Application of poka-yoke principle in software and implementation of torsion bar rotation control system on cabling machines

The article presents software implementation of Poka‑yoke principle and introduction of torsion bar rotation control system on cabling machines, which can significantly reduce production costs caused by the influence of equipment and human error. The aim of this project is to improve software of cabling machine, allowing to identify hidden defects (including along the length of steel cord) in order to reduce share of technically unavoidable waste at the customer, and to reduce share of non‑conforming products in production. The solutions for improving breakage detection system, introducing additional triggers to eliminate “short‑length” during production of steel cord, reducing amount of non‑conforming products (correctable and non‑correctable), calculating and promptly eliminating machine failures and monitoring unintentional operator errors are considered. During the process software for monitoring and counting length of steel cord and a torsion bar rotation monitoring system were developed and implemented.