A

Technical Seminar Report

on

SATRACK

Submitted in partial fulfillment of the requirement for the award of the Degree

of

BACHELOR OF TECHNOLOGY

In

ELECTRONICS AND COMMUNICATION ENGINEERING

By

POREDDY PREETHI (20845A0418)

Under the Guidance of

Mr. VINOD CHAVAN

(Associate Professor)

Department Of Electronics And Communication Engineering

AURORA’S TECHNOLOGICAL&RESEARCH INSTITUTE

(Accredited by NAAC, Affiliated to JNTU, Hyderabad )
Parvathapur,Uppal,Hyderabad-500 098
(2022-2023)
i
 Aurora's Technological and Research Institute
(Accredited by NAAC,Affiliated to JNTU,Hyderabad)
Parvathapur,Uppal,Hyderabad 500098
(2022-23)

CERTIFICATE

This is to certify that the Technical seminar report entitled SATRACK has been
submitted by POREDDY PREETHI bearing roll no 20845A0418 in partial fulfillment
for the award of the degree of Bachelor of Technology in Electronics and Communication
Engineering to the Jawaharlal Nehru Technological University Hyderabad during the
academic year 2022-2023.

Date:

Internal Guide Seminar Coordinator

Mr.VINOD CHAVAN Mrs.N.NIRMALA DEVI
(Associate Professor) (Associate Professor)

Head of the Department Director

Mr. M. Shravan Kumar Reddy Mr. Srikanth Jatla

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 Acknowledgment

I profoundly gratefull to express my deep sense of gratitude and respect towards oue
guide,
Mr . Vinod Chavan, Associate Professor, Department of Electronics and
Communication Engineering, AURORA'S TECHNOLOGICAL AND RESEARCH
INSTITUTE, PARVATHAPUR, for her excellent guidance right from selection of
seminar and her valuable suggestions throughout the seminar work. I am thankful to her
for giving opportunity to work in the laboratory at any time. Her constant encouragement
and support has been the cause for us to success, in completing this seminar in the
college.
She has given us a tremendous support both technical and moral front.

I am thankful to Mrs. N. NIRMALA DEVI, Associate Professor, seminar coordinator

for her valuable suggestions and support in completion of the seminar.

I am thankful to Mr. M. Shravan Kumar Reddy, HOD ECE seminar Review

Committee members for their valuable suggestions and support in completion of the
seminar.

I am thankful to Mr. Srikanth Jatla, Director, AURORA'S TECHNOLOGICAL AND

RESEARCH INSTITUTE for the support during and till the completion of the seminar.

I extend our thanks to College Management for their support and encouragement for the
success of our seminar.

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 Abstract

The origin of the missile can be traced back to the roman war machine the catapult.
The guided missile was born when Werner Von Siemens suggested a guide torpedo
for submarines in the late 19th century. From these beginnings the present day trident
and tomahawk are guided from the skies using the GPS signals. This seminar deals
with the measurement concept that tests the missile accuracy. SATRACK receives,
rebroadcast, records and tracks the satellite signals sent by the GPS signals. The
reception and rebroadcast of the signals is done by a missile hardware called the GPS
translator. The ground telemetry stations consist of the RF antenna and recorders for
the data. Post-flight processing and modelling are done later at the SATRACK
Facility. Also the major error contributors to the missile flight are determined by the
modelling done. There is extensive use of simulated signals in this method. This
seminar also throws light on the major breakthrough technologies that were developed
during the research leading up to the final form of this technology. The major
advantages, disadvantages and future applications of this method is also discussed.
This guidance system evaluation concept is the best in the current test and evaluation
technology for guided weapons systems.

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 INDEX

S. NO Chapters Page No.

1 INTRODUCTION 1
2 GPS SIGNAL 2
3 SATRACK CONCEPT 3
4 MODULES OF SATRACK 5
4.1 GPS Translator 7
4.2 Telemetry Ground Station 7
4.3 Post Flight Tracking and data Processing 7
5 POST FLIGHT TRACKING AND DATA PROCESSING
5 ADVANTAGES
6 APPLICATIONS
7 CONCLUSION 14
8 FUTURE DIRECTION 15
9 REFERENCE 15
LIST OF FIGURES

