Information
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Document No.
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POKAYOKE CHECK SHEET
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TOYOTA MOTOR MANUFACTURING MISSISSIPPI
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Conducted on
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Prepared by
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Personnel
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GROUP:
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QCPS#:
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PROCESS:
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CHECKED BY:
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Select date
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PSET
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START
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1st TARGET
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LOW
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TARGET
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HIGH
TOOL CAPABILITY
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PSI (at regulator) -
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COMMENT:
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RANK A / ¥ Cpk => 2.0 or 1.3 (Rank B Cpk => 1.0)
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COMMENT:
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Tool in use matches QCPS
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COMMENT:
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Tool shuts off when torque is achieved ( hold trigger until green)
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COMMENT:
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Back up tool matches QCPS
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COMMENT:
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Controller dynamic value => target or cut
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COMMENT:
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Reverse disabled
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COMMENT:
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Target tool settings match Dynamic Torque
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COMMENT:
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MIN =. +1 = Target or Cut : MAX :
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COMMENT:
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Parameter Set Up Sheet & Tool Change Record (b)
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COMMENT:
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Angle MAX : $ MIN : Settings
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COMMENT:
AVI / PNC
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PI box labeled with correct node address & tool ID
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COMMENT:
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POKAYOKE operates correctly under normal conditions ( Stack light turns green with correct # of individual OK)
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COMMENT:
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PSET running matches POKAYOKE program for katashiki
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COMMENT:
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Resets after crossing L-10 or when next part is present (Green stack light goes off, Orange turns on)
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COMMENT:
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ANDON comes on correctly (approx. 70% yellow & red at line stop)
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COMMENT:
ANDON/FAULTS (N=2) - (Use Back page for multiple programs)
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Low torque - turns red beacon & stops line at end of pitch.
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COMMENT
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Low torque-turns on red beacon & stops line at end of pitch.
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COMMENT:
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Incorrect number turns on red light at judge point & stops line.
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COMMENT:
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Incorrect number turns on red light at judge point & stops line.
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COMMENT:
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Correct number of QLLS clicks release line.
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COMMENT:
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Correct number of QLLS clicks releases line.
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COMMENT:
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Tool does not pass on a REHIT.
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COMMENT:
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Tool does not pass on a REHIT.
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COMMENT:
PROCESS SETUP
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QLLS Registers in QIS as NGO - all items backup comp
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COMMENT:
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QLLS registers as a defect in CIS (list defect name)
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COMMENT:
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Next process cannot be started until next car crosses L-10 or next part is placed on/in sub assembly process.
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COMMENT:
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Tool / QLLS /QLLS cannot go outside L-10
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COMMENT:
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No part / wrong part selection ( interlock confirmation)
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COMMENT:
BYPASS KEY SWITCH
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Bypass key not present in switch ( only in possession of GL
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COMMENT:
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Red beacon comes on and registers in CIS as POKAYOKE Bypass when INTERLOCK OFF (back key)
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COMMENT:
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When forced complete?
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COMMENT:
GREEN BEACON
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Light goes solid green when process judgement is OK
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COMMENT:
TRUTH TABLE CONFIRMED
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All models programmed
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COMMENT:
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Model Year Updated
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COMMENT:
DOCUMENTATION CONFIRMATION
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DELTA C CONTROL CHART & notebook, MIS & QCPS revised (a)
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COMMENT:
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QLLS/QL setting confirmed (daily click wrench check sheet) (c)
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COMMENT:
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Abnormality check (pokayoke abnormality check repair log ) (d)
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COMMENT:
SIGNATURES
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Responsible Engineer
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TEMA Representative
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Production Representative
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Responsible Engineer
