Poka - yoke check sheet Item Date Time Reason Action Eng. Manager Qua.

Manager Deviation Number

Plant Department Line PumpAssy

Chennai Manufacturing Area Production

Facility Name TI Automotive Chennai Projects YED

Month: Check Result

Judgement machine- Hot

Operator /
Model forming parameters: Judgement machine-
Date Time Shift Inspector
Name - temperature Check valve functions Judgement machine- Judgement machine- Judgement machine- Final Judgement machine- Check Judgement machine- Final Judgement machine - Pump
- force / pressure (opening, closing, forward Presence of components Judgement machine-Final Reference and position of Judgement machine- Judgement machine- position of impeller on valve and/or OPRV presence position of outlet cover on Judgement machine- Judgement machine- Spring performances according to Judgement machine - CV Signature
- distance / final position leakage) prior assembly position of retainer components prior assembly Component cleaning Orientation of turbine upper cap according to BOM armature cover Presence of magnetic field presence Judgement machine -2D Judgement machine -Ground Pump End of Line integrity and absence of
PY-025 PY-026 PY-027 PY-028 PY-029 PY-030 cavities PY-031 PY-032 PY-033 PY-034 PY-035 PY-036 matrix integrity PY-037 pin PY-038 Specification PY-039 contamination PY-040

A YED
1
B YED

A YED
2
B YED

A YED
3
B YED

A YED
4
B YED

A YED
5
B YED

A YED
6
B YED

A YED
7
B YED

A YED
8
B YED

A YED
9
B YED

A YED
10
B YED

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
Reviewed By
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
Shift Leader or Process Engineer
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Poka yoke சரி செய்தபின் Hold செய்த tank-கை 100 % re-check செய்யும் சோதனையின் அடிப்படையில் முடிவை தீர்மானிக்கவும்.

Note : Normally Poka Yoke sample made in positive side. It will not go to negative side. The maximum NG value should not exit above limit. If above the limit value or /below under specification mean stop the line and Follow abnormal procedure

Page1 FM-PD3-071 Rev. 06

Dt 26.09.2021
 Poka - yoke check sheet

Plant Chennai Department Manufacturing Line CV & SOP Assembly

Facility Name TI Automotive Chennai Project YED Area Production

Date: Date: Date: Date: Date: Date: Date: Date:
Yoke No
Station
Si. No

Name

Poka

Characteristic to be controlled by
Poka Yoke Description Time: Time: Time: Time: Time: Time: Time: Time:
poke-yoke

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-

Final position of retainer Machine to allow for mass production

PY - 025

heigh by using of Ok when ever switch off the equipment and

1
sample restart Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
Test Sample SOP 1 Spec:-0.2 t0 0.2

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-

Machine to allow for mass production

PY - 026

Final position of retainer

when ever switch off the equipment and
2 height NG
restart Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
Test Sample SOP 2
Spec:-0.2 t0 0.2

Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:

Presence of components
PY - 027

prior assembly (outlet

No cycle startup, remove part from the
3 cover, spring, ball &
nest and load it again
retainer)
( Production Part)

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-
1. 1. 1. 1. 1. 1. 1. 1.

Recheck of Leak Test Machine to allow for mass production 2. 2. 2. 2. 2. 2. 2. 2.

PY - 028

machine by using of Ok when ever switch off the equipment and

4 sample - for CV restart 3. 3. 3. 3. 3. 3. 3. 3.
Test No 1,2,3&4 Spec: 1 & 2 As per CPPS
3. Spec: 0.5m/min 4. 50Pa/s (leak rate) 4. 4. 4. 4. 4. 4. 4. 4.

