International Journal of Engineering Science Invention

ISSN (Online): 2319 – 6734, ISSN (Print): 2319 – 6726

www.ijesi.org ||Volume 6 Issue 11|| November 2017 || PP. 01-10

Implementation of Poka Yoke in Needle Bearing Assembly

Process
Bhawesh Kumar1, Rakesh2, Prakash Kumar3
1
M.Tech Scholar, Production Engineering, B.I.T. Sindri, Dhanbad, Jharkhand
2,3
Assistant Professor, Production Engineering, B.I.T. Sindri, Dhanbad, Jharkhand

Abstract: Dismissal of made parts at different phases of assembling can't go on without serious consequences
now days underway situation because of extreme rivalry around the world. This paper concentrates on a quality
change extend at SNL Bearings Ltd utilizing botch sealing strategy or Poka-yoke. All assembling businesses are
moving toward zero deformity generation. To actualize this the first and most critical thing which is being
finished by the assembling businesses is to avoid blunder or totally dispose of the mistake with the utilization of
some demonstrated strategies and this paper concentrates on a use of this methods on a needle bearing
assembling organization. Utilization of Poka yoke in assembling forms predominantly to wipe out manual
blunder by outlining appropriate means which diminishes the dismissals. The review is gone for giving changes
thoughts to existing issues at the manual gathering station for the needle roller orientation. Examinations were
directed to recognize reasons for imperfections. Utilizing consequences of unstructured meetings and important
information and from manufacturing plant perception the issue was examined utilizing circumstances and end
results graph where the primary driver were recognized. Subsequently of the Poka yoke on the needle roller
bearing, probability of deformity is disposed of totally.
Keywords: Lean Manufacturing, Mistake Proofing, Needle Bearing, Poka Yoke
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Date of Submission: 09-10-2017 Date of acceptance: 07-11-2017
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I. Introduction
In today's focused world any association needs to make brilliant, imperfection free items at ideal cost.
The new culture of aggregate quality administration, add up to beneficial administration in the assembling and
administration division brought forth better approaches to enhance nature of items. By utilizing different
apparatuses of TQM like KAIZEN, 6 sigma, JIT, JIDCO, POKA YOKE, FMS and so forth association is
planned to create quality culture. The paper is expected to center fundamental idea of poka yoke, sorts of poka
yoke framework, approaches to accomplish straightforward poka yoke instrument. It likewise covers viable
review work done by different analysts. Amid genuine assembling of any item there are an excessive number of
basic and dull strides which are done by administrators. These tedious work operations result into mental
weakness and absence of enthusiasm for work which eventually causes senseless missteps of administrators and
we realize that human is inclined to mistakes despite the fact that he doesn't need it. To stay away from these
straightforward oversights, poka yoke idea assumes vital part. By actualizing some basic arrangements we can
keep away from oversights. The long haul accomplishment of poka yoke gives yield of sparing time and we
discharge the work weight on psyche of laborer. We can utilize imagination and unique aptitudes of laborers for
more innovative operations as opposed to expanding weight for dreary exercises.
The fundamental goal of the venture is to create the deformity free item, i.e. enhancing item and process nature
of needle bearing item by executing preventive instrument – Poka Yoke.

What is poka yoke?

Poka - Yoke is a gadget that is utilized to either identify or keep deserts from happening. The point of
Poka-Yoke is to dispose of imperfections in an item by forestalling or revising mistakes as right on time as
would be prudent. The basic thought of Poka-Yoke is to plan your procedure with the goal that slip-ups are
inconceivable or possibly effectively distinguished and amended. It is in this manner a powerful way to deal
with applying systems to anticipate mistakes arrangement exactly right now they happen. Thought of "grounds
order deserts" known as the strategy or procedure Poka-Yoke is quite recently such system. Poka-Yoke
technique was presented by Shigeo Shingo in 1961, when this was one of architects Toyota Motor Corporation.
This technique, as it were, is to forestall imperfections and blunders beginning in the slip-up. Poka-Yoke method
can be connected both to avoid causes, which will bring about resulting events of mistakes and to complete
cheap control deciding if to embrace or reject the item. A methodic approach to manage creates Poka-Yoke a

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

countermeasure has been proposed by the APS system which includes in a three phases examination of the risks
to be directed:
1. Distinguishing proof of the need
2. Distinguishing proof of conceivable slip-ups
3. Administration of slip-ups before fulfilling the need

These means are mulled over while considering execution of Poka Yoke framework in any field since
this strategy stays same at all the circumstances and conditions.

Fig: 1- Simple Example of Poka Yoke

Above figure demonstrates the idea of the Poka Yoke framework. In upper graph, size of both holes are
same, hence there might be misstep of putting positive terminal into negative hole yet then again, in lower
figure, the sizes of both the holes are distinctive which brings about keeping away from the scattering of the
terminal into wrong hole.