TITLE PAGE NO
1.1 USB Cable 1
1.2 Cost and Zero defects relationship 3
2.1 Sensing object interrupts light 6
2.2 Vibration Sensor 6
4.1 Poka-Yoke system design 10
5.1 Poka-Yoke in Pluges 12

v
5.2 Poka-Yoke to prevent accidents 12
5.3Poka-Yoke in Valves to prevent back flow of blood 12
5.4 Poka-Yoke in Sockets 13
5.5 Poka-Yoke in Roller Coster 13

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 CHAPTER-1

INTRODUCTION

According to the dictionary guidance is the ‘process of guiding the path of an object
towards a given point, which in general may be moving’. The process of guidance is based
on the position and velocity if the target relative to the guided object. The present day
ballistic missiles are all guided using the global positioning system or GPS.GPS uses
satellites as instruments for sending signals to the missile during flight and to guide it to the
target. SATRACK is a system that was developed to provide an evaluation methodology for
the guidance system of the ballistic missiles.

This was developed as a comprehensive test and evaluation

program to validate the integrated weapons system design for nuclear powered submarines
launched ballistic missiles .This is based on the tracking signals received at the missile from
the GPS satellites. SATRACK has the ability to receive record, rebroadcast and track the
satellite signals. SATRACK facility also has the great advantage that the whole data
obtained from the test flights can be used to obtain a guidance error model. The recorded
data along with the simulation data from the models can produce a comprehensive guidance
error model. This will result in the solution that is the best flight path for the missile.

Fig.1.1 Satellite Missile Tracking

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 CHAPTER-2

GPS SIGNAL

The signals for the GPS satellite navigation are two L-band frequency signals. They can be
called L1 and L2.L1 is at 1575.42 MHz and L2 at 1227.60 MHz.The modulations used for
these GPS signals are

1. Narrow band clear/acquisition code with 2MHz bandwidth

2. Wide band encrypted P code with 20MHz bandwidth.

L1 is modulated using the narrow band C/A code only. This signal will give an accu-racy of
close to a 100m only. L2 is modulated using the P code. This code gives a higher accuracy
close to 10m that is why they are encrypted. The parameters that a GPS signal carries are
latitude, longitude, altitude and time. The modulations applied to each frequency provide
the basis for epoch measurements used to determine the distances to each satellite. Tracking
of the dual frequency GPS signals provides a way to correct measurements from the effect of
refraction through the ionosphere. An alternate frequency L3 at 1381.05MHz was also used
to compensate for the ionospheric effect.

Fig.2.1 GPS signal

2
 Fig.2.2 GPS Satellite signals

For the ranging codes and navigation message to travel from the satellite to the receiver,
they must be modulated onto a carrier wave. In the case of the original GPS design, two
frequencies are utilized; one at 1575.42 MHz (10.23 MHz × 154) called L1; and a second at
1227.60 MHz (10.23 MHz × 120), called L2.
The C/A code is transmitted on the L1 frequency as a 1.023 MHz signal using a bi-phase
shift keying (BPSK) modulation technique. The P(Y)-code is transmitted on both the L1 and
L2 frequencies as a 10.23 MHz signal using the same BPSK modulation, however the P(Y)-
code carrier is in quadrature with the C/A carrier (meaning it is 90° out of phase).
Besides redundancy and increased resistance to jamming, a critical benefit of having two
frequencies transmitted from one satellite is the ability to measure directly, and therefore
remove, the ionospheric delay error for that satellite. Without such a measurement, a GPS
receiver must use a generic model or receive ionospheric corrections from another source
(such as the Wide Area Augmentation System or WAAS). Advances in the technology used
on both the GPS satellites and the GPS receivers has made ionospheric delay the largest
remaining source of error in the signal. A receiver capable of performing this measurement
can be significantly more accurate and is typically referred to as a dual frequency receiver

3
 CHAPTER-3

SATRACK CONCEPT

Guidance system evaluation concept of very early weapons

systems depended on the impact scoring techniques. This means that the missile was shot
and the accuracy was formulated on the scoring or the target destruction. This evaluation
method was unacceptable for evaluating the more precise requirements of the latest systems.
A new methodology was needed that provided insights into the major error contributors
within the flight-test environment. The existing range instrumentation was largely provided
by radar systems. they however did not provide the needed accuracy or range in the broad
ocean test ranges. The accuracy projections needed to be based on the high confidence
understanding of the underlying system parameters. SATRACK was developed with the
necessary hardware and telemetry stations.

