Validation process of the automatic poka-yoke systems in case of symmetrical objects

Steps of validation of the testing device which integrate two quality testing channels (symmetrical Poka-Yoke system) have been described in this article. System was required for testing correctness of the welds of sheet metal stampings, which can be produced as two different, evenly balanced objects (left – right pieces). Authors attempted to develop the concept and the implementation of double channel Poka-Yoke system in one housing. Main reason for this integration was requirements for saving space and minimizing changeover time. The goal was reached. However the adverse condition that causes an increase in the possibility of making mistakes by service was observed. This condition was eliminated during the optimization process by the changing in construction and logic in the control program of PLC. All of the reasons for that was described in the article. Particular attention was paid to the positioning of the tested elements, optimization of the proximity inductive sensor layout and mistake proof process depended on wrong manipulation of the tested element. Full 3D CAD model of the end conception and physical implementation was shown in the article. The system was developed and still works in the factory.