POKA-YOKE

POKAYOKE DEFINATION
POKA YOKE

INADVERTENT YOKURE
ERROR TO AVOID

MISTAKE PROOFING.
 POKA-YOKE

“IT’S A HUMAN TENDENCY TO FORGET THE THINGS…..”

WHAT IS “FORGET” ?
- SIMPLY FORGETTING THE THINGS WITHOUT ANY
INTENTION.
- FORGETTING THAT ONE HAS FORGOTTEN SOMETHING.
-POKAYOKE SYSTEMS PREVENT CARELESS ERRORS FROM
TURNING INTO DEFECTS.

-POKAYOKE LOOKS AT THE DEFECT ,STOPS THE

SYSTEM,GIVES IMMEDIATE FEEDBACK TO GET ROOT
CAUSE OF THE PROBLEM. TO PREVENT IT FROM
REOCCURANCE.
 POKA-YOKE

CHECKS
ACTION AND
FEEDBACK

LONG ROUTE
DEFECTS

RESULT
ACTION

CHECK CAUSE
ERRORS AND
FEEDBACK SHORT ROUTE
 POKA-YOKE

STEPS TO ACHIEVE ZERO QUALITY CONTROL………..

WITH THE HELP OF POKA YOKE & SOURCE INSPECTION
-APPLYING A CONTROL FUNCTION AT THE STAGE

WHERE
DEFECTS ORIGINATE.

-USE OF 100 % INSPECTION RATHER THAN SAMPLING

INSPECTION.

-MINIMIZE THE TIME OF CORRECTIVE ACTION.

 POKA-YOKE

WHAT IS POKA-YOKE ( MISTAKE PROOFING )

CAN BE DEFINED AS A SYSTEM FOR ORGANISING WORK

THAT-

•EXCLUDES ANY RISK OF ERROR EVEN BY BEGINNER.

•ALLOWS EVERYONE TO OPERATE WITHOUT

MISTAKE.

•PREVENTS ERRORS THAT ARE ABOUT TO OCCUR.

POKA-YOKE

METHODOLOGY
Identify Problem

Observation at Work Station

Brainstorm for Ideas

Zero in on Best Idea

Implementation Plan

Implement

Monitor & Sign Off

 POKA-YOKE

Speak to the Job / Machine

What is your
Problem?
 POKA-YOKE

PRINCIPLES FACTORS

I ) EASE OF MOVEMENT 1) OPERATING METHOD

II ) OPERATING WITHOUT 2) LAYOUT - STRG. BINS,

SPECIAL
SKILL LIGHTING , NOISE

III ) OPERATIVE SAFETY 3) TOOLS & MACHINERY

IV ) OPERATION NOT BASED 4) PRODUCT DESIGN OR MFG.

ON PERCEPTION PROCESS
 POKA-YOKE

CATEGORIZATION OF POKAYOKE SYSTMES

1) POAKYOKE REGULATORY FUNCTIONS.

I) CONTROL METHODS.
II) WARNING METHODS.

2) POKAYOKE SETTING FUNCTION.

I) CONTACT METHODS.
II) FIXED VALUE METHODS.
III) MOTION-STEP METHOD
 POKA-YOKE

CONTROL METHOD:
WHEN THE ABNORMALITY OCCURS , THE
CONTROL METHOD SHUTS DOWN THE MACHINE TO
HAULT OPERATION AND PREVENTS SERIAL TYPE OF
DEFECTS.
WARNING METHOD:
ALERTS WHEN ABNORMALITY OCCURS WITH AN
AUDIO VISUAL BUZZER.ABNORMALITY WILL CONTINUE
UNLESS THE ALARMS ARE NOTICED & RESPONDED TO.
HENCE IT’S A LESS POWERFUL APPROACH.
 POKA-YOKE

I ) CONTACT METHOD

THE SENSING DEVICE DETECTS ABNORMALITIES

IN PRODUCT SHAPE OR DIMENSION BASED ON
WHETHER OR NOT CONTACT IS MADE BETWEEN THE
PRODUCT & THE DEVICE.

II ) FIXED VALUE METHOD

DETECTS ABNORMALITY BY COUNTING THE

MOTION IN OPERATION THAT MUST BE REPEATED A
CERTAIN NUMBER OF TIMES.
 POKA-YOKE

III ) MOTION - STEP METHOD

DETECTS ABNORMALITIES BY CHECKING FOR

ERRORS IN STANDARD MOTIONS OR
STANDARD OPERATING PROCEDURES.

CATEGORIZATION BY LEVEL OF POKAYOKE

1) LEVEL 1 POKAYOKE
2) LEVEL 2 POKAYOKE
3)LEVEL 3 POKAYOKE
 POKA-YOKE

DETECTION DEVICES

NON-CONTACT TYPE
PROXIMITY SWITCH INLINE TYPE
CONTACT TYPE
PHOTOELECTRIC SWITCH PRESSURE TRANSDUCER
LIMIT SWITCH BEAM SENSORS
MICRO SWITCH PRESSURE SWITCH
FIBER OPTIC SENSORS
REED SWITCH AREA SENSORS FLOW SENSORS
TOUCH SWITCH POSITIONING SENSORS
RTD TEMP SENSORS
LVDT’S DISPLACEMENT SENSORS

LIQUID LEVEL COLOUR MARKING LOAD CELLS

SENSORS
RELAYS
ULTRASONIC SENSORS
VISION SYSTEMS
 POKA-YOKE

OTHER ELECTRICAL FEEDBACK DEVICES :

*RELAYS
*COUNTERS
*TIMERS
*TOTALIZERS
*RPM INDICATORS
*THERMOCOUPLES

ABOVE DEVICES CAN BE CLUBBED WITH

DIFFERENT SENSORS & ALARMS CAN GENERATE .
ALARMS :
*AUDIO ( BUZZERS)
*VISUAL (BLINKERS / INDICATING LAMPS)