The figure shows the SATRACK measurement concept. The main

parts are the GPS satellites, the missile translator and ground telemetry stations. The missile
receives the signals from the GPS satellites. They are translated to another frequency and
relayed to the ground telemetry stations. The telemetry station records the data for playback
and for post processing. The satellite signals received at the missile are translated to S-band
frequencies for the telemetry station using the missile hardware called translators ground
based telemetry station record the data after reception through the antenna after digitising the
signals. Some ground sites uses L1 C/A signals to. ground based telemetry station record the
data after reception through the antenna after digitising the signals. Some ground sites uses
L1 C/A signals to provide real time tracking. uses L1 C/A s

4
SATRACK CONCEPT

Fig.3.1 Satrack Concept

5
 CHAPTER-4

MODULES OF SATRACK

The major modules of SATRACK system are :

 GPS TRANSLATOR

 TELEMETRY GROUND STATION

 POST FLIGHT TRACKING AND DATA PROCESSING

4.1 GPS TRANSLATOR :

This flight hardware is fixed in the missile. The translator receives the GPS
signals and they are amplified, shifted to an intermediate frequency, filtered to cover the
satellite signal modulation bandwidth, shifted to an output frequency. Then they are
amplified for transmission to one or more ground station. The translator does the following

1. Received the satellite signal

2. Translated it to a missile telemetry frequency (S-band)

channels. The user interface is done using windows based PC workstation

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 Fig.4.1.1 GPS Translator

GPS translator are of both Analog and digital types The Analog translators heterodyne the L-band
signal to S-band adds a pilot carrier to allow the monitoring of the reference oscillator variations.
Both wide and narrow band type of Analog translators are used. Digital translators down-convert
the received L-band GPS signal to near base band and digitises it. This digitised data is modulated
into an S-band carrier and transmitted to the ground stations.

FIELD SUPPORT EQUIPMENT

SATRACK is the most useful tool because of its post flight processing facility .The ground
equipment consists of receiving antenna, data recorder and auxiliary reference timing systems. The
equipment receives the translated GPS signal along with other telemetry signals and distributes it to
the data recorder. Most ground stations are capable of generating a precise atomic timing standard.
The earlier equipments were narrowband recorders that

relied on high-speed tape recorders. These gave up to 14 tracks of recording channels with four
mega samples per second. The translator processing system was developed for the national missile
defence exoatmospheric re-entry intercept subsystem where it served as a real-time GPS processor
for range safety as well as data recorder.

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PORTABLE GROUND EQUIPMENT

This hardware is used for the post flight processing and tracking of the satellite signals. The
SATRACK facility processes the raw data into a time series of range and Doppler measurements
for each satellite, and the Kalman filter, which incorporates various corrections and generates a
navigation solution for the missile. The system has undergone a lot of redesign and development as
the requirements evolved with new type of translators and receivers. The latest system processes
the wideband L1/L2 signals dual frequency P-code as required by wide band translators. The
system hardware is based on Analog Device SHARC processor. Most of the custom GPS
processing hardware is based on field programmable gate arrays [FPGA]. Each board has the
ability to track up to eight channels. The user interface is done using windows based PC
workstations.

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 CHAPTER-5

POST FLIGHT TRACKING AND DATA PROCESSING

5.1 POST FLIGHT TRACKING

This is the most important part of the SATRACK technology

Fig.5.1 Basic Satrack Configuration

1. For a number of days surrounding the missile flight, GPS signals are received, tracked, and
recorded at the GPS tracking sites.

2. During the missile flight, GPS signals are received by missile, translated in frequency,
and transmitted to the surface station(s).

9
 3. A tracking antenna at the station receives the missile signals, separates the various
components and records the data.

4. The post-flight process uses the recorded data to give satellite ephemeredes clock
estimates tracked signal-data from the post-flight receiver, and missile guidance sensor
data.

5. After the signal tracking data are corrected, all the data element and the system models are
used by the missile processor to produce the flight test data products.

The figure shows how the post flight tracking facility accomplishes precision tracking of
the GPS signals through the playback of the recorded translator signals. High accuracy
satellite ephemeredes and the clock estimate covering their span of test flight is obtained.
These data along with the processed telemetry data help provide the tracking aids for the
post flight receiver and measurement estimates for the missile processor. The translator
passes signal for all the satellite in view of the missile antenna and the post flight receiver
provides all in view satellite signal tracking. During play back satellite signals are tracked
through delay locked loops

5.2 DATA PROCESING

The post flight processing of the recorded data is used to test the accuracy of the
measurement that is to evaluate the guidance system. The concept can be explained
based on the block diagram given below

