1 Let’s take a minute for SAFETY: Who has a safety concern/ contact or tip? A ship is safe in...
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1 Let’s take a minute for SAFETY: Who has a safety concern/ contact or tip? A ship is safe in harbor, but that's not what ships are for … Learn more about
1 Lets take a minute for SAFETY: Who has a safety concern/
contact or tip? A ship is safe in harbor, but that's not what ships
are for Learn more about mistake-proofing at:
www.freesixsigmasite.com
Slide 2
2 SMILE !! Its Contagious! Sustain the Gain
Slide 3
Where in the World are Poka-yoke? They exist in the world
around us (theyre out there)
Slide 4
Mistake-Proofing Devices On Your Car Cant start the car unless
its in park or clutched Cant fit a diesel nozzle in the gas tank
Doors lock when speed is greater than 5 miles per hour Bell chimes
when headlights left on Headlights automatically burn &
extinguish Bell chimes when seatbelt not worn Indicator lights when
fuel is low Gas cap is attached to car by a lanyard Oil and fuel
specs are listed on caps or tanks Bell chimes when turn signal left
on Light indicates that parking brake is engaged
Slide 5
What Are Guidelines for Poka-Yoke ?
Slide 6
BTW, Dont Do Fake Poka-Yoke! aka: You had one job Just for
fun!! Lets examine a couple
Slide 7
Almost !!
Slide 8
Slide 9
Do Careful pedestrians need to stop??
Slide 10
Almost !! There are 2 Parts to this one Now - notice how far
away sign is from hospital bed
Slide 11
Almost !! falls program Really ??!??!!
Slide 12
Almost !! So many signs! Maybe the pit fell in the void after
catching fire??
Slide 13
Almost !!
Slide 14
At least they had a little fun with this one!
Slide 15
What is the Purpose of Poka-yoke?
Slide 16
Top Causes of Errors Look for these in your processes
Processing omissions: leaving out one or more process steps
Processing errors: process operation not performed according to the
standard Error in setting up: using wrong tooling or incorrect
setting/ adjustment Missing parts: not all parts are included in
assembly/ process Improper part/ item: wrong part installed in
assembly
Slide 17
Top Causes of Errors (cont) Processing wrong work piece: wrong
part machined/ processed Operations errors: incorrect revision or
specification sheet Errors in equipment, maintenance or repair:
Defects caused by incorrect repairs or component replacement Error
in preparation of inspection equipment, fixtures or tools: Damaged
inspection tooling; poorly designed fixtures or wrong tools; mis-
measurement
Slide 18
Q) Why a Mistake-proof Hierarchy? 18 A) So you dont have to fix
the problem again! Full Automation Awareness Fail-Proof
Simplification Training Behavior typically reverts back The process
is changed to be less impacted upon variation caused by people Most
Desired Least Desired No Manual Intervention Impossible to Fail
Eliminate Activity Certification and Audits Notification
Slide 19
2 states for Poka-Yoke
Slide 20
Slide 21
Example Why did you pop open the trunk to gas up?
Slide 22
Example Alert the operator at the point of mistake Four xample,
when one makes a misteak, an effective Poko-Yoke system will alert
the operotor that a misteak was made, where it was made, and even
how the misteak was made
Slide 23
Example IS GAS CAP SECURE? Tighten till you hear the click
Slide 24
Example Computer Start-up Routines [password/log-in/pin etc]
Computer Shut-down Routines [series of low battery warnings/
actions taken]
Slide 25
What are the Conditions? (ripe for poka-yoke) 1.Adjustments
2.Unclear or no instructions 3.Undefined process 4.Many units/mixed
units 5.Multiple steps 6.Infrequent production 7.Ineffective or
lack of standards 8.Multiple handoffs 9.Hand processing 10.Rapid
repetition 11.High volume demand or deadline pressures
12.Environmental conditions
Slide 26
Try It ! Mistake-Proof This: A local countertop company makes
and then loads the countertop pieces on to a truck and goes to the
customers home and installs the countertop. More than 15% of all
installation jobs have to be done with more than one trip to the
customers home because one or more pieces of the countertop was not
loaded on the truck. Propose a change that will ensure all the
material is loaded on the installation truck.
Slide 27
Try It ! Mistake-Proof This: The far-sighted instructor in a
rush to get to work on time often forgot and left his glasses at
home. Propose a change that will ensure the instructor does not
forget his glasses.
Slide 28
Try It ! Mistake-Proof This: Mechanics in the instrument lab
have to calibrate instruments in accordance with a procedure that
has several steps. They sometimes inadvertently skip a step in the
procedure. Propose a change that will ensure no steps are
skipped.
Slide 29
Go Forth Identify what your impediments to improvement are Work
on those and you will be on the right track In particular, what are
barriers to higher equipment uptime higher process capability safer
environments or equipment higher capital and labor productivity
without adding cost or more highly trained personnel I call this
building better process stability
Slide 30
Surfin for Ideas? Better Practice Sharing
Slide 31
A Better Practice Use CAPS: (Action Verb) then, the event In
your Outlook Calendar
Slide 32
A Better Practice Label, Label, Label Color code
Slide 33
A Better Practice Which side is gas cap on? Points to left side
(see white arrow)
Slide 34
A Better Practice Sign (Warning)Metal tabs (Shut-out)
Slide 35
A Better Practice This rental truck has a door latch that will
not allow the loading ramp to slide out while the latch is in the
closed position.
Slide 36
Countdown to Takeoff Get on the plane, people !! A Better
Practice
Slide 37
Green tag for Carry On bags that had to be checked.
Slide 38
A Better Practice Slotted metal guard (stand-off) to prevent
accidently stopping luggage conveyor at the airport.
Slide 39
A Better Practice Place sign above (or below) the Fire
Extinguisher
Slide 40
A Better Practice P.P.E. REQUIREMENTS to enter into the
operation. Steel toe shoes, reflective vest, hard hat, etc.
Slide 41
A Better Practice COFFEE/ SINK AREA (signage) for galley
operations. Considerate but firm
Slide 42
A Better Practice TIME ALERT (signage) for coffee operations.
Denotes type and how long coffee has been sitting
Slide 43
What Did We Cover Today?
Slide 44
Oops !! [Mistakes, - some are obvious]
Slide 45
[ some recover well!] Story on back of each bag of chips
Slide 46
[And some, not so much!]
Slide 47
Lots O Reasons to address Focus your analysis on those
causes
Slide 48
An idea you can put into practice
Slide 49
Look for these Conditions: 1.Adjustments 2.Unclear or no
instructions 3.Undefined process 4.Many units/mixed units
5.Multiple steps 6.Infrequent production 7.Ineffective or lack of
standards 8.Multiple handoffs 9.Hand processing 10.Rapid repetition
11.High volume demand or deadline pressures 12.Environmental
conditions Key Points about Mistake Proofing
Slide 50
Mistake Proof This! A great idea you can put into everyday
practice Process / Step: _________________________ Describe the
Error: ______________________ Mistake-proofing Measure:
_________________ _____________________________________ What
foolish action does it prevent?
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