II. Technical Aspect Of Poka-Yoke Method

Poka-Yoke system can be connected both to avert causes, which will bring about ensuing events of
blunders and to complete modest control deciding if to embrace or reject the item. It is not generally 100%
likelihood end of all mistakes, in such cases it is the undertaking of Poka-Yoke techniques is discovery at the
earliest opportunity. Examine the procedure of item imperfections arrangement noticed that between an
oversights coming about because of the deformity is yet one, the potential plausibility: The perception error and
its right. It is along these lines the proposition - technique for diminishing inadequate is arranging conditions in
which mistake may not occur, or will be instantly obvious and caught. Consider the above Shigeo Shingo built
up an accomplishing "zero deformities" in modern conditions, i.e. in such a route as straightforward and modest.
Was itself at the matter, that it is impractical to lessen the deformities utilizing irregular checks. It is important
to the aggregate control - 100% control. Shigeo Shingo received after presumptions:
• For the situation of disarray applying the factual procedure control is inadequate,
• Monitoring and control the poka-yoke ought to be:
• Autonomous, i.e. operations did by the contractual worker without intercession all things considered,
• 100% - the aggregate
• Cheap.

When to use it?

Poka-yoke can be utilized wherever something can turn out badly or a blunder can be made. It is a
strategy, an instrument that can be connected to a procedure be it in assembling or the administration business.
Mistakes are of many sorts;
1. Processing blunder: Process operation missed or not performed per the standard working strategy.
2. Setup blunders: Using the wrong tooling or setting machine modification inaccurately.
3. Missing part: Not all parts incorporated into the get together, welding, or different procedures.
4. Improper section/thing: Wrong part utilized as a part of the procedure.

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

5. Operations blunder: Carrying out an operation inaccurately; having the off base adaptation of the
determination.
6. Measurement blunder: Errors in machine alteration, test estimation or measurements of a section rolling in
from a provider.

How to use it?

Well ordered process in applying poka-yoke:
1. Identify the operation or process - in light of a Pareto.
2. Analyze the 5-whys and comprehend the ways a procedure can come up short.
3. Decide the privilege poka-yoke approach, for example, utilizing a close out sort (keeping a mistake being
made), or a consideration sort (highlighting that a blunder has been made) poka-yoke adopt a more
exhaustive strategy rather than only considering Poka-yoke as point of confinement switches, or
programmed shutoffs a poka-yoke can be electrical, mechanical, procedural, visual, human or whatever
other shape that forestalls wrong execution of a procedure step
4. Determine whether a contact - utilization of shape, size or other physical characteristics for recognition,
steady number – mistake activated if a specific number of activities are not made arrangement strategy -
utilization of an agenda to guarantee finishing all procedure steps is suitable
5. Trial the technique and check whether it works
6. Train the administrator, audit execution and measure achievement.

Fig: 2- Mechanism of Poka Yoke

Problem
The issue requires to be gone to with high need and it is imperative to lessen dismissal since it
influences organization's notoriety and cost too. The human mistake end is required such that it wipes out the
blunder. For that reason, Poka Yoke procedures is recognized and it will be actualized in assembling process,
i.e. change in assembling process so the said issue can be disposed of.

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

Fig: 3 Cage, Needle and bearing

Table 1: Analysis of Causes of Defective Bearings:

S.No. Nature of Defects in Bearing Percentage Contribution Major Minor
1 Needle Missing 30 ✓ 
2 Shell crack 9 ✓ 
3 Slot variation 12 ✓ 
4 Line thickness variation 5 ✓ 
5 Needle rusty 11 ✓ 
6 Defective cage 8 ✓ 
7 OD over size 4  ✓
8 OD under size 3  ✓
9 Shell Pitted 3.25  ✓
10 Mix bearing 1.5  ✓
11 Loose fit 0.5  ✓
12 Tight fit 1  ✓
13 Corrosion 3.25  ✓
14 Axial crack 0.75  ✓
15 Normal fatigue 1.25  ✓
16 Insufficient heat temperature 0.5  ✓
17 Defective shell bearing 2.5  ✓
18 Miss alignment 1.5  ✓
19 Shell OD rusty 2  ✓

The issue for this situation was needle missing, shell crack, slot variation, Line thickness variation,
needle rusty, defective cage is major defects in needle bearing. These were results in wastage of time and
material which in a roundabout way influence profitability of the plant and organization. This was the major
issue.