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 Fig.5.2 strategic weapons systems accuracy evaluation concept

The procedure was developed by whish the uncertainties with which we observe a
performance as well as the finitude of test programs was translated in to specified
confidence in the accuracy parameters being estimated. Information theory provided the
basis for developing the algorithms that could quantify the confidence with which accuracy
could be estimated. Next performance needed to be known, not just the system level but at
the subsystem level also. The accuracy evaluation program had to be able to isolate faults
and estimate performance of the subsystems or the various phases of the system. Since the
allowable number of test used for the determination of estimates were limited to 10to 20 the
instrumentation had to be of high quality to provide the high confidence measurements
hence to get good confidence estimates. In addition to this, we also needed to extrapolate
the untested condition that is to predict tactical performance with high-quantified
confidence from test data.

Data from each accuracy test was analysed using some variant of the Kalman filter. Within
these filters are the detailed models of both the system and the instrumentation for each
system. The figure depicts how this analysis is accomplished. Given a particular test or
scenario measurement, data are collected on the various subsystems. Using rigorous
methods, these data are collected with prior information generally developed and
maintained by builders of the various parts of the system under test. This prior information
is necessary for the single test processing, given the incomplete observability of the error
sources. The outputs of the filter provide the basis for understanding particular realizations
of system and subsystem behavio sources and causes of the inaccuracy. The results of the

11
multiple tests –the outputs of the Kalman filter –serve as the inputs to the cumulative
parameter estimation process. All prior information regarding the relative error models is
removed so that the estimate accuracy is derived solely from the test data.

Fig.5.3 Reconstruction of source of missile impact miss distance error

The graph shows a hypothetical diagram used to allocate contributions to the impact miss.
this method is based on projecting each error contributor and its uncertainty into impact
domain.

1. first level allocation is at the subsystem level: initial conditions, guidance, and
deployment and re-entry

2. second-level allocation provides data for major error groups within each subsystem eg:
accelerometers

3. third-level allocation (not given in figure) produces estimates of fundamental error terms
of guidance model eg: an accelerometer scale factor.

This process solves the highly non linear equations for the means, variances, and Markov
parameters that characterize the overall system accuracy performance. In addition
uncertainties in the parameter estimates are calculated so that we have a quantitative
measure of our confidence in the solution .The ultimate desired product is system

12
performance under tactical not test conditions. Here we rely heavily on the tactical gravity
and weather conditions developed from data and instrumentation. These models along with
deterministic simulations of the system are then used to propagate the fundamental model
parameter estimates and the uncertainties to the domain of interest-system accuracy at the
target.

The carrier phase tracking of the signals provide the critical measurements .The
measurements of the GPS signal; phase sense range changes along the line of sight for
each signal to a small fraction of the wavelength usually a few millimetres. These
measurements which when compared to their values computed from guidance sensor data
and satellite position and velocity estimates, provide most of the information. Noise in the
measurement of the recovered GPS range code signals is of secondary importance. In
essence, the inertial sensors provide high frequency motion information better than the
signal processes, the Doppler information senses the systematic errors associated with the
inertial sensors and the range data provide an initial condition for all the dynamic
measurements. The range noise remaining after the process of smoothing of the noise is
smaller than the other bias like uncertainties that set the limit on absolute position
accuracy e.g.: the satellite position.

The missile and satellite trajectories including stimulated errors for satellite position and
clocks were used dot drive the satellite signal generators to produce the simulated GPS
signals. These are then passed through digitally controlled phase shifters and time
multiplexing switch to emulate the missile GPS antenna network. This is connected to a
missile translator hardware simulator that produced the GPS signals at S-band. An S-band
antenna hardware simulator produced the outputs, which were recorded by the prototype
telemetry station receiver, and the recording equipment .The hardware simulator drivers
were conditioned to encompass all anticipated effects including signal refraction through
the ionosphere and troposphere. The recorded data were equivalent to the data that would
be received from telemetry site.

The post flight processing facility now has all the inputs, GPS ephemeredes, clock files,
telemetry data and translated signal data tape. These data are then processed and an estimate

13
of the underlying model errors is produced. In addition, the testing of the post processing
system is done by this method.

CHAPTER-6

HARDWARE REQUIREMENTS

The hardware requirements of satrack are :

1. Sharc processor
2. Data simulators
3. Telemetry
4. Satracker

Sharc processor :

The SHARC is unique in that its internal memory is capacble of holding a large program
as well as large amount of data
It is designed for point to point connection
Sharc has 6 link ports that can transport data at high rate

Data simulators :

Data simulation is taking a large amount of data and using it to simulate or mirror real -
world conditions to either predict a future instance , determine the best course of action or
validate a model

Telemetry :

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 Telemetry is an automated communication process by which measurements and other data
monitoring.

