Using Arduino based sensors for Poke-Yoke

a.temel

Starting to get Involved
#1
Greetings All,

I work in an injection molding company as a QA eng. and i have some ideas for poke-yoke systems based on arduino.I know this device isnt designed to work in a manufacturing env. but its cheap and could solve huge quality issues.

For example,we install metal nut to a plastic part and sometimes operator skip this process by mistake and this could be easily solved with a metal detecting circuit.But i m afraid to suggest this to menagement because,
a) Its not my area of expertise,
b)I dont know if it would be reliable in the long run,

Kindly expecting your insights.
 
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Tagin

Trusted Information Resource
#2
It would seem that there would need to be two sensors: one to detect when the assembly is present to be checked, and one for the actual metal detection. Then, there would need to be some notification or intervention as a result of a failure, such as a flashing light, buzzer, email alert, shutting off power to that station, etc.

As for reliability, the concern would be false positives, so you would want to try to make the design so that if it fails, it always fails as false negative.

Those devices are cheap enough that replacement cost probably isn't an issue. Most of the cost would be in the initial configuration design and any software programming. But that should be reasonable for a simple device like an Arduino.

Maybe you could propose in more general terms that "an automated QC check device" would be advantageous. Then, give as an example, "maybe something not too complex - like an Arduino."

Hopefully, management is not going to be negative just because you have an idea for improvement.
 

Bill Levinson

Industrial Statistician and Trainer
#3
Re: "sometimes operator skip this process by mistake "

Shigeo Shingo (Zero Quality Control: Source Inspection and the Poka-Yoke System) dealt with problems of this nature very frequently and yours is very similar to those for which he has numerous case studies. The case studies often used mechanical sensors like limit switches to detect the presence (or absence) of parts that were supposed to be there.

If the part is in a jig or fixture, where the metal nut will always be in the same place, the metal detector (or limit switch) could be placed to detect the nut. Alternatively, if the part leaves the work station on a conveyor or work slide, a gate could be installed that will not open unless the metal detector senses the presence of the metal nut. Shingo's examples often had a sensor that would actually prevent a nonconforming part from leaving (jidoka or autonomation).

(Does not constitute formal engineering advice)
 

optomist1

A Sea of Statistics
Trusted Information Resource
#4
don't know your firms budget constraints...but a sure fire method is (and its is $$$) an AOI or automatied optical inpsection....camera machine vision to confirm correct fastener is in place correctly oriented etc...this then requires among other things use of a Golden Rabbit and a Red Rabbit...know good and bad part or assembly.....once properly vetted/proven and implemented works well. If this route (easier to rationalize the captial expenditure as well) is taken the AOI system can be implemented across other process steps and other production lines.
 
Last edited:

a.temel

Starting to get Involved
#5
@Bill Levinson
We have a gate system already.Gate is only activated if the nut assembly machine sends the signal.Problem is, this systems costs between 3000-5000 euros.So we cant implement it for every part.My idea is like this.Arduino controls magnetic sensor and movement sensor.If both is activated when operator drops the part into the box,part is ok.If only movement sensor is activated but not the magnetic sensor,part is NG.And all this costs below 50 euros.But i dont know if its reliable because i didnt see anyone in our line of business use arduino based sensors before

@optomist1

We use AOI's only for critical parts for OEMS.And they are even more expensive.
 

Bill Levinson

Industrial Statistician and Trainer
#6
50 euros is about the price range for a typical Shigeo Shingo error proofing system. If the movement sensor detects the part but the metal detector doesn't detect the nut, I suppose it could stop the box from continuing (jidoka/autonomation) and use a visual or audible control to alert the operator.
 

optomist1

A Sea of Statistics
Trusted Information Resource
#7
@Bill Levinson
We have a gate system already.Gate is only activated if the nut assembly machine sends the signal.Problem is, this systems costs between 3000-5000 euros.So we cant implement it for every part.My idea is like this.Arduino controls magnetic sensor and movement sensor.If both is activated when operator drops the part into the box,part is ok.If only movement sensor is activated but not the magnetic sensor,part is NG.And all this costs below 50 euros.But i dont know if its reliable because i didnt see anyone in our line of business use arduino based sensors before

@optomist1

We use AOI's only for critical parts for OEMS.And they are even more expensive.
I kind of suspected that might be the case....but when justified and properly implemented they are worth the effort...Cheers optomist1
 
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