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Several changes have occurred in the manufacturing industry since the post-liberalization after 1991. Original equipment manufacturers (OEMs) dominate the organized sectors. Moreover, companies of all sizes including micro, small and medium (MSME) act as mediators by supporting as Tier-1 and Tier-2 suppliers for these OEMs. The lifting of trade restrictions has been blessing in disguise for both Indian manufacturing industry as well as consumers. In recent times, the Indian subcontinent has seen a paradigm shift in manufacturing culture with the advent of many reputed global brands establishing their manufacturing facilities in India. As a result, India’s manufacturing culture has adopted modern technological tools and techniques in place of traditional manufacturing methods. Component manufacturers have been forced to modify their working cultures to adapt and adjust to the dynamic requirements such as change in material specifications, tolerances and surface treatments like heat treatment, plating etc. The purpose of this case study is to gauge the outcome after the implementation of one of the lean tool: Poka-Yoke. This tool was invented by a Japanese industrial engineer in 1961, who specialized in quality control. He is also known for introducing various quality techniques, such as Just-in-time production (JIT), Single Minute Exchange of Die (SMED), Jidoka (building quality into the process), Kaizen (continues improvement) etc. Poka-yoke technique was applied in a tractor parts manufacturing company that is a Tier-1 supplier for an OEM. Although the company has achieved quality due to sophisticated technology and superior manufacturing capabilities, inadvertent errors due to human mistakes can still occur. This was resolved by changing fixture design, where human mistake is negligible. However, applying poka-yoke helped to eradicate these issues related due to human errors there by leading to reduction in overall customer complaint.
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