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-
bly -Cover outlet assy (SOP + CV assy)

Check Valve-Without Check-valve functions by a sequence

PY - 029

Spring assembly of air pressure tests- without spring

5
Test Sample -1 loading Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
Spec: As per CPPS
 Pump Assembly -Cover outlet assy (S
Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-

Check Valve -Spring

Struck up inside
Check-valve functions by a sequence

PY - 030
assembly
of air pressure tests - Spring struck up /
6 Test Sample 2 -(Check
Double spring Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
valve functions (opening,
Spec: As per CPPS
closing, forward
leakage))

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-

Check Valve -The stem

PY - 031

Check-valve functions by a sequence

rubber damaged
7 of air pressure tests- Rubber Damage
condition Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
Spec:290 to 330 Kpa / 0.5ml/min
Test Sample 3

Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value- Actual Value-

SOP Without Ball

PY - 032

loading assembly SOP functions by a sequence of air

8 Test sample 4 pressure tests- Without ball loading Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
Spec:290 to 330kpa / 50Pa/s

Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:

Hot forming NOK if any one parameter

Hot forming parameters:
PY-33

is out of set limit- Already hot canning

9 - temperature
process completed components
- force / distance
recheck - distance /force will NOK.

Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP

NOK part = calibrated leak over

Check-valve & SOP rejection threshold installed on leak
PY-34

10 tightness by air pressure tester device or serial part with Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement: Judgement:
test damaged valve
Spec: 0.5ml/min and 50Pa/s

Checked By

Reviewed BY ( Team Leader )

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK", (Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on h
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK
Poka yoke சரி செய்தபின் Hold செய்த tank-கை 100 % re-check செய்யும் சோதனையின் அடிப்படையில் முடிவை தீர்மானிக்கவும்.
 Doc Number: YED : DS-OP-F-MFG-173
Rev Date - No 20/06/24 - 02

Month:

Date: Date: Date: Date:

Time: Time: Time: Time:

Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

Judgement: Judgement: Judgement: Judgement:

Actual Value- Actual Value- Actual Value- Actual Value-

1. 1. 1. 1.

2. 2. 2. 2.

3. 3. 3. 3.

4. 4. 4. 4.

Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

 Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

Actual Value- Actual Value- Actual Value- Actual Value-

Judgement: Judgement: Judgement: Judgement:

Judgement: Judgement: Judgement: Judgement:

Act: CV SOP Act: CV SOP Act: CV SOP Act: CV SOP

Judgement: Judgement: Judgement: Judgement:

to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
er அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும்,
வும்.
 Poka - yoke check sheet
Plant Chennai Department Manufacturing Line Sub Pump Assembly

Facility Name TI Automotive Chennai Project YED Area Production

Date: Date: Date: Date: Date: Date: Date: Date: Date: Date:

Yoke No
Carbon Brush height Station
Si. No

Name

Poka
Characteristic to be controlled by
Poka Yoke Description
poke-yoke Time: Time: Time: Time: Time: Time: Time: Time: Time: Time:

OK Master value: OK Master value: OK Master value: OK Master value: OK Master value: OK Master value: OK Master value: OK Master value: OK Master value: OK Master value:

Calibrate the machine , IF NG machine

PY-041
check

Carbon brush height check with OK requires manual reset and put in RED NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value: NG Master Value:
1
master & NG master bin interlock system
Record LH and RH data

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Armature cover assy

Component cleaning - Armature Part Presents - No cycle start, remove

PY-042

cover assy part from the nest .

2
Vacuuming of pumping elements Machine requires manual reset and
Presence detection cannot start auto cycle

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Magnet clip assy

Judgement machine-Reference and Reference and wrong position of

PY-043

position of components prior components prior assembly- Clip

3
assembly Position - Try to start cycle without
(Production part) component or in a wrong position

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Magnet clip assy

Component cleaning- Semi assy

Part Presents - No cycle start, remove
parts
PY-044

part from the nest .

4 ( before and after assy parts )
Machine requires manual reset and
Vacuuming of pumping elements
cannot start auto cycle
Presence detection

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
&Armature assy
Upper cover

Part Presents - No cycle start, remove

Component cleaning - Upper Cap
PY-045

part from the nest .

