19 Best Manufacturing Practices

PEMP
PDN 505
Session 19
Best Manufacturing Practices
Lecture delivered by
Prof. M. N. Sudhindra Kumar
Professor MSRSAS-Bangalore
Sudhindra MSRSAS
 M.S Ramaiah School of Advanced Studies - Bangalore 1

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Session Objectives
At the end of this session the delegate would have
understood
• Inspection techniques in the field of Quality Control
• Statistical Process Control
• elimination of defects
• Consumer Driven Company and its benefits
• Avoiding errors
• Three Strategies for ‘ZERO DEFECTS’
• Elements of Production in better level
• About POKA- YOKE and Five Best POKA – YOKEs
Sudhindra MSRSAS
• The Basic Functions of POKA-YOKE

• Five “S” through the examples
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Session Topics
• Inspection Techniques
• SPC and Elimination of Source of Defect
• Poka – yoke
• All about Defects
• Strategies for Zero Defects
• Different kinds of Errors
• Five elements of Production
• All about Poka – Yoke
• The Basic Functions of Poka-yoke
• Poka – Yoke hints
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• Role of Management
• The Eight Principles of Poka – Yoke
• Five “S”
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INSPECTION TECHNIQUES:
Three major inspection techniques in the field of QUALITY CONTROL are:
1. Judgment Inspection: Separates defective products from good ones

after processing . It prevents from being delivered to customers , but
does not decrease a company’s defect rate.
2. Informative inspection: Investigates the causes of defects and feeds
back this information to the appropriate processes so that action can
be taken to reduce the defect rate . The check – feedback – action
cycle does not begin until after defects occur , it essentially tolerates
their existence.
3. Source inspection: A defect is result , or an effect , usually caused by
a simple mistake, through 100 percent inspection at the source, the
mistake can be corrected before it the mistake can be corrected before
it becomes a defect.
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“Defects = Zero” can be achieved.

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SPC and Elimination of Source of Defect:
Statistical Process Control (SPC) developed in the United

States, is based on the premise that 100 percent inspection
is burdensome and time consuming and can be adequately
replaced by sampling inspection and statistics , but
statistics is really no more than qualified guess work - a
certain level of defects is tolerated. SPC is merely a tool of
quality control, it can not eliminate the source of defects.
In a zero Quality Control (ZQC) system 100 percent

inspection is achieved through Poka – Yoke, an approach
that is inexpensive and requires little effort.
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 Poka – yoke is a technique for avoiding simple human
error at work.
 Developed by Dr. Shigeo Shingo, formerly called ‘fool
proofing’, to achieve zero defects and eventually
eliminate quality control inspection.
 Translated as ‘mistake – proofing ‘ or ‘ fail - safing’ from
the Japanese words
Yokeru –to avoid
Poka – inadvertent errors.
(It was felt that ‘fool- proofing’ may offend many workers)
• The idea behind Poke – Yoke is to respect the

intelligence of workers – or take over repetitive tasks or
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actions that depend on vigilance or memory and free a

worker ‘s time and mind to pursue more creative and
value adding activities.
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Zero Quality Control has three components that lead to the elimination of defects :
1. Source Inspection - checks for factors that cause errors, not the resulting
defect.
2. 100 percent inspection – uses inexpensive poka – yoke (mistake – proofing )
devices to inspect automatically for errors or defective operating conditions.
3. Immediate action - operations are stopped instantly when a mistake is made
and not resumed until it is corrected .
The weightage of importance of these three features can be :
Source inspection - 60%

100 percent inspection ( Poka – Yoke) - 30%
Immediate action - 10%
Source inspection is the most important function with 100 percent inspection using
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Poka – Yoke.

