Detection of Nut Welding Using Poka-Yoke Roller Coaster Jig

This paper describes the proposal of Poka Yoke Roller Coaster (PKYC) jig as a device to detect nut weld missing of door patch base line model (BLM) at assembly line station. The PKYC was proposed in order to detect nut weld missing problem and to reduce cycle time and manpower that lead to higher cost by applying quality management concept as a problem-solving tool. This special purpose tool was capable to meet specific job based on industrial need by providing repeatability, interchangeability and accuracy in the manufacturing of products. A Quality Control (QC) approachcalled the Zero Quality Control (ZQC) was used to achieve zero defects at production line. In order to reach zero defects, poka yoke method was applied in this research. Outcomes indicate that PKYC can be utilised as a custom-tailored jig for detecting nut weld missing as well as fulfilling other objectives.