poka yoke
the zero-defect target at KERN-LIEBERS


Even where employees have many years of experience and work with great care, minor defects that are actually avoidable can and will sometimes happen. As this in turn leads to customer dissatisfaction, our approach is to make processes fail-safe against inadvertent defects of this kind. The technique of defect avoidance – called "poka-yoke" in the TPS – is based on simple and robust measures.

Typical defects involving seat belt spring cassettes are incorrect fitting and inadequate greasing. Here, KERN-LIEBERS has developed approaches using sensor detection or simple tests, through which bad parts are discharged automatically or the assembly station is locked for the manufacture of further parts. This ensures that the product is defect-free, as operators identify the defect clearly and unambiguously because they have to discharge the bad part and unlock the assembly equipment. This approach makes it possible for us to achieve our zero-defect target in many cases.

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