Agricultural and Construction

Equipment

NH AG
NH CE

Poka Yoke

06. QC Pillar Training Material

CNH - World Class Manufacturing Team

April 2010
Contents

 Zero Quality Control

 Poka-Yoke System

 Application Examples

April 2010
What is ZQC?

 Zero Quality Control is a quality control (QC) approach

to achieve Zero defects on products.
 The Basic Principle
 Defects are prevented by controlling the performance
of a process so that it cannot produce defects – even
when a mistake is made by a machine or man.
 ZQC is a method for Mistake-proofing

April 2010
Why focus on Zero Defects?

 Maintain customer satisfaction

and loyalty. I’ll never buy this @#$%*
brand again, also I’ll
recommend my friends not
 Defect always cost something, in to buy!!!

terms of scrap or rework.

 Zero defect is a key factor to
keep smaller inventory and lean
production.
 Zero defects make work go
smoother and keep higher
employee morale.

April 2010
What causes Defects?

MAN
Lack of training or
motivation, overtime

MACHINE MATERIAL
Worn machine parts, Supplier defects, improper
4M
damaged tools handling, excessive variability

METHOD MANAGEMENT
Inappropriate procedures, Excessive product variability,
lack of process standards poor production planning

April 2010
Quality Improvement Cycle

Traditional approach ZQC approach

Plan Plan

Do
Check Do-
Check

• Catch defects after they • Inspection occurs at the

occur source
• Take improvement action • Check is integrated with
Do

April 2010
3 Approaches to Product Inspection

Judgment Informative Source

Inspection Inspection Inspection

• Discovers defects but • Giving constant • Catches errors and

does not reduce them feedback to the process gives feedback before
• Does not give quick that produce defects processing
feedback to improve the • Focus is on addressing • Every single product is
process for not making the cause to solve it as inspected
defects quickly as possible • Quick feedback to
• Generally done at the • Example: SQC, self correct the errors right
end of the process certification away
• Cannot eliminate • This is the basic
defects completely concept of ZQC

April 2010
Using Poka-Yoke Systems

Poka-Yoke systems use sensors or other devices installed in

processing equipment to detect errors that might slip by the operator
and prevent defects by one of the following:
• A control system stops the equipment when irregularity happens
or,
• A warning system signals the operator to stop the machine

Both the systems use three basic methods for using Poka-Yoke:
1. Contact method
2. Fixed Value method
3. Motion step method

April 2010
Contact method

Works by detecting whether a product makes physical or

energy contact with a sensing device.

Example

April 2010
 Fixed Value method

A device counts the number of times something is done and signals or

releases the product only when the required number is reached. This
method can be used when a fixed number of repeated operations
needs to be done at a process station.

Example

April 2010
 Motion-step method

This method is used to sense whether a motion or step in the process

has been carried out within a certain expected time, such as a machine
cycle time. It can also be used to ensure that things happen according to
a certain sequence, which avoid errors.

Example

April 2010
 Types of Sensing devices

The sensing devices used in Poka-Yoke can be divided in 3 broad

categories:

• Physical contact sensing devices

• Energy sensing devices
• Sensors to detect physical condition changes

Example

April 2010
 Physical contact sensing devices

These devices work by physically touching the product or machine part.

An electrical signal is generated by the physical contact to stop or start
a machine.

Examples
April 2010
Energy sensing devices

These devices use energy rather than physical contact to

determine whether an error is occurring.

Examples
April 2010
Energy sensing devices…contd.

More Examples
April 2010
Physical condition change sensing devices

These type of poka-yoke sensors detects change in physical

conditions like pressure, temperature, electrical currents etc.

Pressure change Temperature Electrical current

sensors change sensors change sensors
• Used to detect • Used to check surface • Used to control the
problems like oil supply temperatures of dies causes of defects by
interruptions electronic parts and detecting the
motors. occurrence of
• Example: Pressure electrical current.
gauges and pressure- • Example:
sensitive switches. thermometers, • Example: meter
thermostats, thermistors relays, current eye etc.
etc.

April 2010
 EXAMPLES OF POKA-YOKE APPLICATIONS

April 2010
Example 1. Catching an incorrectly positioned work piece

Before After

April 2010
Example 2. Preventing incorrect mounting of work piece

Before After
1st process 2nd process Pins for
these
positions
Correctly mounted

Correctly mounted
New drilled
holes

Incorrectly mounted Pin prevents incorrect mounting

TOP VIEW CROSS-SECTION VIEW

April 2010
Example 3. Detecting unprocessed parts in a chute

Before After

chute
CROSS-SECTION
VIEW

blocks chute

unmilled part milled part TOP VIEW

SIDE VIEW unmilled part

milled part passes
cannot pass through
blocks

April 2010
Example 4. Ensuring proper positioning of blanks for stamping

Before After

April 2010
Example 5. Detecting wrong positions of bonded metal parts

Before After

April 2010
Example 6. Catching mispositioned parts in a press

Before After

press press press Limit switch

detects correct
positioning

Work- Work- Work-

p/c p/c p/c
to operating
jig jig jig circuit

correct incorrect only correct

mounting possible

April 2010
Example 7. Preventing omitted welds

Before After

April 2010
Example 8. Reminding operator to change welding tips

Before After

April 2010
Example 9. Making sure all bolts are installed

Before After

April 2010
Example 10. Avoiding assembly with wrong parts

Before After

Model 6
use parts D
& E?

April 2010
Example 11. Preventing omission or doubling of washers

Before After

April 2010
Example 12. Catching uncut bolts before further processing

Before After

April 2010
Example 13. Ensuring adequate testing of solder joints

Before After

April 2010
Example 14. Testing for uncut grooves in a product

Before After

April 2010
Example 15. Inspecting for missing staples on cases

Before After

April 2010
Example 16. Inspecting for missing staples on cases

Before After

April 2010