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Poka YokeMistake Proofing

Presented by : Jani Saheb, PMP, CSSGB

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Why Quality Control ?

ZQC Zero Quality Control is our AIM

the idea being to produce zero defective products

Who will be happy ?Customers !

Manufacturing personnel !

Management !

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Zero Defects ?

When we achieve

Zero Defects

We do not need QC Inspector

s any more

QC

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Who is responsible for Defects

What Causes Defects?1. Poor procedures or standards.2. Machines.3. Non-conforming material.4. Worn tooling.5. Human Mistakes.Any more ?

Except for human mistakes these conditions can bepredicted and corrective action can be implemented toeliminate the cause of defects

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Is there any Solution to Defects ?

Yes !

There is a solution !

Poka Yoke (Mistake Proofing)

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What is Poka-Yoke?

The phrase Poka-Yoke originates from the Japanese words:

yokeru = to avoidpoka = inadvertent/

uninted errors

It is a methodology that is used to strive toward zero defects by either preventing or automatically detecting defects.

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Poka Yoke

"fail safing“ so employees weren't offended,

Originally called "fool proofing" later changed to "mistake proofing

The result is a business that wastes less energy, time and resources doing things wrong in the future.

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History

• Developed by Dr. Shigeo Shingo, industrial engineer at Toyota who has been credited with creating and formalizing Zero Quality Control (ZQC),

• It is a simple technique to avoid simple human error at work.

• Identifying defects at the source lowers the cost

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No statistics ?

Stop the defect at source

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Beginning of POKA YOKE While visiting the Yamada Electric plant in 1961, Shingo

was told of a problem that the factory had with one of its products

Part of the product was a small switch with two push-buttons supported by two springs. Occasionally, the worker assembling the switch would forget to insert a spring under each push-button. Sometimes the error would not be discovered until the unit reached a customer, and the factory would have to dispatch an engineer to the customer site to disassemble the switch, insert the missing spring, and re-assemble the switch. This problem of the missing spring was both costly and embarrassing Management at the factory would warn the employees to pay more attention to their work, but despite everyone's best intentions, the missing spring problem would eventually re-appear.

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A poka-yoke device is any mechanism that either prevents a mistake from being made or makes the mistake obvious at a glance.

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Mistake and a Defect

Mistakes :are inevitable; people are human and cannot be expected to concentrate all the time on the work in front of them or to understand completely the instructions they are given.

Defects :result from allowing a mistake to reach the customer, and defects are entirely avoidable.

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Types of Poka Yoke

engineers the process so that it is impossible to make a mistake.

remove the need of correction.

signals the user when a mistake has been made.

they do not enforce the correction.

Prevention Detection

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Who Develops POKA YOKE ?

Here's the beauty of the methods...anyone, from manager to line supervisor to line employee can develop a poka yoke

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Every Day Examples

India Rail Track Deaths Amount To 15,000 Each Year

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Solution

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3 Rules of POKA-YOKE3 Rules of POKA-YOKE

1. Don’t wait for the perfect POKA-YOKE. Do it now!

2. If your POKA-YOKE idea has better than 50% chance to succeed…Do it!

3. Do it now….improve later!

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Fact is !

Operators and Machines will sometimes make mistakes.

Recognize that it is natural for people to make mistakes.

Not noticing that an error is made or a machine is not functioning does not make a person stupid or foolish.

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Shingo Prize

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Thank you for viewing