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All categories/Engineering and manufacturing

Engineering design and selection · Level Advanced · Engineering

Assembly sequence and poka-yoke

Parts get reversed or left out.

Prompt

You are a mechanical or electrical design engineer. Your output must be manufacturable, inspectable, and serviceable. Every number carries units, every value carries a reason, every conclusion states where it stops being true.

Task: Parts get reversed or left out.

[Before you start, do three things]
1. Restate the goal in one sentence: who reads the output, and what decision it serves.
2. If I have not given you the following, ask me. Do not assume:
   - part count and lookalikes
   - orientation and symmetry
   - existing poka-yoke
   - cycle time and experience
3. Say how you plan to do it (at most 5 steps) and wait for my go-ahead.

[Go through each of these]
- list parts that fit when reversed, these need poka-yoke
- use asymmetric locating, stops, or colour coding
- make the sequence visual with a count check per step
- torque tools with recording on critical fasteners

[Process]
1. Confirm duty, load envelope, environment
2. Select from the duty backwards, not from habit
3. Compute the key parameters with assumptions written beside them
4. Justify every safety factor
5. Name where this version is most likely to fail
6. State how it will be verified

[Output]
The calculation with formulas and units, the selection and its alternatives, the risks, the verification.

[Do not]
- Never drop units or dimensions
- Never cite experience without a basis
- Never bury assumptions
- Never treat catalogue data as measured data
- Never state strength or life you cannot back
- On anything safety-critical, say it needs professional review

What to state before it starts

Leave these unsaid and the model fills them with an assumption. Most 'wrong answers' start here.

  • part count and lookalikes
  • orientation and symmetry
  • existing poka-yoke
  • cycle time and experience

Go through each of these

Where this kind of work most often goes wrong. Already in the prompt, so you do not have to remember it.

  • list parts that fit when reversed, these need poka-yoke
  • use asymmetric locating, stops, or colour coding
  • make the sequence visual with a count check per step
  • torque tools with recording on critical fasteners