Professional Documents
Culture Documents
Poka Yoke
Poka Yoke
8:30--
JIT
KANBAN POKA-YOKE
QCC P Q
TQM C
TPM D
KAIZEN
Suggestion Scheme
Collecting data Analyzing data Finding problem Countermeasure Implementation Checking result
Technological Process
by K. Takemura
PRACTEC.PPT
-9:00
Method of KAIZEN
9:15
POKA-YOKE
Mankind is an animal which makes mistake
Which idea do you take ?
Admitting( affirm ) mistake and hating( deny ) those who made mistake.
Hating( deny ) mistake and admitting( affirm ) those who made mistake.
9:30
Type of POKA
1. POKA by Carelessness 2. POKA by misunderstanding 3. POKA by brief look 4. POKA by novice ( amateur ) 5. POKA by selfishness 6. POKA by dull-witted 7. POKA by irresponsibility 8. POKA by mal function 9. POKA on purpose
Countermeasures
Periodical confirmation and in advance. Confirmation by call. Confirmation in advance. Meeting. Operation standard Meeting. Caution. Confirmation by call. Training. Operation standard. Basic education on self-discipline and custom. Training. Standard work. Instructions on the job. Standard work T otal Productive M aintenance (TPM) Standard work Basic training on discipline
-9:40
tytsys16.doc
9:40--
1) Wares cant be fixed to the jig in case of wrong work. 2) A machine doesnt start processing in case the wares is something wrong. 3) A machine doesnt start processing in case of miss-work. 4) A machine proceeds processing after correcting miss work or miss-operation automatically. 5) A following process checks the results of preceding process and stop processing in case of wrong wares. 6) A following process doesnt start in case there were missing works.
Jig system
Give ideas to jigs so that wrong wares cant be fixed Or processing doesnt start in case of miss-fixing
Automatic system
A machine stops autoMatically in case of wrong processing
10:00
Type of POKA
Type of POKA Real Cause
1, 2,3 3,15 3,4,8,10,12,15,17 5,6,10 5,6,7,9,10,14 5,10,16 5.6,11 5,6,10 11,12,13 4,5,6,10,12,17 4, 10, 17,18,19 4,10,12,16,17,20
Wrong Assembly or Processing Wrong Work-set Wrong ( Foreign) Parts assembly Wrong amount in number Missing Assembly or Processing Missing Parts at assembly or processing Mistake of operation Missing parts Wrong setting of arrangement Mistake of parts Mistake of indication Mixing of foreign parts
Inverse setting of up/ down, right/left and inside/outside due to the similar or symmetrical shape.
No system for breaking away from the position at the time of rest, interruption and other job. Imperfect system of transfer of the job at the time of shift change. Operator does his job as he like and forgets
Only the person in charge knows parts and jigs storage yard. Then, helpers make mistake. No system to stop the work to flow to the next process in case of missing assembly or processing The letters of indication or drawing are small or thin, therefore miss-reading takes place. Operating conditions such as temperature, humidity, and pressure etc., differ. Then, mistake happens. Mistake of parts and material because of similar shape, size and color.
Difficult to detect missing parts and process because of so many parts and works. Operator does his job and takes parts at his convenience because no rule for stock yard. No system to stop the works in inner process when defective products happen. No fixed storage yard of parts and products. The amount is not constant and missing. Recording and counting of lot No. of indication is done by just memory. Indications, such as Labels and cases, are similar in size and color.
10:30 Break
Assembly of corrugated cartons and labeling are done by lot because of shipping information in mass.
Mechanism of POKA-YOKE
Stop on abnormality
10:20-
Stop
Prediction alarm
A defective product
Control
Stop on failure
POKAYOKE
Detection on occurrence
( Happened ! )
Alarm
Flow control
Devices Situation
Alarm on occurrence
2) by Dimension Method
Set standard by dimension such as length, height, thickness and diameter, and then detect defective one by comparison with the standard.
Good product
Nut
Stop!
Defective product
3) by Shape Method
Set standard of correct article by making use of distinctive shape such as, hole, edge, projection, bend or quality of material, then detect defective one by comparison with the standard.
Defective product
Good product Selection arm Defective product Next process Correct product
Blanking
Corner cutting
Bending
Welding
Buzzer
Touching Sensor
Parts Box
Prepare one set of parts in a box, and pick up one by one , assemble in numerical order.
A B C D E F G H I
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Correct
Failure !
N sets
PK-YK4.PPT
-10:40
Air pressure, Temperature, Oil level, Thickness Electric current, Voltage -----etc.
After KAIZEN
After KAIZEN
work Nut
Shield plate
Work
work
Heating coil
Foot switch
Micro switch
Before KAIZEN A operator makes hole by counting number. Then, mistake of number of hole happens.
Wrong work
Correct work
Before KAIZEN It was decided in standard to let the drill go through, however, sometimes an operator draws the drill back before enough penetration. The operator judged the timing of drill draw-back by intuition. Therefore wrong holes were found sometimes in assembly.
L/S1
Buzzer
L/S
4. Missing parts
Theme Problem Prevention of missing insert parts in assembly process After die casting an insert part has to be attached, however, missing of the part takes place often. In spite of total inspection by full-time inspector, the company still gets claims by customers for missing the parts.
Before KAIZEN Insert part was often missing, and the work was sent to following process. After KAIZEN A sensor was attached in bar removal pressing process after die casting to detect insert parts. In case insert was missing, the machine did not work and at the same time buzzer made alarming. Press Cross section of the work Sensor Missing !! Insert parts Die
After KAIZEN
A B C D Panel E F G H I J K L
Request
L
B A
C D E F G H
K J I
Rotating Rack
11:15--
Tightening terminals
Lets be creative!!
Takemuras advice
1. Lets have flexible mind. 2. Curiosity is the driving power of creativity. 3. Make your own tools/methods for developing idea. 4. Concentrate to make idea (by hands) then ideas will visit you. 5. Be prepared to record ideas. 6. Lets be positive all ways.
Xin cam on !
Th ch
Ma
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n
gn ify ?
t? ap Ad
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M in if y
e? Rearrang
? se r e Rev
e bin m Co
Eliminate ?
+ KAIZEN=VJCC +
X
C : loi b, dng
= +/-
IE
TPM
JIT
Layout Impvmt Unit Consu. Yield Ratio VE/ VA Daily Control Product Control
P,C P,C C P P Q P,C P,C,D C,D P,C,D P,C,D C C C C C C C C P,C,D C,D D D,C
Improvement of Job Method Efficient Man Power Elimination of Muda in Material Improvement of Operational Ratio Improvement of Machine Efficiency Good Quality with machine Capable Operator for machine Production System for Small Lot Reduction of WIP Layout Change Steps for layout improvement What is Unit Consumption Production Cost by Process Elimination of Muda in Material Material Change New Idea for Product Development Summary of Product Performance Design with Cost Consciousness Plan for Cost Reduction Variation of WIP Term in Process Clear Process Progress Standard Process Schedule Note: Note: P: P: Production Production C: C: Cost Cost D: D: Delivery Delivery
Productivity Improvement
JIT
3 Elements in Standard
Big Category
KANBAN System
Middle Category