5 Vacuuming of pumping elements
Machine requires manual reset and
Presence detection
cannot start auto cycle

Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load:
&Armature assy
Upper cover

Final position of upper cap on flux Auto cycle stop and NG box interlink -
PY-046

6 tube - Judgement machine-Upper Based on Force NG

Cap Load NG Spec: 5000 to 7000N (as per CPPS)

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
&Armature assy
Upper cover

Upper cap reference-

PY-047

Sensor to detect shape and part No cycle startup until part is detected
7
present with out part loading
(production part)

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
&Armature assy
Upper cover

Armature family
Wrong direction of loading armature
PY-048

Laser sensor for commutator

8 assy- No cycle startup until part is
Sensor for shaft position
detected with out part loading
(Production part)

Checked by

Reviewed BY ( Team Leader )

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டு
check செய்யும் சோதனையின் அடிப்படையில் முடிவை தீர்மானிக்கவும்.
 Doc Number: YED : DS-OP-F-MFG-173
Rev Date - No 20/06/24 - 02

Month:

Date: Date: Date: Date:

Time: Time: Time: Time:

OK Master value: OK Master value: OK Master value: OK Master value:

NG Master Value: NG Master Value: NG Master Value: NG Master Value:

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Act Load: Act Load: Act Load: Act Load:

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

r correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Poka yoke சரி செய்தபின் Hold செய்த tank-கை 100 % re-
 Poka - yoke check sheet
Plant Chennai Department Manufacturing Line Sub Pump Assembly
Facility Name TI Automotive Chennai Project YED Area Production
Yoke No Date: Date: Date: Date: Date: Date: Date: Date: Date: Date:
Station
Si. No

Name

Poka

Characteristic to be controlled by
Poka Yoke Description
poke-yoke Time: Time: Time: Time: Time: Time: Time: Time: Time: Time:

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Inlet & Impeller assy

Wrong Orientation of impeller cavities

Judgement machine-
PY-056

Camera Checking
1 Orientation of impeller cavities
No cycle start, remove part from the
(Use production Part)
nest and try to load it again.

Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load:
Inlet & Impeller assy

Final position of inlet cap on

Auto cycle stop and NG box interlink -
PY-057

outer shell
2 Based on Force NG
Judgement machine- Inlet
Spec: 3500 to 6000 (as per CPPS)
cover Load NG
Inlet & Impeller assy

Stack up control by laser sensor

Judgement machine-
Manual process - Machine requires
PY-058

Final position of impeller on

3 manual reset and cannot restart until Act distance Act:
upper cap
NOK part is detected in the lock red box
(Poka Yoke Sample)
Spec: +/- 0.04

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Inlet & Impeller assy

Inlet Cap reference-

PY-059

No cycle startup until part is detected

4 Sensor to detect shape and
with out part loading
part present

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Inlet & Impeller assy

Camera to detect shape or color

PY-060

Judgement machine- Try to start cycle with wrong impeller

5
Impeller (Turbine) reference with all possible combinations
No cycle startup until part is detected

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Inlet & Impeller assy

Part present sensor to detect the

Thrust pin presence
PY-061

Broken centering pin on inlet

6 Manual process - Machine requires
adapter
manual reset and cannot restart until
NOK part

Checked by

Reviewed BY ( Team Leader )

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100%
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த
yoke சரி செய்தபின் Hold செய்த tank-கை 100 % re-check செய்யும் சோதனையின் அடிப்படையில் முடிவை தீர்மானிக்கவும்.
 Doc Number: YED : DS-OP-F-MFG-173
Rev Date - No 20/06/24 - 02

Month:
Date: Date: Date: Date:

Time: Time: Time: Time:

Judgement Judgement Judgement Judgement

Act Load: Act Load: Act Load: Act Load:

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

ader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
து Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Poka
 Poka - yoke check sheet
Plant Chennai Department Manufacturing Line Sub Pump Assembly
Facility Name TI Automotive Chennai Project YED Area Production
Date: Date: Date: Date: Date: Date: Date: Date: Date: Date:

Yoke No
Station
Si. No

Name

Poka
Characteristic to be controlled by
Poka Yoke Description
poke-yoke Time: Time: Time: Time: Time: Time: Time: Time: Time: Time:

