Product development of lever cam follower using poka yoke

Poka yoke is a very powerful set of technique that either keeps defects from occurring or indicating immediately when a defect occurs. It relies on creativity and common sense to create low cost, effective inspection devices. Like many quality tools, mistake-proofing is not a solution for every kind of defect or quality problem. The poka yoke aims to reduce the rejection, increase the production and avoid fatigue of worker. The beauty of this lies in that anyone, from manager to line supervisor to line employee can bring this concept into service. These devices are used either to prevent the special causes that result in defects, or to inexpensively inspect each item that is produced to determine whether it is acceptable or defective. The paper contains poka yoke fundamentals to improve the production of lever cam follower and to achieve the target of zero defects over the whole process machining.