International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025
p-ISSN: 2395-0072
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Lean Manufacturing through Karakuri Kaizen: Implementation of a Nut Dispenser Mechanism Using Poka-Yoke in the Automotive Industry Kartikaey1, Gurpreet Singh2, Vikas Salotra3, D K Bhalla4 1,2,3 UG Student, Department of Mechanical Engineering, Lingaya’s Vidyapeeth, Faridabad, Haryana, India 4 Professor, Department of Mechanical Engineering, Lingaya’s Vidyapeeth, Faridabad, Haryana, India
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Abstract – This research explores the application of lean
low-cost, high-impact solutions to streamline workflows and reduce operational inefficiencies. By incorporating simple mechanical devices, Karakuri Kaizen facilitates substantial productivity gains and error reductions within the manufacturing process [3]. It has been especially beneficial in sectors such as automotive manufacturing, where affordability and practicality are essential for process optimization [4].
manufacturing techniques in the automotive industry through the development of a Nut Dispenser Mechanism that enhances manual assembly accuracy. Designed using Karakuri Kaizen principles and incorporating Poka-Yoke features, the mechanism addresses common issues associated with manual nut picking, such as incorrect quantities and loose fasteners. The system operates without external power, using a magnetassisted rotating wheel and guided slope to dispense exactly two nuts per cycle.
Another key principle in Lean manufacturing is Poka-Yoke, or mistake-proofing, which aims to eliminate human errors in production systems by designing error-proof mechanisms. These systems automatically prevent potential mistakes, ensuring that production processes remain smooth and defect-free. In the automotive industry, Poka-Yoke is commonly applied to prevent errors such as incorrect component placement, assembly mistakes, and missing parts, thus ensuring higher quality and reducing defects [5]. Recent advancements indicate that the implementation of Poka-Yoke can significantly boost both the operational efficiency and quality in manufacturing environments [6].
After implementation, the average nut picking time reduced from 3 seconds to 1.5 seconds, and loose nut defect cases dropped from four per month to zero. These improvements demonstrate the mechanism’s effectiveness in streamlining workflow, reducing variability, and enhancing product quality. This case study validates the potential of simple, cost-efficient mechanical solutions in achieving lean objectives, offering valuable insights for similar manual assembly processes across industries. Key Words: Lean Manufacturing, Karakuri Kaizen, PokaYoke, Manual Assembly, Automotive Industry, Nut Dispenser
This paper examines the Nut Dispenser Mechanism in the automotive sector, which integrates the principles of both Karakuri Kaizen and Poka-Yoke. The mechanism is designed to automate the process of dispensing small parts, such as nuts, during assembly. The incorporation of Poka-Yoke ensures the correct number of nuts are dispensed each time, thereby preventing errors and minimizing the chances of defects in the final assembly.
1.INTRODUCTION In the context of a highly competitive global marketplace, manufacturing industries—especially those in the automotive sector—are under constant pressure to enhance production efficiency, minimize waste, and improve the overall quality of their products. Lean manufacturing, rooted in the Toyota Production System (TPS), provides an effective framework for achieving these objectives. Lean manufacturing is centered on eliminating waste, optimizing processes, and fostering a culture of continuous improvement (Kaizen), all while empowering employees to participate in the enhancement of operational systems [1]. Numerous recent studies have demonstrated that the successful adoption of Lean principles not only boosts operational efficiency but also helps in reducing costs and improving product quality [2].
The objective of this research is to assess the effectiveness of the Nut Dispenser Mechanism in improving production efficiency, reducing waste, and enhancing overall product quality within automotive manufacturing. By lowering errors and promoting continuous improvement, this study assesses how the combination of Karakuri Kaizen and PokaYoke can help create manufacturing processes that are more dependable and efficient.
2. LITERATURE REVIEW The automotive manufacturing sector is continuously seeking ways to improve operational efficiency, reduce waste, and enhance product quality. Lean manufacturing, a framework derived from the Toyota Production System (TPS), is a widely adopted approach designed to achieve
A significant aspect of Lean manufacturing is Karakuri Kaizen, which involves employing simple mechanical systems to improve production processes without the need for costly automation. This technique emphasizes the use of
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