Errorproofingtechnique Pokayoke 100605213544 Phpapp02

8/18/2019 Errorproofingtechnique Pokayoke 100605213544 Phpapp02

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EPREFER.PPT - 01

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ERROR-PROOFING TECHNIQUES

(Poka-Yoke) CONCEPT

SENSOR INFORMATION:BASIC TYPES OF SENSORS• Discrete sensors• Analog sensors

TYPES OF PRESENCE SENSORS

• Physical contact• No physical contact

TYPES OF NONCONTACT SENSORS• Ree! relays• In!"cti#e• Capaciti#e

• Photoelectric sensors

AD$ANTA%ES OF T&E $ARIO'S TYPES• F"nctionality• Costs• Areas o( application



EPREFER.PPT - 02

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(Poka-Yoke) CONCEPT

BASIC TYPES OF SENSORS:

ANA)O% SENSORS• Ans*er the +"estion: ,-here is the part./

or • ,To *hat le#el ha#e *e (ille! the container./

DISCRETE SENSORS

• The part is present or is not present0• Most (re+"ently as1e! +"estion in a 2an"(act"ring

operation0



EPREFER.PPT - 03

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(Poka-Yoke) CONCEPT

TYPES OF PRESENCE SENSORS:

P&YSICA) CONTACT• e0g0 )i2it s*itches

• A!#antages Can carry 2ore c"rrent %ap 3et*een ter2inals

NO P&YSICA) CONTACT• A!#antages No physical contact

Better (or co"nting sensiti#e s"r(aces4 e0g0 painte! or polishe! s"r(aces

No 2o#ing parts

Faster



EPREFER.PPT - 04

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(Poka-Yoke) CONCEPT

TYPES OF NONCONTACT SENSORS:

REED RE)AYS• Target is 2agnetic• -ill not respon! to non2agnetic targets

*ith relia3ility0

IND'CTI$E• Base! on 2etal targets5 *ill not respon!

to non2etallic targets *ith high relia3ility0

CAPACITI$E

• Cannot !isting"ish 3et*een the real target an! so2ething else in the target region0

M"st control *hat co2es close to the target0

P&OTOE)ECTRIC• Can 3e (oole! 3y a nontarget0



EPREFER.PPT - 05

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(Poka-Yoke) CONCEPT


REED RE)AYSTypical range: 'p to 607 in0 8appro90 c2;• Two hermetically sealed metal foil reeds which mae co!tact

with each other to close the circ"it# whe! i! the $ici!ity of a

ma%!et &'erma!e!t or electro-ma%!et(.• The differe!tial is determi!ed )y differe!ci!% the 'oi!t of first

co!tact from the 'oi!t of last co!tact.• *a%!et a''roach m"st )e i! a directio! 'arallel to the directio!

of the li!e co!!ecti!% the tow reeds.

Best applications (or 2agnetically act"ate! s*itches in general:• +ec"rity a!d safety

• to a$oid false tri''i!%• sec"rity door i!terloc for hea$y machi!ery, e!d of tra$el

for ele$ators# cra!es# a!d the lie.• +e!si!% thro"%h walls &!o!-ferro"s# e.%. l"mi!"m a!d

*a%!esi"m(.• Pallet ide!tificatio! i! sy!chro!o"s a"tomated assem)ly li!es.• Relati$e dirty e!$iro!me!ts &e.%. d"st# dirt# sa!d# oil# or coola!t

fl"ids(.• he!e$er hi%h res'o!se s'eeds are re"ired.

Disa!#antages poor longter2 relia3ility 82o#ing parts;



EPREFER.PPT - 0

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(Poka-Yoke) CONCEPT


IND'CTI$E SENSORS

• Principle o( Operation:• E!!y c"rrents are in!"ce! in the target 82etallic;

3y the electro2agnetic0• The target reacts *ith the E!!y c"rrents as a

("nction o( the !istance (ro2 the (iel!0• Insi!e the (iel!4 the target atten"ates the 2agnit"!e

o( the E!!y c"rrents0• O"tsi!e the (iel!4 the target !oes not i2pe!e the

E!!y c"rrents0• This type o( oscillator is re(erre! to as a EC<O

8E!!y C"rrent <ille! Oscillator;0


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(Poka-Yoke) CONCEPTTYPES OF NONCONTACT SENSORS:

CAPACITI$E SENSORS• Principle o( Operation:

