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Poka Yoke PDF
Poka Yoke PDF
(Mistake Proofing)
1
Scope of Presentation
Introduction
Defects & Costs
Waste Management
Zero Defect Quality ( ZDQ)
Understanding Process Errors
Four Elements of ZDQ
Seven Steps To Poka-Yoke Attainment
Poka-Yoke Methods
Summary
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Why is “Zero Defects” an
Important Concept?
3
Why Kaizen
SIX SIGMA
Process
Improvement • Data Driven Methodology to Magnify Impact of
Project
Implemented Process Improvement
Savings
Maintenance
Kaizen
Kaizen Time
Savings
• Use Small Teams to Optimize Process CPI
Performance by Implementing Incremental Change
• Apply Intellectual Capital of Team Members Intimate
with Process Kaizen Projects
Emphasize Incremental
Improvements Time 4
Why is “Zero Defects” an
Important Concept?
Maintain Customer Satisfaction & Loyalty
5
Why is “Zero Defects” an
Important Concept?
COST
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Costs of Defects ?
$1000
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Introduction
Defects & Costs
Waste Management
Zero Defect Quality ( ZDQ)
Understanding Process Errors
Four Elements of ZDQ
Seven Steps to Poka-Yoke Attainment
Poka-Yoke Methods
Summary
9
Why is “Zero Defects” an
Important Concept?
Everything we do that
costs something without
adding value to the product
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The nine types of waste
Overproduction 9
Delays (waiting time) Wastes
Transportation
Process
Inventories
Motions
Defective products
Untapped resources
Misused resources
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Elimination of Waste
The Method
Identify
waste
Implement
continuous
improvement
13
Elimination of Wastes and
Continuous Improvement
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What is a Zero Defect Quality
System (ZDQ)?
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What is a Zero Defect Quality
System (ZDQ)?
No Finger Pointing.
Operators and Machines
will sometimes make
mistakes.
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What is a Zero Defect Quality
System (ZDQ)?
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How ZDQ Makes Work Easier
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How ZDQ Makes Work Easier
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How Do We Achieve ZDQ ?
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Poka-Yoke results in Quality of
Processes
Inspection….eliminated ???
Transport
Dedicated lines
Storage
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Relationship between processes and quality defects.
And
Reduce the
variation of the process
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What Causes Defects?
Process Variation From
1. Poor procedures or standards.
2. Machines.
3. Non-conforming material.
4. Worn tooling.
5. Human Mistakes.
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What Causes Defects?
Human Mistakes
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Ten Types of Human Mistakes
Forgetfulness
Misunderstanding
Wrong identification
Lack of experience
Willful (ignoring rules or procedure)
Inadvertent or sloppiness
Slowliness
Lack of standardization
Surprise (unexpected machine operation, etc.)
Intentional (sabotage)
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Relationship of Defects & Human error
Relationship of Defects and Human Errors
Misunderstanding
Non-supervision
Misidentification
Human errors
Inadvertant
Intentional
Amateurs
Slowness
Forgetful
Surprise
Willful
Causes of defects
Missed operations
Processing errors
Missing parts
Wrong parts
Misoperation
Adjustment error
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highly correlated correlated
The 4 Components of ZDQ
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Inspection
Detect Error
By combining Check and Do in the
ZDQ approach; the Doing is controlled Feedback/Corrective Action
so it cannot be wrong 100% of the time!
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ZDQ/Check and Do/Point of Origin
Inspection
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100% Audit Checks
Point of Origin Inspection on every piece.
The second of the 4 basic elements of ZDQ.
Differs from SQC inspection:
Does not rely on sampling Zero Defects
Prevents defects
Does not assume defects will statistically occur
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Quick Feedback
Error correction as soon as possible
The third of the 4 basic elements of ZDQ.
Differs from traditional inspection approaches that:
Correct problems after the process
Address the problem when errors are already defects
In some cases never identify an error has occurred
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The Seven Guidelines to Poka- Yoke Attainment
1.) Quality Processes - Design “Robust” quality processes to achieve zero defects.
2.) Utilize a Team Environment- leverage the teams knowledge,experience to
enhance the improvement efforts.
3.) Elimination of Errors -Utilize a robust problem solving methodology to drive
defects towards zero.
4.) Eliminate the “Root Cause” of The Errors-Use the 5 Why’s and 2 H’s approach
5.) Do It Right The First Time- Utilizing resources to perform functions correctly the
“first” time.
6.) Eliminate Non-Value Added Decisions- Don’t make excuses-just do it !
7.) Implement an Incremental Continual Improvement Approach-implement
improvement actions immediately and focus on incremental improvements; efforts do
not have to result in a 100% improvement immediately.
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Poka-yoke
Mistake-proofing systems
The fourth of the 4 basic elements of ZDQ.
“The machine shut
Does not rely on operators catching mistakes down. We must have
made an error!”
Inexpensive Point of Origin inspection
Quick feedback 100% of the time
BEEP!
BEEP!
BEEP!
Most Poka-yoke devices are sensor or jig devices
that assure 100% compliance all the time!
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Poka-yoke
What is Poke-yoke?
A method that uses sensor or other devices for catching
errors that may pass by operators or assemblers.
Poka-yoke effects two key elements of ZDQ:
Identifying the defect immediately ( Point of Origin Inspection)
Quick Feedback for Corrective Action
How effective the system is depends on where it is used: Point of Origin or
Informative Inspection.
37
Poka-yoke
Poke-yoke and Point of Origin Inspections( Proactive Approach):
A fully implemented ZDQ system requires Poka-yoke
usage at or before the inspection points during the
process.
38
Poka-yoke
1. Control Approach
Shuts down the process when an error
occurs.
Keeps the “suspect” part in place when
an operation is incomplete.
2. Warning Approach
Signals the operator to stop the process
and correct the problem.
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Control System
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Warning System
BEEP!
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Methods for Using Poka-yoke
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Contact Method
Toggle Switches
Limit Switches
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Energy Contact Devices
An example of a
contact device using a
limit switch. In this
case the switch makes
contact with a metal
barb sensing it’s
presence. If no
contact is made the
process will shut
down.
47
Contact Methods
Do not have to be high tech!
Passive devices are sometimes the best method. These can be as
simple as guide pins or blocks that do not allow parts to be seated
in the wrong position prior to processing
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Counting Method
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Counting Method
“I have an extra
part. I must have
omitted a step!”
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Motion-Sequence Method
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Motion-Sequence Method
In order to help operators select the right parts for the right step in a process
the “sequencing” aspect of the motion-step method is used. This is especially
helpful when using multiple parts that are similar in size and shape.
In this example, each step of the machine cycle is wired to an indicator board
and a timer. If each cycle of the machine is not performed within the required
“time” and “sequence”, the indicator light for that step will be turned on and
the machine will stop.
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Machine Indicator Board
Types of Sensing Devices
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Physical Contact Sensors
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Touch Switch
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Energy Sensors
Fiber optic
Vibration
Photoelectric
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Warning Sensors
Color Code
Warning sensors signal the
operator that there is a
problem. These sensors use
colors, alarms, lights to get
the workers attention !
Lights connected
Lights to Micro switches
& timers
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To prevent mistakes, develop error proofing
devices
POKA-YOKE
to avoid (yokeru) inadvertent errors (poka)
Checklists
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3 Rules of POKA-YOKE
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Some examples of POKA-YOKE devices
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THANK YOU
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