Abstract
The paper represents a case study which focuses on Poka Yoke which is a concept coined by Japanese people. We have studied a system that eliminated the rework and increased productivity of the plant which results in achievement of 0 PPM as well; in the company based in Satpur, Nashik. There was a punching machine there in the plant which was punching a hole on a rear end cap of Mahindra Scorpio’s rear bumper. There were 4 metal clips which were fitted on that component before the part gets punched on punching machine. After some of the lots get punched, we observed that component is getting punched unless those clip fittings. At that time, company needs more time to fit metal clips on the component again which was time consuming. So this problem can be avoided by implementing Poka Yoke system to it. So, the aim of the project was avoid the mistake of missing of metal clip on it and make a system which will not allow to punch the hole unless and until all 4 metal clips are arranged on it.
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