ZERO-DEFECT QUALITY

SYSTEM
POKA YOKE

ERROR VS. DEFECTS

ERRORS are the causes of DEFECTS

DEFECTS are the results of ERRORS

ZERO-DEFECT QUALITY SYSTEM

A quality concept to manufacture ZERO defects and

eliminate wastes associated to defects

Shigeo Shingo developed Poka-Yoke

Yokeru means to prevent; Poka means inadvertent errors

TYPES OF HUMAN MISTAKES

1.

Forgetfulness

2.

Misunderstanding

3.

Wrong identification

4.

Lack of experience

5.

Willful (rule ignorance)

6.

Inadvertence/sloppiness

7.

Slow response

8.

Lack of standardization

9.

Surprise

10.

Intentional (sabotage)

GUIDELINES TO POKA-YOKE ATTAINMENT

1.

Quality processes

2.

Utilize a team environment

3.

Elimination of error

4.

Eliminate the root cause of errors

5.

Do it right the first time

6.

Elimination of non-value adding decisions

7.

Implementation of an incremental continual improvement

approach

APPROACHES OF A POKA-YOKE SYSTEM

1.

2.

CONTROL APPROACH

Shuts down the process when an error occurs

Keeps the suspect part in place when an operation is

incomplete

WARNING APPROACH

Signals the operator to stop the process and correct the

problem

METHODS FOR USING POKA-YOKE

SYSTEM
1.

CONTACT (Physical detection and control)

2.

COUNTING

3.

Identify items by their physical characteristics

Assure correct groupings, orderings, and the use of all
and only the correct components

MOTION-SEQUENCE

Assure simple proximity switch that opens after all

components are loaded in the proper order

TYPES OF SENSING DEVICES

1.

Physical contact devices

2.

Energy sensing devices

3.

Warning sensors

TYPES OF SENSING DEVICES

To prevent mistakes, develop error-proofing devices:

Checklists

Dowal and locating pins

Error and alarm detectors

Limit or touch switches

Detectors, readers, meters, counters