Satracker :

1. The highly integrated , self contained asset tracking device including : GPS receiver ,
simplex satellite transmitter , internal battery and antennas packaged in a rugged.

2. The c3 series high security magnetic contacts with trip-biased reeds are highly resistant
to defeat by external magnets . For added security , magnetic field tamper and removal
tamper create an alarm notification

3. Messages on start and stop , engaged interval override on motion for time or motion
duration

Fig.6.1 stracker

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 CHAPTER-7

ADVANTAGES

 Supervisory Position Reporting :

Device wakes up, locates by GPS, transmits location, resumes sleep mode. Up to 12
programmable sleep intervals or wake up settings.

 External Sensors Supported :

Sensors can be Dry contact, Custom Serial, Universal Multimode Sensors (humidity, light,
refrigerated temperature, door, dry contact).

 Integrated Motion Sensor :

Message on start and stop, engage interval override on motion for time or motion duration.

 Geo-Fencing :

Device alarms when it is outside the geographical boundaries set for it.

 Field Programmable :

Configurable using a laptop or PDA

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 CHAPTER-8

APPLICATIONS

1. The best flight path for Aircrafts during post flight processing. Provides
error guidance model.

2. Orbitary Determination of Vehical Tracking.

3. In the Satellite Communication used recorder,guidance system, and

interpeter

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 Fig.1.2:Cost of zero defects relation

1.5 TECHNICAL ASPECTS OF POKA-YOKE METHOD

Poka-Yoke technique can be applied both to prevent causes, which will result in
subsequent occurrences of errors and to carry out inexpensive control, determining
whether to adopt or reject the product. It is not always 100% probability elimination of
all errors, in such cases the task of Poka-Yoke methods is detection as soon as
possible.Analyze the process of product defects formation and its correction. It is
therefore the proposed method for reducing defective products by planning conditions
with requisite solutions in which error may not happen, or will be immediately visible
and captured.Shigeo Shingo has analysed in detail the process formation of defects and
errors from the source to effect. He said that mistake from the producer becomes defect
for the user. It should be therefore a maximum reduced and speed up action coupling
back, and so on :

• As earliest as possible signal error before it becomes the defect.

• Eliminate possibility of the occurrence error (inspection at source, verify the

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POKA -YOKE

conditions under which runs the operation in order to eliminate the possibility of
formation of error).

The Poka-Yoke is a technique for avoiding human error at work. A defect exists in either
of two states,the defect either has already occurred, calling for defect detection, or is about
to occur, calling for defect prediction. Poka-yoke has three basic approaches to prevent or
reduce defects: shutdown, control, and warning. The technique starts by analyzing the
process for potential.

1.6 USES

• Processing errors: Missing a process operation or not performing it according to the

standard operating procedure.
• Setup errors:Setting machine adjustments incorrectly or using the wrong tooling.
• Missing parts:Not all parts included in the assembly,welding or other processes.
• Improper parts/items:Wrong part used in the process.
• Operations errors:Carrying out an operation incorrectly; having the incorrect version
of the specifications.
• Measurement errors:Errors in machine adjustment,test measurement or dimensions of
a part coming in from a supplier.
POKA -YOKE

CHAPTER-2
COMMON DEVICES IN POKA-YOKE SYSTEMS

The common device used in Poka-Yoke systems are:

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1. Guide pin

2. Blinking light and Alarms

3. Limit Switches

4. Proximity switches(sensor)

1. Guide pin:

Guide pins are often used as a means of ensuring the accuracy with which machined parts
are stacked on top of one another. They may also be used as a means of correctly aligning
one component of a two-part system with the other.

The pin may actually come in the form of a bolt with a tapered end or even in the shape
of a bullet with the corresponding piece containing metal or plasticized grommets at
every contact point. The grommets would allow the guide pins to penetrate the secondary
component in order to ensure the accurate configuration of the two parts being put
together.

2. Blinking light and alarm:

Modular design with sturdy housing for all indoor and outdoor applications in tough
conditions wherever machine status needs to be displayed and warning signals given.