• Senses all 2aterials• Contain a high (re+"ency oscillator *ith one o( its

capacitor plates 3"ilt into the sensor0

• Metho! o( Application:• All 2aterials are sense! thro"gh a change on the

!ielectric characteristics0• I!eal applications incl"!e 3"l1 2aterials an! li+"i!s

in containers o( glass an! plastic0

• Characteristics:• Poor choice (or 2etal targets0• Is #ery sensiti#e to en#iron2ental (actors0• Sensing range !epen!s greatly on the 2aterial 3eing

sense!0• Can 3e 2isle! an! there(ore it is i2portant to control

the 2aterial *hich is presente! to the sensor0



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(Poka-Yoke) CONCEPT


P&OTOE)ECTRIC SENSORS

Photoelectric co!trols !eed !o 'hysical co!tact a!d are ideal where se!sed

o)ects m"st remai! "!to"ched. Photoelectric co!trols res'o!d ra'idly to

'arts mo$i!% "icly a!d i! $aryi!% 'ositio!s alo!% a co!$eyor# yet o'erate

de'e!da)ly if act"ated o!ly i!fre"e!tly. There are co!trols for i!door or o"tdoor "se# for $aryi!% am)ie!t li%ht co!ditio!s# for hi%h $i)ratio!# for areas

restricti$e i! s'ace# a!d e$e! for e'losi$e locatio!s.

Typical applications incl"!e:• o"!ti!%• 6a)eli!%• o!$eyor co!trol• 7i! le$el co!trol• Parts i!s'ectio!• Feed a!d/or fill co!trol• Paca%e ha!dli!%• Thread )rea detectio!

• Ed%e %"ide• e) )rea detectio!• Re%ristratio! co!trol• Food 'rocessi!%• Parts mo!itori!% a!d sorti!%• 7atch co"!ti!%• Ro)otics• Parts ha!dli!%



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(Poka-Yoke) CONCEPTTYPES OF NONCONTACT SENSORS:


Con#eyor ControlThis a''licatio! i!$ol$es sorti!% )row! card)oard )oes which are coded with "' to fo"r )lac mars 'er

)o. The a''licatio! is to se!se the !"m)er of mars o! each )o.

Pac1age &an!ling diff"se sca! 'hotoelectric co!trol is "sed to detect the li%ht reflected from the o)ect i! this a''licatio!.

The co!trol detects the li%ht reflected off the )o# t"r!i!% 9: a!d 9FF the %l"i!% machi!e.

)a3elingThis a''licatio! is desi%!ed to detect the leadi!% ed%e of a )lac )ar code o! a read a!d write la)el. The

la)els are ed%e to ed%e o! a s'ool. he! the )ar code is detected the se!sor o"t'"t tri%%ers a laser )ar

code reader which reads the )ar code.

Foo! ProcessingThis a''licatio! mo!itors the le$el of a! acc"m"lator i! a meat 'rocessi!% facility. 'hotoelectric co!trol

detects a fill le$el of hot-do%s i! the acc"m"lator the! t"r!s o! the co!$eyor for a 'reset time 'eriod. +idewalls of the acc"m"lator are 'olished stai!less steel. The e"i'me!t is s")ect to daily washdow!.

Fill )e#el ControlThis a''licatio! i!s'ects the fill le$el of $ario"s ars of food 'rod"cts. The 'hotoelectric system 'rod"ces

a! o"t'"t whe! either a! "!der or o$er fill co!ditio! is detected.

Parts &an!lingFi)er o'tics are ideal for areas too small for a sta!dard 'hotoelectric co!trol. The fi)er o'tic ca)les direct

the li%ht from the )ase to where the se!si!% is !eeded.



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Target

Thru:

•Light source (emitter) andreceiver are placed oppositeeach other.

•The object to be detected passesbetween the two.

Advantages:

1. Most reliable when target is opaque

2. Long range scanning, most excess gain

3. Use in high contamination areas, dirt, mist,condensation, oil film, etc.

4. Precise positioning or edge-guiding of opaquematerial

5. Parts counting

Types of Non-Contact Sensors

Photoelectric Sensors

Emitter Receiver

THRU


(Poka-Yoke) CONCEPT



2/13/00


(Poka-Yoke) CONCEPT

Diffuse:

• Light beam is directed at theobject to be detected.

• Light will be reflected off theobject in many directions.

• Some of the light reflected fromthe object will be sensed by the

receiver.

Advantages:

1. No reflector required.2. Convenient for installation.

3. One sided scanning.

4. Senses clear materials whendistance is not fixed.

5. Ease of alignment



Target



EPREFER.PPT - 012

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(Poka-Yoke) CONCEPT



Pro9i2ity 8!i(("se; Bac1gro"n! S"ppression

7ac%ro"!d s"''ressio! "tili;es 2 recei$ers )ehi!d the recei$i!% le!s. They areaimed at a 'recise 'oi!t i! fro!t of the "!it a!d se!se the 'rese!ce of a tar%et

*hen the o"tp"t o( 3oth recei#es are e+"al.

