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Poka yoke presentation

This document discusses the concept of poka-yoke, or mistake-proofing, which aims to prevent human and machine errors in processes. Poka-yoke was formalized by Shigeo Shingo as part of the Toyota Production System. It involves implementing fail-safe methods that detect or prevent errors at their source. There are different types of poka-yoke including prevention and detection devices. It is important as it helps improve quality and reliability by driving defects out of products and processes. Poka-yoke can be applied wherever errors may occur and includes techniques to prevent or highlight errors.

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Presented by: Akshay Pai - 11 Ankur Patil - 14 Rohan Salian - 32
 Poka-yoke (ポカヨケ) is a Japanese term that means "mistake- proofing". A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka).  The concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota Production System. It was originally described as baka-yoke, but as this means "fool-proofing" (or "idiot-proofing") the name was changed to the milder poka-yoke.  Poka-Yoke example: Ethernet cable plug is designed to be plugged in, in only one orientation.
Poka Yoke over Errors  Help operators avoid mistakes in their work caused by choosing the wrong part, leaving out a part, installing a part backwards, etc.  Involves the implementation of fail-safe ways methods that detect or prevent human and machine error at or near the source.  Provides instant feedback and prevention of quality problems
Poka-Yoke as a...  Poka Yoke as Prevention Device: Examples: Part locators, Part present sensors.  Poka Yoke as Detection Device: Examples: Vision system, Limit sensors
Poka-Yoke as a…
Poka Yoke Example…
Why is it important ??  Helps people and processes  Refers to techniques that make it impossible to make mistakes.  Helps drive defects out of products and processes and substantially improve quality and reliability.  Used to fine tune improvements and process designs from six- sigma.  Use the ideas and methods in product and process design which can eliminate both human and mechanical errors.
Why is it important ??
When to use it?  It is a technique, a tool that can be applied to any type of process be it in manufacturing or the service industry.  Poka-yoke can be used wherever something can go wrong or an error can be made.  Errors can be of any type – • Processing Error • Setup Error • Missing Part • Improper part/item • Operations Error • Measurement Error
How to use it?  Step by step process in applying Poka-yoke:  1. Identify the operation or process  2. Analyze the 5-Ws and understand the ways a process can fail.  3. Decide the right Poka-yoke approach, such as using a, • Shut out Type: Preventing an error being made, or • Attention Type: Highlighting that an error has been made.  4. Determine whether a • Contact Method • Constant Number or Counting Method • Motion-Sequence Method  5. Trial the method and see if it works.  6. Train the operator, review performance and measure success.
Methods in Detail  Contact Methods:- The contact method identifies product defects by testing the product's shape, size, color, or other physical attributes.  Constant Number or Counting Method:- The fixed- value (or constant number) method alerts the operator if a certain number of movements are not made.  Motion-Sequence Method:- The motion-step (or sequence) method determines whether the prescribed steps of the process have been followed.
Day to Day Examples of Poka- Yoke Disk  File cabinets, opening one drawer locks all the rest, reducing the chance of the file cabinet tipping.  Sinks  Microwaves  Washing machines  Central locking in modern cars  Key locks in mobiles  Refrigerators  Beeps in automobiles if key is left in ignition
Characteristics of Poka-Yoke devices  Simple and cheap  Part of the process, permitting 100% inspection  Placed close to where the mistakes occur, providing quick feedback  Designed to stop a particular mistake  It will catch the errors before a defective part is manufactured 100% of the time.
Poka yoke presentation