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

Cause & Effect Diagram for Needle Missing

Cause-and-Effect Diagram

Environment Material Man

Unskilled
Rainy season Variation in
width of cagr
strips Negligence
Frequent power improper
failure phosphate Experience
coating
Needle
missing
Not effective plan Vibration in machine
work instruction
Air pressure valve
Length setting of jam
Voltage fluctutation
Checking
Welding mendral Improper tooling

Method Machine

Fig: 4 Cause & Effect Diagram for Needle Missing

Table 2: IS or IS-NOT Analysis of Needle Missing:

S.No. Causes Factor Major Minor Percentage
Contribution
1. Unskilled Man  ✓ 1.1
2. Negligence Man ✓  19
3. Experience Man  ✓ 3
4. Improper tooling Machine  ✓ 4.4
5. Voltage fluctuation Machine ✓  20
6. Air pressure valve jam Machine  ✓ 5.5
7. Vibration in machine Machine ✓  15.1
8. Variation in width of cage Material  ✓ 1.75
9. Improper phosphate coating Material  ✓ 2.25
10. Welding mandrel setting not Method  ✓ 7
proper
11. Checking frequency not Method  ✓ 9
effective
12. Length setting of slide not Method  ✓ 4
proper
13. Work instruction not followed Method  ✓ 15.5
by operator
14. Not effective plan Method  ✓ 4.5
15. Rainy season Environment  ✓ 2.5
16. Frequent power failure Environment  ✓ 2.5

Table 3: Major Contributor Table:

S.No. Causes Factor Major Minor Percentage
Contribution
1. Voltage fluctuation Machine ✓  20
2. Negligence Man ✓  19
3. Vibration in machine Machine ✓  15.1

Table 4: Cause and Remedy for Major Contributor:

S.No. Causes Factor Remedy
1. Voltage fluctuation Method Voltage stabilizer must be
operated regularly to provide
sufficient voltage for proper
needle feeding.
2. Negligence Material Operation must have to reduce
negligence during needle filling
in slot by complete rotation of

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 Implementation of Poka Yoke in Needle Bearing Assembly Process
cage.
3. Vibration in machine Method The base of machine must be
put on damping free bed.

Cause & Effect Diagram for Needle Rusty

Ishikawa diagram for Needle rusty

Material Machine Personnel

OD P itted lack of experience

needle wire rusty

improper hardening operator absent

and tempering

Needle Rusty

rainy season

disruption in polishing

power failure frequently

Environment Method

Fig: 5 Cause & Effect Diagram for Needle Rusty

Table 5: IS or IS-NOT Analysis of Needle Rusty

S.No. Causes Factor Major Minor Percentage

Contribution
1. Needle wire rusty Material  ✓ 6
2. OD Pitted Machine ✓  27
3. Improper hardening and Tempering Machine ✓  16.9
4. Lack of experience Man  ✓ 1.7
5. Operator absent Man  ✓ 3.3
6. Disruption in polishing Method ✓  31
7. Rainy season Environment  ✓ 9
8. Power failure frequently Environment  ✓ 5

Table 6: Major Cause of failure

S.No. Causes Factor Major Minor Percentage

Contribution
1. Disruption in Method ✓  31
polishing
2. OD Pitted Machine ✓  27
3. Improper Machine ✓  16.9
hardening and
Tempering

Table 7: Cause and Remedy for Major Cause

S.No. Causes Factor Remedy

1. Disruption in polishing Method The polishing of needle
must be continuously and
finish any disruption
occurs.
2. OD Pitted Machine Heat treatment
temperature is checked

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 Implementation of Poka Yoke in Needle Bearing Assembly Process
regularly as per lot.
3. Improper hardening and Machine Cutting tool must be
Tempering inspected regularly i.e.
Weekly.

Cause & Effect Diagram for Shell Crack

Cause-and-Effect Diagram

Environment Material Man

Insufficient
lighting Un-skilled
Rainy season Raw material
rusty
Negligence
Frequent power
failure
Shell crack

Condition of barrel

Work instruction Air pressure valve

not followed by jam
operator
Improper tooling

Method Machine

Fig: 6 Cause & Effect Diagram for Shell Crack

Table 8: IS or IS-NOT Analysis of Shell Crack

S.No. Causes Factor Major Minor Percentage

Contribution
1. Unskilled Man  ✓ 2.2
2. Negligence Man  ✓ 3.8
3. Improper Loading Machine  ✓ 3.3
4. Air pressure valve jam Machine  ✓ 1.7
5. Condition of barrel Machine ✓  54
6. Raw material rusty Material ✓  18.0
7. Work instruction not followed by Method  ✓ 7
operator
8. Insufficient lighting Environment  ✓ 7.1
9. Rainy season Environment  ✓ 1.8
10. Frequent power failure Environment  ✓ 2.1

Table 9: Major Cause of failure

S.No. Causes Factor Major Minor Percentage

Contribution
1. Condition of Machine ✓  54
barrel
2. Raw material Material ✓  18
rusty