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement

With out part loading Fixture A side LH&

RH single spring missing
1
cannot start auto cycle machine requires
manual reset

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement

With out part loading Fixture B side LH

& RH single spring missing
2
cannot start auto cycle machine requires
Brush spring assy

manual reset
Judgement machine- Spring &
PY-066

Retainer brush spring presence

Product sample Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement

part wrong loading Fixture A side LH &

RH Double spring
3
cannot start auto cycle machine
requires manual reset

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
part wrong loading Fixture B side LH &
RH Double spring
4 cannot start auto cycle machine requires
manual reset

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Brush spring assy Brush spring assy

Sensor to detect cavities of the outlet

Pump positioning cover
PY-067

5 Boundary sample = specific support Manual process - Machine requires

giving wrong angle to the outlet cover manual reset and cannot restart until
NOK part is detected in the lock red box

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement

Spring cap assembly

Manual process - Machine requires
PY-068

Pre-positioning of Retainer cap into

6 manual reset and cannot restart until
the outlet cover
NOK part is detected
(Production Part)

Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement Judgement
Out let cover press Out let cover press

Judgement machine- Check valve Sensor Check

PY-069
fit assy

7 and SOP assy presence Machine requires manual reset and auto
(poka-yoke sample) cycle cannot start

Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load: Act Load:

Judgement machine- Outlet cover Auto cycle stop and NG box interlink -
PY-070
fit assy

8 Load NG Based on Force NG

(Poka Yoke sample) Spec: 800 to 2500N (as per CPPS)

Checked by

Reviewed BY ( Team Leader )

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Pok
செய்யும் சோதனையின் அடிப்படையில் முடிவை தீர்மானிக்கவும்.
 Doc Number: YED : DS-OP-F-MFG-173
Rev Date - No 20/06/24 - 02

Month:
Date: Date: Date: Date:

Time: Time: Time: Time:

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Judgement Judgement Judgement Judgement

Act Load: Act Load: Act Load: Act Load:

correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
 correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Poka yoke சரி செய்தபின் Hold செய்த tank-கை 100 % re-check
 Poka - yoke check sheet
Plant Chennai Department Manufacturing
Facility Name TI Automotive Chennai Project YED
Date: Date: Date: Date:

Poka Yoke
Station
Si. No

Name

No
Canning Poka Yoke Description Characteristic to be controlled by poke-yoke Time: Time: Time: Time:

PY-075
Judgement machine -2D matrix integrity With out barcode scanning cycle start
1
Poka-yoke Sample Machine requires manual reset
Canning

PY-076

Judgment of Canning Force NG Auto cycle stop and NG box interlink - Based on
2
Poka Yoke sample Force NG
Canning

Recheck Canning Test machine by using of

PY-077

3 Ok sample Auto cycle compilation

LH Judgement LH Judgement LH Judgement LH Judgement

Continuity test between ground pin and outer
shell(LH side)
Judgement machine -Ground pin
PY-078
Aging

4
Boundary samples= pumps & without ground RH Judgement RH Judgement RH Judgement RH Judgement
pin contact
Continuity test between ground pin and outer
shell(RH side)

LH Judgement LH Judgement LH Judgement LH Judgement

Continuity between pump connections

Electrical continuity
PY-079
Aging

Manual process - Machine requires manual

5 Boundary sample = pump with caps but
reset and cannot restart until NOK part is RH Judgement RH Judgement RH Judgement RH Judgement
without springs
detected in the lock red box

LH Judgement LH Judgement LH Judgement LH Judgement

Continuity between pump connection

Continuity test for power supply Manual process - Machine requires manual
PY-080
Aging

6 Boundary sample = pump with armature reset and cannot restart until NOK part is
where wire is cut detected in the lock red box RH Judgement RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement LH Judgement

Presence of magnetic field Manual process - Machine requires manual

PY-081
Aging

7 Control by sampling - reset and cannot restart until NOK part is

Boundary samples= pump without magnets detected in the lock red box RH Judgement RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement LH Judgement

Continuity between pump connections

Electrical continuity
PY-082
Aging

Manual process - Machine requires manual

7 Boundary sample = pump with caps but
reset and cannot restart until NOK part is
without springs
 Continuity between pump connections
Electrical continuity

