Mistake-Proof a Kitting Step Before It Reaches Assembly
Design a mistake-proofing countermeasure that prevents or immediately detects wrong-part kitting.
Two similar bushings are repeatedly mixed in a wing-rib kit before assembly catches the error. Poka-yoke should act where the error happens and either prevent the wrong selection or detect it before release. The common shortcut is adding a reminder label while leaving the same visual confusion and release path intact. If the wrong tube can still be picked, issued, and used, the process is still relying on perfect attention. Before Two bushing bins sit side by side. The kitter reads similar labels and assembly is the real detection point. After Correct bushing fits the foam pocket, barcode must match…
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