Poka-yoke is a technique used in manufacturing to prevent mistakes and defects from occurring. The concept of poka-yoke, as well as the term, come from Japan and translate to “mistake-proofing” or “error-proofing.” Both were developed in the 1960s by Shigeo Shingo, an expert industrial engineer who worked for Toyota.

The objective of poka-yoke is to design processes and systems in such a way that mistakes or defects become nearly impossible to make. This can be accomplished through a variety of methods, such as designing parts or machines that only fit together in one way, adding sensors or alarms to alert operators of potential issues or using visual cues to make it clear how a process should be carried out.

Poka-yoke is often associated with lean manufacturing and Six Sigma methodologies, which aim to reduce waste and improve efficiency in manufacturing processes. By preventing mistakes and defects from occurring, poka-yoke helps to reduce the need for rework, improve product quality and increase customer satisfaction.

From time to time, we sit down with a Designetics innovator to talk about his or her career as well as topics relevant to the fluid applications industry. This month: Senior Plastics Engineer Billy Hesser.

When I think about the last 12 months, the first feeling that comes to mind is gratitude. I suppose, at this point, we’re all joking about “turning the page” and moving past this difficult and tumultuous year. I know I definitely have those feelings. But most importantly, I’m reflecting on the positive aspects…and for those I remain eternally grateful.

At Designetics, we focus on solutions, not products. And sometimes, that means pivoting from our core competency of fluid application to solve an important problem – but one that isn’t related to fluid application – for a client. Here’s a story of just how flexible and entrepreneurial our team is, and how this pivoting mindset is helping to keep front-line workers, and the general public, safe during the COVID-19 pandemic.

For precise, consistent fluid application, holding a constant pressure between the fluid applicator and the substrate is key. But this can pose a challenge for even sophisticated automation systems, because any time the applicator changes position – as a result, for example, of part deviations that cause inconsistent perpendicularity between the applicator and the substrate – the pressure between the applicator and the substrate will vary.

This is where Designetics’ Precision Air Compliance comes into play. The Precision Air Compliance is an end-of-arm tool that can be used on a robot or a stationary machine to ensure constant pressure between the applicator and the substrate, regardless of part deviations or changes in the applicator’s position. It works by using air bearings with a pressure differential to create a downward pressure on the applicator. A float ensures that the applicator “rides along” any variations in the substrate, always maintaining constant pressure between the applicator and the substrate, so fluid delivery is consistent and reliable.

The desired pressure is set via regulators, which can be mounted on the Precision Air Compliance unit or elsewhere on the machine or in the work cell.