PY-082
Aging
Manual process - Machine requires manual
7 Boundary sample = pump with caps but
reset and cannot restart until NOK part is RH Judgement RH Judgement RH Judgement RH Judgement
without springs
detected in the lock red box

LH Judgement LH Judgement LH Judgement LH Judgement

Continuity between pump connection

Continuity test for power supply Manual process - Machine requires manual

PY-083
Aging
8 Boundary sample = pump with armature reset and cannot restart until NOK part is
where wire is cut detected in the lock red box RH Judgement RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement LH Judgement

Pump performances according to Pump End of

Judgement machine - Pump performances
PY-084

Line Specification
EOL

5 according to Pump End of Line Specification

Current + flow vs. voltage + pressure variation RH Judgement RH Judgement RH Judgement RH Judgement
Poka Yoke sample- Impeller broken parts
Auto cycle stop and NG box interlink

Actual value Actual value Actual value Actual value

current: current: current: current:

Pump performances according to Pump End of

Line Specification flow vs. voltage: flow vs. voltage: flow vs. voltage: flow vs. voltage:
Current + flow vs. voltage + pressure variation
(LH side)
pressure variation: pressure variation: pressure variation: pressure variation:
PY-085

Recheck of EOL machine performance by

EOL

6
using of Ok sample
Actual value Actual value Actual value Actual value
current: current: current: current:

Pump performances according to Pump End of

Line Specification flow vs. voltage: flow vs. voltage: flow vs. voltage: flow vs. voltage:
Current + flow vs. voltage + pressure variation
(RH side)
pressure variation: pressure variation: pressure variation: pressure variation:

LH Judgement LH Judgement LH Judgement LH Judgement

Leak test

Judgement machine - CV integrity and

PY-086

Pressure low NG and Interlink with NG box

7 absence of contamination
CV rubber part damage condition assembled RH Judgement RH Judgement RH Judgement RH Judgement
Poka Yoke sample

Checked by

Reviewed BY ( Team Leader )

Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
Containment details :
*If the Poka yoke Ok, write On the check sheet "OK"
(Poka yoke OK- என்றால் .Check Sheet-ல் OK என்று எழுதவும்)
“If the Poka yoke NG , write on the check sheet "NG" and Stop the production, Hold the products produced from last ok result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. A
Poka yoke NG- என்றால் .Check Sheet-ல் NG என்று எழுதவும், production-னை நிறுத்தவும் பிறகுPoka yoke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உ
முடிவை தீர்மானிக்கவும்.
Poka - yoke check sheet
Line Pump Assembly
Area Production
Date: Date: Date:

Time: Time: Time:

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

Actual value Actual value Actual value

current: current: current:

flow vs. voltage: flow vs. voltage: flow vs. voltage:

pressure variation: pressure variation: pressure variation:

Actual value Actual value Actual value

current: current: current:

flow vs. voltage: flow vs. voltage: flow vs. voltage:

pressure variation: pressure variation: pressure variation:

LH Judgement LH Judgement LH Judgement

RH Judgement RH Judgement RH Judgement

result immediately, Inform to shift leader/ process engineer for correcting the poka-yoke. After correction, re-check products on hold 100% and decide based on check result”
oke சரிசெய்ய Shift Leader அல்லது Process Engineer- க்கு தெரிவிக்கவும்/ உடனடியாக கடைசியாக Poka yoke OK செய்த எட்டு மணி நேர tank-கை hold செய்யவேண்டும், Poka yoke சரி செய்தபின் H
 Revision Level History
Training Topic MPR Poka Yoke Verification
Revision No Reason for Change
0 Initial Review

1 vision camera instalation

2 Revised based on Global requiremnet fulfill

Training Record Details

Trainer Name: Training Date:

Operator Name Operator Sign Revision No Operator Name

ision Level History
MPR Poka Yoke Verification
Date
7/15/2023

10/06/24 - 01

20/06/24 - 02

ning Record Details

Training Date:

Operator Sign Revision No

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