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Poka Yoke System: Error Prevention in Actuator Assembly

maio 11, 2025

Customer Information: Our client is a major Spanish pharmaceutical company specializing in the research, development, production, and marketing of drugs for various medical conditions. It offers a wide range of pharmaceutical products that treat respiratory, cardiovascular, metabolic, oncological, neurological, and immune system disorders. Additionally, the company is actively engaged in innovating new therapies and treatments to improve patient health.

Initial Challenge: The client encountered significant difficulties in correctly installing valve actuators when mounted on butterfly valves positioned beneath the BIN. Operators made mistakes during assembly due to the difficulty in seeing the position of the valve disc, resulting in incorrect disc placement and product loss during the BIN filling phase. As a result, the client requested a solution that would simplify the assembly process for operators, reduce errors, and improve overall productivity.

Proposed Solution: In response to the client’s challenge, our team proposed the implementation of a Poka Yoke system tailored to the specific needs of their assembly process. The Poka Yoke system, derived from Japanese lean manufacturing principles, focuses on error prevention through processes that make mistakes either impossible or immediately detectable. The Poka Yoke system designed for this project included the following key components and features:

Unique Mounting System: We developed a mounting system that ensures the actuator can only be installed in the correct orientation on the butterfly valve, eliminating the possibility of incorrect installation.

Implementation and Results: After the client’s approval, the Poka Yoke system was implemented in their assembly process with the assistance of our technical team. The installation of the unique mounting system was seamlessly integrated into their existing operations. The results of the implementation were highly promising:

Error Reduction: The Poka Yoke system eliminated actuator installation errors, removing inefficiencies and, most importantly, the risk of loading the BIN with an open disc and the resulting product loss during the filling phase.
Increased Efficiency: With an optimized assembly process and improved control mechanisms, operators were able to complete installation steps more efficiently, resulting in increased productivity.
Improved Quality: The unique positioning of the actuators improved the overall quality and reliability of the system, minimizing the risk of failures or leaks.

Conclusion: By leveraging the principles of the Poka Yoke solution, our client successfully addressed the assembly challenges and achieved significant improvements in productivity, quality, and operational efficiency. The implementation of the Poka Yoke system highlighted the importance of proactive error prevention in production processes, ultimately contributing to the client’s commitment to advancing health through pharmaceutical innovation.

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