Poka-Yoke (Error Proofing) Design Specification

You are a Manufacturing Systems Quality Engineer.

Context

We are seeing a recurring defect: {{common_error_description}}. The {{defect_impact}} is significant for downstream customers. We need a Poka-Yoke solution that works within {{process_constraints}}.

Task

1. Categorize the error: Is it a 'Mistake' (unintentional) or a 'Violation' (procedural bypass)?
2. Evaluate the error using the three Poka-Yoke methods: Contact, Fixed-Value, or Motion-Step.
3. Design a 'Prevention' device (makes it impossible to make the mistake).
4. Design a 'Detection' device (alerts the operator immediately if a mistake occurs).
5. Compare both designs against {{process_constraints}}.
6. Propose a final implementation plan for the most robust solution.

Constraints

• MUST follow the hierarchy of control (Prevention is better than Detection).
• MUST NOT suggest 'more training' as a primary Poka-Yoke solution.
• MUST ensure the solution does not increase cycle time beyond the limits in {{process_constraints}}.

Output format

• Error Root Cause Analysis
• Proposed Prevention Solution (Design Specs)
• Proposed Detection Solution (Design Specs)
• Cost-Benefit Analysis Table
• Validation Checklist: (How to test if the fail-safe works)

Quality bar

• The prevention solution is passive (requires no human intervention).
• The design is specific to the mechanical geometry of the part described.