Email the author OPTIMIZING CABLE CLIP PLACEMENT WITH A POKA-YOKE APPROACH FOR HIGH-PRECISION AUTOMOTIVE ASSEMBLY
Abstract
In automotive manufacturing, securing plastic cable clips with cable ties might seem like a simple task, but it is critical for wire harness integration. Misalignment can lead to faulty connections, wasted materials, and production slowdowns. This study presents a tool designed to improve the accuracy of clip placement. It uses a mechanical release system with springs and applies Poka-Yoke principles to prevent errors. The goal is to make the process more precise, reliable, and cost-effective. Measurement techniques and coordinate metrology show that the tool can keep placement deviations within 0.5 mm, and in some cases, as low as 0.2 mm. Statistical Process Control (SPC) is introduced for real-time quality tracking, improving efficiency and reducing inspection needs. Flexibility is ensured through rapid prototyping, enabling adaptation to different cable sizes and insulation materials. The study also opens pathways toward full automation of the process.
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