power partners, inc de-mold pokayoke. © 2015 power partners, inc t:706.548.3121 process overview...

Power Partners, Inc

De-mold Pokayoke

© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com

Process Overview

• Power Partners in Athens, GA makes transformers

• Transformers utilize coils of conductor that are wound around aluminum molds

• After the coils are wound, the molds must be pressed out to make room to insert the cores

MoldsMolds

Cores go here after tooling is removed


Process Overview (continued)

• To remove the tooling, coils are slid onto this arbor

• Parts of the arbor expand to clamp the coil in place

• Rods extend out just above and below the arbor to press tooling out


Before State• After the top and bottom

tooling is removed, the coil drops and rests on top of the arbor until removed

• On occasion, an operator would become distracted and start the machine before removing the coil

• This would cause the rod to drive into the coil ruining it


Pokayoke Idea • A raised “rail” was added

to the center of the arbor on each side

• The mold plates had a groove cut to match the rail in the Arbor

• With the new design, the coil now suspends itself after the top/bottom material was removed


Pokayoke Effect• Now, if the machine is

accidentally cycled again the rods simply glide past the coils where the molds were previously

• This makes it impossible to damage the coil by striking it with the rods

• All work was done in house by our Maintenance Team and one of our Process Engineers

power partners, inc de-mold pokayoke. © 2015 power partners, inc t:706.548.3121 process overview...

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