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MSAI 04 - Jidoka
MSAI 04 - Jidoka
Manufacturing systems
analysis and improvement
Jidoka (Autonomation, according to Ohno)
Jidoka
Autonomation Automation with a human touch (Ohno)
Machines can work autonomously, not in the sense of their capacity
to work unattended, but in the sense of being able to stop in the
case of abnormal conditions
Safety devices
Mistake-proofing systems
http://www.lean.org/lexicon/jidoka
POKA YOKE
Poka-Yoke
The Poka Yoke concept was developed by Shigueo
Shingo in order to improve inspection activities and
guarantee 100% quality in manufactured parts leading to
processes that would produce Zero Defects
It refers to physical and visual tools that are used to avoid
errors, thus reducing defect rates and improving the
efficiency of all equipment.
Should be used in conjunction with inspection at the
source in order for both techniques to be effective.
Defects
There are 2 attitudes for dealing with defects
Error Safeguard
1. Forgetfulness Alerting operators or review at regular intervals
2. Errors due to lack of knowledge Training, early verification, process standardization
3. Identification errors Training, attention and vigilance
4. Errors due to lack of experience Training, standardization of work
5. Voluntary errors Basic education and experience
6. Distraction caused errors Attention, discipline, work standardization
7. Errors due to slow processing Training, standardization of work
8. Errors due to lack of standards Standardization of work, work instructions
9. Lack of maintenance Total Productive Maintenance, standardization of work
10. Intentional errors Fundamental education, discipline
Poka-Yoke
Causal relationships between human errors and defects
Distraction
Intentional
experience
Lack of
identification
No
Voluntary
Slowness
ness
Forgetful
maintenance
Lack of
Surprise
knowledge
Lack of
Human error
Causes of defects
Omitted process
Process errors
Errors while mounting parts in
machines Connection
strong
Omitted parts
Wrong parts
Connection
Processing wrong parts
Faulty operation
Adjustment error
Equipment not properly
mounted
Badly prepared tools and
templates
Source: Shimbun, N. K., (1991) Poka-Yoke: Improving product quality by avoiding the defects,
Ed. Technology and Production Management
Defect prevention with Poka Yoke
Most human errors occur through carelessness or
distraction.
Poka-yoke mechanisms help build quality into the process
and avoid defects even when careless mistakes are made
Useful examples of poka-yoke
Guiding blocks of different sizes
Error detection and alarms
Limit and correct placement switches
Counters
Checklists
Defect prevention with Poka Yoke
Defect prevention with Poka Yoke
Defect prevention with Poka Yoke
A defect can be in two states:
About to happen
Already occurred
The basic functions of poka-yoke are stoppage, control
and alarm
State Function Poka-Yoke
Stop For normal functions when It produces a defect
Before it
occurs Control Make even intentional errors impossible
(Prevention) Points out errors / anomalies when they are
Alarm about to happen
Defect
Stop For normal functions when It produces a defect
Occurred Defective parts can not move to the next
Control process
(Detection)
Alarm Says the occurrence of defects
Defect prevention with Poka Yoke
Videos
https://www.youtube.com/watch?v=RdhJ5RQA8cU
https://www.youtube.com/watch?v=TRbC9TjFdhU
http://www.dailymotion.com/video/x1sbg34_poka-yoke-
system_webcam
http://www.dailymotion.com/video/x2vi1iy
Prevention of defects with Poka Yoke
8 basic principles for improvement using Poka-Yoke and
Zero Defects
1. Build quality into processes
2. Eliminate all errors and defects by distraction
3. Interrupting the wrong practice and start doing the right one now!
4. Do not think of excuses, think of how to do it right
5. 60% chance of success is good enough, implement the idea!
6. Mistakes and defects can be reduced to zero if all work together
to remove them
7. Ten heads are better than one
8. Investigate the root cause using the 5 questions: What, How,
When, Where, Why
FIXED-POSITION STOP
SYSTEM, 5 WHYS AND
ANDON
Fixed-Position Stop System
Remember that in a typical mass production system:
http://www.lean.org/lexicon/fixed-position-stop-system
5 Whys (Root cause analysis)
Why did the machine stop?
There was an overload and the fuse burned
Examples:
GOOD: Customer received a part with a broken mounting pad
NOT: Customer received a part that was broken due to improper
machining
WHY?
Sensor was
damaged
WHY?
No system to
assure sensors
are
This is still a systemic failure working properly
& needs to be addressed,
but its not the root cause
of the lack of detection.
Other Root Cause Analysis tools
Ishikawa (bonefish diagram)
4W2H
What?
Where?
Why?
When?
How?
How often?
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