3. Limit Switch:

A limit switch is an electromechanical device that consists of a actuator mechanically

linked with a set of contacts. When any object comes into contact with the actuator, the
device operates the contacts to make or break an electrical connection. Limit switches are
used in a different type of applications and environments because of their ruggedness, ease
of installation, and reliability of operation. Limit Switch can determine the presence /

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 POKA -YOKE

absence, passing, positioning, and end of travel of an object. Limit switch were first used to
define the limit of travel of an object; hence the name "Limit Switch".

4. Sensor:

A sensor is a transducer whose purpose is to sense (that is, to detect) some characteristic of
its environs. It detects events or changes in quantities and provides a corresponding output,
generally as an electrical or optical signal; for example, thermocouple converts temperature to an

output voltage.

But a mercury-in-glass thermometer is also a sensor. Sensing devise are traditionally used
in poka-yoke.
i. Physical contact device
ii. Energy sensing device

(a) Photo electric Sensor

The transmitter and receiver of the thru-beam sensor and housed in different cases that are
separated from each other the Emitter(E) Transmits directly to the receiver(R). If object(O)
interrupt the light beam, the receiver voltage drop and function is initiated.The thru-beam
sensor are used to monitor production and packing lines to measure full state .

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POKA -YOKE

fig.2.1 Sensing object interrupts the light

(b) Vibration sensor

Page | 365 (b) Vibration sensor

Despite the advances made in vibration monitoring and analysis equipment, the selection of
sensors and the way they are mounted on a machine remain critical factors in determining
the success of any monitoring program.
Money saved by installing inferior sensors is not a prudent investment since the
information provided about the machine of interest often is not accurate or reliable. Poor
quality sensors can easily give misleading data or, in some cases, cause a critical machine
condition to be completely overloaded.

Fig.2.2 Vibration sensor

CHAPTER-3

TYPES OF POKA-YOKE

7
POKA -YOKE

3.1 Poka-yoke methods :

The Poka-Yoke is an innovative technique for to keep away human error at work. A
defect or imperfection exists in either of two states; the defect either has already occurred
in that case calling for defect detection, or is about to occur in that case calling for defects
prediction. The technique starts by analysing the process for potential problems, identifying
parts by the characteristics of dimension, shape & size and weight, detecting process
deviation from nominal procedures and norms. Depending on the basic functionality Poka-
yoke has three types.

1. Shutdown Poka yoke

2. Control Poka yoke

3. Warning Poka yoke

3.1.1 Shutdown (Prevention) Method:

In shut down i.e. prevention method Poka-yoke devices checks critical process
parameters and shut down the process when a situation moves out of the tolerance zone, it
is indicates of a defective product has either been produced or is about to be produced. That
is well known note that prevention is always better than cure. By implementing shutdown
method we can assure about 100% defect free products. It has 0 % chances to produced
defective products, up to this level we can reliance on it. E.g. Use of fuse in the electric
circuit. When there is an short circuit then fuse is operated and cut down the supply of
electricity resulting in avoiding any further accidents.
3.1.2 Control method:

In control method Poka-yoke devices are regulatory in working which are installed
on process equipment and/or Work pieces which make it impossible to produce defects
and/or to flow a nonconforming product to the next process. As like shut down is an
method control method gives 100% defect free products. The control make certainty that if

8
POKA -YOKE

there is any defect, it is not coming outside the production line and does not reach to the
customer.
E.g. To avoid any wrong job loading in reverse direction on machine we can provide work
rest for the job which will avoid wrong job loading.

3.1.3 Warning (Alert) method:

This is the method which makes the operator conscious about something is going
wrong. The Mechanism or simple idea is generated in such a way that Poka-yoke devices
Indicates or show to a worker that a defects has been produced. When operators get such
warning then he must immediately interfere the process to correct the process responsible
for causing the defect. In case of irresponsible behaviour of operator irrespective of
getting warning notice the next products will continue the same defect and produce
nonconforming products. In short again warning (alert) method depends human nature and
behaviour. It is concluded that alert method gives 30% of the guarantee of good products.
Actually warning method tells about existence of defect but does not assure and does
not produce 100% quality. The common warning method are use of blinking light and use
of beeping sound as alarm alert. e.g. Beeping sound or flashing of light in ATM machine
after removing ATM card from machine to warn operator that he is safe and ensure that
card is not in machine. Once top management decides to implement TPM culture in
organization then to compensate for defect free products successfully one should follow the
methodology of Poka-Yoke.
3.2 USES

Step by Step process in applying poka-yoke:

1. Identify the operation or process.

2. Analyse and understand the ways in which a process can fail.
3.Decide the right Poka-Yoke approach, such as using a,
• Shut out Type: Preventing an error being made or an
• Attention Type: Highlighting that can error has been made.
4.Determine whether a

9
POKA -YOKE

• Contact Method
• Constant Number or Counting Method
• Motion-Sequence Method
5.Trail the method and see if it works.
6. Train the operator, review performance and measurement success.