Table 10: Cause and Remedy for Major Cause

S.No. Causes Factor Remedy

1. Condition of barrel Machine Speed of barrel must be desirable for polishing.

2. Raw material rusty Machine Raw material for shell formation must be kept in
rust free environment.

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

Cause & Effect Diagram for Damaged cage

Cause-and-Effect Diagram

Method Personnel Material

operator
Improper heat awareness Shortage of material
treatment
temperature Maintenance
frequency by
Lack of standards Raw material rusty
operator absent
Defective
and
damaged
Regulating wheel cage
insufficient lighting High feed rate
OD grinding
Frequent power
shedding Tool blunt/failure

Rainy season Face grinding

Vibration in

Environment Machine

Fig: 7 Cause & Effect Diagram for Damaged cage

Table 11: IS or IS-NOT Analysis of Defective and Damaged Cage

S.No. Causes Factor Major Minor Percentage

Contribution
1. Shortage of material Man  ✓ 0.3
2. Raw material rusty Man  ✓ 1.7
3. High feed rate Machine  0.8
4. Regulating wheel angle are not ok Machine  ✓ 2.3
5. Vibrations in machines Machine ✓  36.2
6. Face grinding Machine   1.3
7. Tool blunt and failure Material ✓  9.4
8. OD grinding Material  ✓ 1.0
9. Operator awareness Method  ✓ 2.8
10. Maintenance frequency by operator Method  ✓ 0.2
11. Operator absent Method  ✓ 0.2
12. Improper heat treatment temperature Method ✓  29.9
13. Lack of standard Environment  ✓ 3.1
14. Rainy season Environment  ✓ 2.7
15. Frequent power shedding Environment  ✓ 4.1
16. Insufficient lighting Environment  ✓ 2.2

Table 12: Major Cause of failure

S.No. Causes Factor Major Minor Percentage

Contribution

1. Vibrations in machines Machine ✓  36.2

2. Improper heat treatment temperature Method ✓  29.9

3. Tool blunt and failure Material ✓  9.4

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 Implementation of Poka Yoke in Needle Bearing Assembly Process

Table 13: Cause and Remedy for Major Cause

S.No. Causes Factor Remedy

1. Vibrations in machines Machine The base of machine must
be put on damping free
bed.
2. Improper heat treatment Method Heat treatment
temperature temperature is checked
regularly as per lot.
3. Tool blunt and failure Material Cutting tool must be
inspected regularly i.e.
Weekly.

Table 14: Analysis of Causes of Defective Bearings after using Poka Yoke Techniques:
S.No. Nature of Defects in Percentage Contribution before Percentage Contribution FINAL
Bearing After using Poka yoke %

1 Needle Missing 30 11 36.67

2 Shell crack 9 3 33.24
3 Slot variation 12 4 33.33
4 Line thickness variation 5 1 20
5 Needle rusty 11 3 27.27
6 Defective cage 8 3 37.5
7 OD over size 4 2 50
8 OD under size 3 3 100
9 Shell Pitted 3.25 3 92.3
10 Mix bearing 1.5 1.5 100
11 Loose fit 0.5 0.5 100
12 Tight fit 1 1 100
13 Corrosion 3.25 2.4 73.84
14 Axial crack 0.75 0.7 93.33
15 Normal fatigue 1.25 1.25 100
16 Insufficient heat 0.5 0.5 100
temperature
17 Defective shell bearing 2.5 2 80
18 Miss alignment 1.5 1 66.66
19 Shell OD rusty 2 0 0

III. Conclusion
The various defect in assembly of needle bearing are shown above in my thesis in which improper
welding variation, needle miss causes more amount of rejection in needle bearing assembly. The root cause has
been identified using Poka-yoke tool. The factors are main material method material and measurement systems
are the root causes which have been shown in root cause ishikawa diagram. To make error is human nature so
we cannot blame human being for each and every mistake as like errors intelligence is also human nature by
next nature so we can dominate preceding nature by next nature. Initially the case of needle missing in bearing
where 30 %, but after implementation of lean tool Poka-Yoke the case of needle missing is totally decreased the
is obtained maximum efficient bearing and this case not any complain from customer side. This increases
customer satisfaction regarding company and faith in product so that company sells increase and profit as well
as production also high.

Acknowledgements
We take this opportunity to express our deepest sense of gratitude and sincere thanks to those who have
helped us in completing this task. We express our sincere thanks to our thanks to our guide who has given us
valuable suggestions. We are very thankful to staff members of SNL industry for cooperation and
encouragement for collecting the information and preparation of data. We, also, thank to my friends for helping
us.

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International Journal of Engineering Science Invention (IJESI) is UGC approved Journal with
Sl. No. 3822, Journal no. 43302.

Bhawesh Kumar Implementation of Poka Yoke in Needle Bearing Assembly Process.”

International Journal of Engineering Science Invention(IJESI), vol. 6, no. 11, 2017, pp. 01-10.

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