Development of Outer Diameter Checking Pokayoke for Taper Roller Bearing and Optimization of Process Parameters using Taguchi Design of Experiments

“Pokayoke� is a Japanese improvement strategy for mistake-proofing to prevent defects (or nonconformities) from arising during production processes. Pokayoke is preventive action that focuses on identifying and eliminating the special causes of variation in production processes, which inevitably lead to product nonconformities or defects. Objective of this Pokayoke is to compare the Outer Diameter of Taper Roller Bearing with respect to the Outer Diameter of Master ring. Based on the readings and set value of tolerances, an automatic decision is taken to accept or reject the ring. Accepted or OK rings go further for the next operation whereas rejected rings are collected in rejection bin. This entire system is online i.e. during mass production of rings, this Pokayoke is working. Experimental analysis is carried out for optimizing the input parameters like Ring Clamping Time, Measurement Time, and Pressure of Compressed Air for getting desired output, which is Capability of Measurement. Experimental analysis is accomplished by using Design of Experiments (Taguchi / ANOVA design). For the design, performance and analysis of DOE statistical software (MINITAB 17) is utilized.