms was very clever and in this respect all that adopted this approach showed that they had listened to the information given on the day. The names were well thought out and truly represented the Poke Yokes. ”
Aisling Wood-Miller, Business Class Teacher said, “I agree with Gordon, the students had some brilliant named suggestions and it is great news for the winners. These students will be delighted. We enjoyed our visit and would like to say thank you to all of the fabulous team at BCW. Our students gained a lot from your tour and it was relevant to them. I appreciate all the time that you all put in for my students and it was really well organised.”
Winners features below:
Congratulations to Conor Pomeroy & Reuben Sutton with their winning name S.T.E.V.E
Congratulations to Olivia Payne with her winning name B.E.T.T.I.E
S – Smart T – Technology E – Error Proof Manufacturing V – Visual Display E – Equipment
B – Barcode Scanning E – Electronic T – Technology T – Training I – Intelligent E – Equipment
Since the implementation of the benches our production rate has improved and they have consistently achieved fantastic results with the reduction of non-conformities. The bespoke design and creation was carried out by BCW including build and installation.
Poka Yoke’s Capabilities:
- Provides a visual step by step guide to the assembly process, which therefore reduces the requirement for operator training on the system.
- The visual display is also a touch screen to allow operator navigation throughout the process. i.e: inputting passwords specific to each operator via onscreen keypads.
- As each operator logs into the system with a unique ID we can monitor information like exact parts per hour count, or log part failures and non-conformities that occur during specific operator operation.
- The system has a quick-change mechanism for part fixturing to facilitate the smooth changeover from one part to another. There are currently 12 variations which can be assembled on one system.
- It uses a Smart Camera to inspect various features of the part ensuring they are assembled correctly by the operator.
- The camera also self identifies the part before the process starts ensuring the assembly procedure is correct for the part displayed.
- Further part identification is done using a barcode scanner to read information from batch cards specific to the part being made.
- Bolts are assembled using a digital torque wrench so as to always insert the bolt to a specific preset torque. Process control measures the bolting application to assess this on every bolt insertion.
- Upon the completed assembly of a part the adjacent label is automatically printed and indication is given on the screen on where the label needs to be put. The system also checks upon application of the label that it is in the correct place.
- The barcode reader is then used to read the label and ensure it is printed correctly.
- Throughout this procedure the component is locked into the system and cannot be removed until completion of assembly.
- If the component fails any feature through the process then it is locked into the system and a supervisor’s password is required to release the part. It can then be dealt with accordingly relative to its failure.
- Bung insertion,
- The bolting on of a secondary part,
- The application of the correct label.