POKAYOKE

RAKESHAMBRE04319401 L.SUNDARAVALLI04419801

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Presentationplan

Introduction WhatisMistakeProofing? ClassificationsbyDr.ShigeoShingo ZQCVs.SPC CasereportPushbuttons ClassificationsofPokayokedevices EverydayExamples CharacteristicsofgoodPokayoke devices Pokayokeinsoftware Conclusions
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Introduction

PronouncedasPOHkahYOHkay PokayokeistheJapanesewordformistake proofing Discriminationbetweenmistakesanddefects Mechanismthatpreventsamistakefrombeing madewhichisobviousataglance. Examples: Pushbuttons Weldingnutsintopanels

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TOERRISHUMANNATURE BUT INTELLIGENCEISALSOHUMAN NATURE SO NEVERSTOP,FINDINGWAYSOF NOTMAKINGMISTAKES

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POKAYOKE(MistakeProofing)
CAUSES
DISTRACTION CONFUSION LACKOF PRACTICE UNCERTAINTY
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EFFECTS
DEFECTS (QUALITY) INATTENTION ERROR INSUFFICIENT NUMBER (QUANTITY) ACCIDENTS (SAFETY) WORKDELAY
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NoSystemofBarriersisPerfect
Error

Harm
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NoSystemofBarriersisPerfect Butimprovementscanbemade
Error Error

Harm
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Harm
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WHATISMISTAKEPROOFING
ASYSTEMForOrganizingWorkthat

Excludesanyriskoferrorevenbythe beginner

Allowseveryonetooperatewithoutmistake Preventserrorthatareabouttooccur

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ClassificationsbyDr.ShigeoShingo

Judgmentinspection

Inspectioninquality Usesdatagainedfrominspectiontocontrol theprocessandpreventdefects.Examples: TraditionalSPCandrepeatedchecksandself checksinZQC Beforethefactatsource,beforereaching customerorForcingfunction

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Informativeinspection

Sourceinspection

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ZQCVs.SPC

"...alookatSPCmethodsastheyare actuallyappliedshowsthatfeedbackand correctiveactionthecrucialaspectsof informativeinspectionsaretooslowtobe fullyeffective." PokaYoketechniquestocorrectmistakes+ Sourceinspectiontopreventmistakes= ZQC

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Continued

ZQCisnotaseffectiveasSPCfordefects thatresultfromvarianceinmeasurementdata ZQC is a special case of SPC for defects that resultfromvarianceinattributedata. ZQC'ssourceinspectioncanbeusedeffectively toeliminatemistakesandinconjunctionwithSPC toeliminatetherecurrenceofspecialcauses.

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CaseReportPushbuttons

Inthe old method, a worker beganbytaking two springs out of a large parts box and then assembledaswitch. In the new approach, a small dish is placed in frontofthepartsboxandtheworker'sfirsttaskis totaketwospringsoutoftheboxandplacethem on the dish. Then the worker assembles the switch.Ifanyspringremainsonthedish,thenthe worker knows that he or she has forgotten to insertit.
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PokaYokedevices

Apreventiondeviceengineerstheprocess sothatitisimpossibletomakeamistake atall.

A3.5inchcomputerdiskette

Adetectiondevicesignalstheuserwhena mistakehasbeenmade,sothattheuser canquicklycorrecttheproblem

Smalldishforpushbuttons

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EverydayExamples

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Whichdialturnsontheburner?

StoveA

StoveB

Otherexamples

Preventiondevices

Microwaves Washingmachines Centrallockinginmoderncars Keylocksinmobiles Refrigerators Messaginginmostsoftwares Beepsinautomobilesifkeyisleftinignition

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Detectiondevices

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CharacteristicsofPokaYoke devices

Simpleandcheap Partoftheprocess,permitting100%inspection Placedclosetowherethemistakesoccur, providingquickfeedback. Designedtostopaparticularmistake Adetectiondevicecannotprovideacomplete errorproofsolution Necessaryandnotasufficientsolution

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CommonMistakeproofingDevices

GuidePins Blinkinglightsandalarms Limitswitches Proximityswitches Counters Checklists

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PokaYokeinsoftware
Preventiondevices

Developmentofprogramminglanguages Softwaretesting

Detectiondevices

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Conclusions:

Thinksimple Thinkspecific Thinkattributes Thinkearly Thinkresponsive Thinkreuse

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THANKYOU

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