10
POKA -YOKE

CHAPTER-4

METHODOLOGY OF POKA-YOKE

The methodology of poka-yoke are:

1. Identify Problem
2. Observation at workstation
3. Brainstorming for idea
4. Select best idea
5. Implementation plan and implementation
6. Monitor and sign off

Step 1: Identify problem

In this stage the complaints coming from the customers (Both internal and external
customer) are collected. The principle of standard is determined by considering various
criteria’s like number of complaints from the customer& PDI( pre dispatch classify), the
quantity of defects detected by quality control, materiality defects (their impact on the
customer, costs, implemented process) and then data is collected broadly. As per analysis
all results of the collected data company plans for developing poka -yoke system for the
selected problem.
In this way in first stage the problem is selected.

Step 2: Observation at work stations

In this step the actual on site study of the problem is carried out. The causes behind the
problem are sort out by using fishbone diagram (fishbone diagram is cause and effect
diagram given by Japans management guru Ishikawa).The causes may be related to man
skill, machine, material or method accordingly the complete sorting is carried out.

11
POKA -YOKE

Step 3: Brainstorming for Idea

This is a technique to capture all creativity and skills of employee’s. In brainstorming

session the problem under study is put forward to committee. Then study problem given by
all members and give various solutions to avoid that defect. As each person has one
uniqueness this step concludes with various solutions to avoid that defect. As each person
has one uniqueness this step conducts with various alternative for some problem.

Step 4: Select best ideas

After getting all various alternative solutions it is time to select best one out of all collected
solutions. Criteria for selection may be cost, problem create after istallation, time required,
changes in existing system, opportunity to develop new solutions, simplicity in operation
etc. By referring all selection criteria’s committee concludes With one best solution.

Step 5: Implementation plan and implementation

This step is concerned with implementation planning& installation. It deals with material
requirement, processing the material and finally manufactured mechanism is implemented
at actual working site.

Step 6: Monitoring and sign off

The produced products are checked for defects under study also the performance of poka-
yoke system is also monitored and project is shut downed.

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fig-4.1 Poka-yoke System design

4.2 Methods Of Obtaining Poka Yoke

Poka yoke ideas are simple but creative in operation and generation. According to
Shingo [Shingo,1986],"Defects will never be reduced if the workers involved do not
modify operating methods when defects occur."

Following are some of the simple ideas (hints) to avoid mistakes: -

1) Using Shapes and Colors

2) Software Warnings and Reminders
3) Using Dialogue Boxes and Software Checks
4) Using Switches and Automatic Braking
5) Using Checklists
6) Visual Prevention Methods

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7) Using Lights, Sounds, Signs and Barriers Etc.

CHAPTER-5

CHALLENGES AND LIMITATIONS OF POKA YOKE

5.1 Challenges and Limitations of Poka Yoke

As per up till discussion in the paper it seems that poka yoke is one of the best tool in total

quality management but we have to think about the obstacles and challenges against poka yoke.
1. Practical implementation of the mechanism or solution is not possible.
2. Process parameters don’t allow changing the existing system.
3. Sometimes the poka yoke is not cost effective.
4. Interdepartmental relations between production and quality depth are not good so
each one think that I don’t have to do anything with that issue.
5. Now also we are depending on statistical process control.
6. Expert advice is needed for new creative and challenging tasks .It may happen that
experts are not available with small scale industries and expert advice is not
economical for their financial health.

5.2 Examples of Poka Yoke

1. Spindle of CNC machine starts only after closing the safety door. If door is open
then machine will not run. It is shut down poka yoke to avoid accidents.
2. The guide pins are used in stamping dies for correct alignment of upper and lower
portion. If there is improper matching assembly of dies will not take place. It is shut
down poka yoke.
3. If we want to close any file in operating software (e.g. Microsoft Word) it asks for
save it or cancel dialogue box. This is warning system against by mistake closing of
file. It is warning poka yoke. corresponding pin in opposite or wrong way. It is
control poka yoke system.

