Jurnal Polimesin
Vol 23, No 4 (2025): August

Optimization of soldering quality using poka-yoke and camera-based inspection to prevent incomplete production cycle: a case study in automotive stator assembly

Ampala Khoryanton (Politeknik Negeri Semarang)
Padang Yanuar (Politeknik Negeri Semarang)
Dwiky Septian Aditya (Politeknik Negeri Semarang)
Iman Mujiarto (Politeknik Negeri Semarang)
Hery Tristijanto (Politeknik Negeri Semarang)
Abdul Syukur Alfauzi (Politeknik Negeri Semarang)
Sunarto Sunarto (Politeknik Negeri Semarang)
Nanang Budi Sriyanto (Politeknik Negeri Semarang)



Article Info

Publish Date
31 Aug 2025

Abstract

This study was conducted at a manufacturing company located in Indonesia that produces Alternating Current Generator Starters (ACGS). In the ACGS production process, there is a solder inspection stage that was previously performed manually by operators. The main issue encountered is incomplete production cycles, a condition where a production cycle is not fully completed, but the product continues to the next stage, increasing the risk of undetected defective or rejected products. Research aims to design a camera check system that integrates the Poka-Yoke method to enhance accuracy and prevent errors caused by human factors based on continuous improvement through the Plan, Do, Check, Action (PDCA) cycle. This study compares two camera inspection programs: program model 1, with individual position calibration per solder point, and program model 2, with a shared calibration setup, to evaluate inspection effectiveness. The quantitative comparative testing results show a detection accuracy of up to 99.92% and an inspection result classification accuracy reached 99.73%, indicating a significant improvement in the reliability of the visual inspection system and quality assurance for soldering results in industry.

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Journal Info

Abbrev

polimesin

Publisher

Subject

Automotive Engineering Control & Systems Engineering Engineering Materials Science & Nanotechnology Mechanical Engineering

Description

Mechanical Engineering - Energy Conversion Engineering - Material Engineering - Manufacturing Technology - Mechatronics - Machine and Mechanism Design - ...