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• Defects are wasteful and if they are not discovered they disappoint
the customer ‘s expectations of quality .
• It is not acceptable to produce even a small number of defective
goods .
• Poka – yoke methods are simple concepts for achieving zero
defect production
• Zero Quality Control System
“A person is an animal that makes mistakes . Therefore we must
practice poka – yoke more than we make errors”.
Mistake Proofing A system to detect and prevent mistakes.
Sources of User’s misuse and abuse of products.

problems
Manufacturer’s mistakes in conceiving, designing
and manufacturing
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A Successful Modern Factory

‘Inadvertent Mistakes Increase Work’
Hiroyuki Hirano, JIT Management
Research Institute
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Are Errors Unavoidable?

There are two approaches to dealing with errors:
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Is Sampling Inspection Really the Best Method?

One method of preventing errors is inspection. There are two major
types of inspection:
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One method of preventing errors is inspection.

There are two major types of inspection:
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The User is the Best Inspector

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Three Strategies for ‘ZERO DEFECTS’

1. DON’T MAKE IT
2. MAKE IT TO WITHSTAND ANY USE
3. ONCE YOU HAVE MADE IT USE IT RIGHT AWAY
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The Basic Functions of Poka-yoke

A defect exists in one of two states:
It is either about to occur, or it has already occurred.
Poka-yoke have three basic functions to use against
defects - shut down, control, and warning.
Recognising that a defect is about to occur is called
‘prediction’.
Recognising that a defect has already occurred is called
‘detection’.
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Detection Devices to
Use for Poka-yoke.
No contact devices
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Role of Management
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The “ five S’s are key concepts of

industrial house keeping
that begin with “S” in Japanese.
They are :
seiri ( organization ), sorting out
seiton (orderliness), systematic arrangement.
seiso ( the act of cleaning), spic and span
seiketsu (the state of cleanliness), standardization
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shitsuke ( the practice of discipline) self - discipline

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Summary
• Best manufacturing practices are techniques used in the

shop floor for efficient manufacture of products
• They are required to eliminate defects in the product during
manufacturing owing to errors of man, machine or material
• They are required to ensure consistent product quality and
reliability, reduce product cost, and avoid wastage
Sudhindra MSRSAS

19 Best Manufacturing Practices

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PEMP

 M.S Ramaiah School of Advanced Studies - Bangalore 1

• The Basic Functions of POKA-YOKE

1. Judgment Inspection: Separates defective products from good ones

“Defects = Zero” can be achieved.

 M.S Ramaiah School of Advanced Studies - Bangalore 4

SPC and Elimination of Source of Defect:

Statistical Process Control (SPC) developed in the United

In a zero Quality Control (ZQC) system 100 percent

 M.S Ramaiah School of Advanced Studies - Bangalore 5

• The idea behind Poke – Yoke is to respect the

actions that depend on vigilance or memory and free a

The weightage of importance of these three features can be :

Source inspection - 60%

 M.S Ramaiah School of Advanced Studies - Bangalore 7

Sources of User’s misuse and abuse of products.

 M.S Ramaiah School of Advanced Studies - Bangalore 8

A Successful Modern Factory

 M.S Ramaiah School of Advanced Studies - Bangalore 9

 M.S Ramaiah School of Advanced Studies - Bangalore 10

 M.S Ramaiah School of Advanced Studies - Bangalore 11

 M.S Ramaiah School of Advanced Studies - Bangalore 12

Are Errors Unavoidable?

 M.S Ramaiah School of Advanced Studies - Bangalore 13

Is Sampling Inspection Really the Best Method?

 M.S Ramaiah School of Advanced Studies - Bangalore 14

One method of preventing errors is inspection.

 M.S Ramaiah School of Advanced Studies - Bangalore 15

 M.S Ramaiah School of Advanced Studies - Bangalore 16

The User is the Best Inspector

 M.S Ramaiah School of Advanced Studies - Bangalore 17

Three Strategies for ‘ZERO DEFECTS’

 M.S Ramaiah School of Advanced Studies - Bangalore 18

 M.S Ramaiah School of Advanced Studies - Bangalore 19

 M.S Ramaiah School of Advanced Studies - Bangalore 20

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The Basic Functions of Poka-yoke

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