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4. To avoid parallax error in reading the measuring instrument small mirror is placed
below the moving pointer. By referring pointer and its mirror image we can take
proper reading. It is warning poka yoke.
5. The socket for USB on the computer is designed in such a way that we can’t connect
pen drive or any corresponding pin in opposite or wrong way. It is control poka
yoke system.

6. Pressure relief valves are used in hydraulic circuit to prevent damage to system due
to high pressure. In case of high pressure the excess oil bleed off through check
valve to the reservoir. It is control poka yoke system.
7. Check list is used to confirm that all sub components in assembly are assembled.
It is control poka yoke system.

Eg.5.1.Poka yoke in these pluges ensure

they can enter only in a certain way

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Eg.5.2 This form mistake-proofing helps

Prevent accidents

Eg.5.3 Valves are an error-proofing example in nature that

Prevent back-flow of blood

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Eg.5.4.This electric socket has used poka yoke in a cover to make it child-proof

Eg.5.5 Roller coasters have error-proofing devices for safety

CONCLUSION :

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To err is human nature so we can’t blame human being for each and every mistake. As like
err, Intelligence is also human nature so we can dominate preceding nature by next nature.
Poka yoke is just a face of that intelligence. We can avoid all the mistakes at the source
itself by using above mentioned methodology. About mistake proofing we can say that it is
a system for organizing work that eliminates any chances of error by new user is also. It
also allow user to function without mistake or prevent error that are about to occur. In
order to implement quality management system successfully each activity should aim
towards excellence.
Poka yoke is one of the most important tools in TQM (total quality management).
Efficacious poka yoke results in increased productivity with minimum waste (waste due to
rework, scraps) because we are sure about the quality of product, as mistakes are blocked at
source itself. There may be any practical limitations in poka yoke but we have to overcome
all that for achieving the aim of product manufacturing “Fault, Waste & Delay” all of them
zero. In one decision Poka-yoke (Mistake proofing) is launching preventive actions for
systematic movement on the success ladder of QMS with higher level of performance and
productivity of system with high quality products at minimum cost.

FUTURE SCOPE :

The response to the questionnaire may be limited by respondent’s knowledge about poka-
yoke. The person who has extensive knowledge about poka-yoke could only provide
correct response to the questionnaire; else, the outcome will be unreliable input data/poor
response rate. Despite these limitations, this study will provide a foundation to trigger
furthering poka- yoke research. Further research in this area is needed to develop suitable
training programs to teach poka-yoke concepts, train the employees, and transform them as
lean thinkers. This would help to foresee the firm’s operations, learn to recognize the
value-added and non- value-added activities. This new proposal has to be effectively
implemented, not only to industries, but also to reach the minds of young engineers.
REFERENCES

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[1]. M. Dudek-Burlikowska*, D. Szewieczek, “The Poka-Yoke method as an improving

quality tool of operations in the process”; Journal of Achievements in Materials and
Manufacturing Engineering VOLUME 36ISSUE 1 September 2009

[2]. StewartAnderson,“Poka-Yoke: Mistake-Proofing as a Preventive Action”; THE

INFORMED Outlook Reprint: March 2002Volume7, Number 3

[3]. PAUL DVORAK Senior Editor; “Poka-yoke designs make assemblies mistake proof”;
http://www.penton.com/md MARCH 10, 1998MACHINE DESIGN

[4]. John R. Grout, and Brian T. Downs; “A Brief Tutorial on Mistake-proofing, Poka-
Yoke, and ZQC”; Lean Business Solutions UnitedStates

[5]. “Lean Six Sigma Operational - Delegate Workbook”; Mistake Proofing techniques;
The British Standards Institution; SSG06101ENUK - MP/Issue 1.1/ September 2008

[6]. Anil S. Badiger, R.Gandhinathan, V. N. Gaitonde, Rajesh S. Jangaler “Implementation

of Kaizen and Poka-yoke to Enhance Overall Equipment Performance - A case study”

[7]. Spath P L. Reducing errors through work system improvements. In: Spath PL, ed.
Error reduction in health care.Chicago: AHA Press, 2000. 202

[8]. Senders J W, Senders S J. Failure mode and effects analysis in medicine. In: Cohen
MR, ed. Medication errors: causes, prevention, and risk management. Sudbury, MA:
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[9]. Anon Word Net Search 2.1. Word net.Princeton.Edu/Perl/web

[10]. Ulrich K T, Eppinger S D. Product design and development. 2nd ed. Boston: Irwin
McGraw‐Hill, 1995

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