The project involves designing two poka-yoke devices. What are poka-yoke devices
ID: 469191 • Letter: T
Question
The project involves designing two poka-yoke devices. What are poka-yoke devices? (These devices prevent defects from occurring.).The elements of its grade will depend on your:
a)knowledge of poka-yoke
b)originality of design (design your own device: it is ok to use examples of other devices to generate ideas, but do not just copy another device you have seen.) Your device should promote sustainability and environmental responsibility. (The device should help the environment: save energy, reduce waste, promote recycling, etc.)Your design does not have to be a working model; you can describe an idea or a process that would be improved with poka yoke.
c)description of your designs with terms used in poka-yoke design
d)explanation of why your devices are effective and how they increase productivity and sustainability.
Explanation / Answer
Poka-yoke devices are used for mistake proofing, i.e. to prevent defects in the process, thereby ensuring higher productivity of the process. The poka-yoke devices defined here can be used in trouser manufacturing plant. (Garment manufacturing industry)
Device 1: In the side seam manufacturing operation of trouser manufacturing, it is crucial the seam allowance left on both the panels being attached is even throughout the side seam, otherwise if the allowance of the side seam is not even on both the panels, the defect will cause a change in the size of the trouser leg.
Hence, a guard or mark can be used, at the 1/4th inch distance from the needle (generally the width of the allowance to be left). This guard will help the operator to align both the panels to touch the guard when stitching, this way the time needed to ensure the allowance on both panels is equal and as per requirement will be saved for each piece, and the defect of uneven allowance will also be avoided. The guard can be made from a waste cardboard piece.
Device 2: In the cutting room, the fabric is spread in lays, which is constituted of plies. The length of the play is determined by a marker made, where the pattern of the garment being cut are aligned and adjusted to fit in a way, we get the maximum number of pieces possible in the minimum length of fabric being used. In the spreading process, the fabric is ply is spread as per the marker length. If automatic spreaders are being used, the length of the plies is accurate, hence fabric loss is prevented ensuring better fabric utilization, but since automatic spreading machines are expensive capital expenditure, generally manual spreading is used, where two spreading operators spread the fabric from the roll, ply by ply, into a lay. In manual spreading the length of each ply is not exact as needed. Hence fabric wastage is higher. To ensure fabric utilization is optimum, we can use a similar longer guard, made of cardboard piece that is of length of the spreading table’s width and average height of 3-4 inches, or as per the average height of lays in the factory. Before every lay is spread, as per the marker length, this guard can be placed at the spreading table. This way every play can be cut exactly of the marker length ensuring minimal fabric wastage in end losses. Fabric constitutes 60% of the total garment’s cost, hence fabric saving is crucial for sustainability of garment manufacturing operations.
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