9/7/2018

SPC Limitations
Jidoka
(Stopping the process) • Relies on sampling to identify
changes in the process
and • Can miss “fleeting” changes
• Can miss defects not caused by
Pokayoke changes in the process (i.e., defects
(Error-proofing the process) caused by inadvertent mistakes)
• Does not prevent inadvertent
defects

Definitions: Mistake vs. Defect Jidoka

• Mistake: the failure of a planned action to be • No mistake or defect is allowed to proceed
completed as intended or the use of a wrong
plan to achieve an aim.
in a process
• Defect: the end result of a mistake. • Worker control
– Andon cord
Example http://www.youtube.com/watch?v=B_nSvN_L
4hc&feature=related

• Mistake: not checking for drug interaction and – Andon signals

compatibility before administering a drug to a
patient.
• Defect: patient suffers adverse reaction to the
drugs.

Andon Signals
Andon Signals
• A visual signal to indicate an abnormal
condition;
• Usually it is a light that is green, yellow, or red,
depending on situation
• Types
– Paging
• Signals a request for forms, material, or people
– Caution
• Often associated with Kanban; a warning about something
that will interrupt process flow
– Equipment
• Signal operating status of equipment
http://www.youtube.com/watch?v=Np0yVVP-
pEg&feature=related

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Pokayoke Levels of mistake-proofing

1. Prevent mistake from
Most desirable
Any device that prevents a mistake ever occurring
from occurring, or that stops the
process or signals an alert that a 2. Detect mistake before
it becomes a defect
mistake is about to happen or has
already happened
3. Detect mistake that has
Least desirable caused a defect, but prevent
defect from causing damage

Mistake-proofing Devices, Examples

Mistake-proofing process The little chamber with the blue lid is a
measuring device. You fill it by taking off the
blue lid and squeezing the bottle. There is a
1. Define the mistake straw-like tube up the side of the bottle into the
or defect chamber. When you have filled the chamber
and stop squeezing, air gets sucked back into
the main bottle through the tube. Any excess
2. Identify red flags fluid flows back down the tube, so that you get
a relatively exact amount of detergent in the
small chamber.

3. Determine root causes

P 4. Generate ideas
A iPod Shuffle stops playing music
D 5. Develop the device or when the earphone is unplugged.
method The music resumes where it left off
C when the earphones are plugged
back in.
pokayoke.wikispaces.com/

Mistake-proofing Devices, Examples Mistake-proofing Devices, Examples

This device continuously
Linksys really wants you to run monitors the water level. If the
the CD before connecting the level is too low, a valve opens
cables. To insure you get the
to add water to the pool.
message, they place a label over
the outlets where the cables are
plugged Many smoke detectors are
designed so they cannot
be mounted on the wall
until a battery is installed.

This Stove burner turns off

automatically when pot or pan is
The fawcett is fitted with a light removed.
sensor. This sensor insures that the
water is turned off.

pokayoke.wikispaces.com/ www.mistakeproofing.com/example1.html

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• Mistake proofing device for hand sanitizing before

entering or leaving a hospital room.
http://www.youtube.com/watch?v=0sK--VfyR7E