Applications:

• *aterial ha!dli!% - co!$eyi!% systems

• ollisio! detectio! for <=>s &"tomatic <"ided =ehicles(• ar / tr"c wash• 6e$el se!si!%



EPREFER.PPT - 013

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Retroreflective:

•Light beam is directed at a reflective target(reflector, tape or other reflective object) -one which returns light along the samepath it was sent.

•The object to be detected passes betweenphotoelectric control and reflective target.

Advantages:

1. One-sided scanning


3. Immune to vibration



Target

Retroreflective

Reflector


(Poka-Yoke) CONCEPT



EPREFER.PPT - 014

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Convergent:

• Light beam is directed at object to bedetected (ignores backgroundsurfaces)

• Object must be at a given distance inrelationship to photoelectric controlbefore light will be reflected to receiver

Advantages:

1. First choice for detecting clearmaterials

2. Ignores unwanted backgroundsurface reflection

3. Detects objects with low reflectivity

4. Detects height differential



Target

Convergent Beam

FixedDistance


(Poka-Yoke) CONCEPT



EPREFER.PPT - 015

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(Poka-Yoke) CONCEPT

TYPES OF NONCONTACT SENSORS:P&OTOE)ECTRIC SENSORS

Fi3er Optic Sensors

hat do yo" do whe! the 'hysical co!strai!ts of the a''licatio! do!>t allow for

i!stalli!% re%"lar# self-co!tai!ed se!sors? *ay)e the tar%et is i! a hi%h tem'erat"re

or chemically a%%ressi$e e!$iro!me!t. Perha's the tar%et is small or $ery fast-mo$i!%.

Fi)er-o'tics# a''lied to 'hotoelectric sca!!i!%# sol$es these 'ro)lems.Fi3er Optics an! Sensing

ll fi)er o'tic se!si!% mode are im'leme!ted "si!% o!e ty'e of am'lifier which co!tai!s

)oth emitter a!d recei$er i! o!e ho"si!%.

Fi3er Optic Thr"3ea2 Scanning

@si!% two o''osed# i!di$id"al fi)er o'tic ca)les# the o)ect to )e detected )reas the

)eam. The tar%et m"st )e at least the same dime!sio! as the effecti$e )eam# which i!

this case# is the )"!dle diameter. 7eca"se the )eam is $ery small# the detectio! ca! )e$ery 'recise. ty'ical a''licatio! mi%ht )e ed%e detectio! for a we) 'ri!ti!% 'ress.

:eedle ti's red"ce the )eam dime!sio! for "se with etremely small tar%ets# ty'ical for

a''licatio! i! semico!d"ctors a!d 'harmace"tical i!d"stries.

Typical application:• +mall 'arts detectio!• Ed%e detectio!• Ai%h tem'erat"re e!$iro!me!t &00 de%rees FB(



EPREFER.PPT - 01

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Fiber Optic:

• Not a scanning technique but rather another way of transmitting light beam.

Advantages:

1. High temperature applications 4. Corrosive areas

2. Where space is limited 5. Noise immunity

3. Size and flexibility of fiber leads 6. Color sensing



Target orReflector

Thru


(Poka-Yoke) CONCEPT



EPREFER.PPT - 01

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Polarized:

• Will work only with comercubereflector or special polarizedreflective tape.

• Will not false trigger whensensing shiny object.

Advantages:

1. One-sided sensing

2. Does not false trigger offhighly reflective object

3. Senses clear materials


5. Immune to vibration



Target

Polarized

SpecialReflector


(Poka-Yoke) CONCEPT



EPREFER.PPT - 01

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(Poka-Yoke) CONCEPT

APP)ICATION SCAN TEC&NI='E

+mall 'arts detectio! Fi)er o'tics or Thr" sca! with a'erat"res

6o!% dista!ce sca!!i!% Thr" sca!

Ai%h tem'erat"re se!si!% Fi)er o'tic

+hi!y o)ect or film detectio! Polari;ed sca!

+e$ere e!$iro!me!t &Etreme d"st or dirt( Thr" sca!

6imited mo"!ti!% s'ace Fi)er o'tic

E'losi$e e!$iro!me!t Thr" sca! or Retro

ashdow! e!$iro!me!t Thr"# Retro-reflecti$e or Ciff"se

!alo% 'ositio! se!si!% Ciff"se or Fi)er 9'tic

o!$eyor *o!itor

- Dam detectio!

- Part co"!t

- Part 'ositio!

Polari;ed# Ciff"se or Retro

=i)ratory Feeder Fi)er o'tic

6id or a' detectio! o!$er%e!t )eam or Fi)er 9'tic

lear )ottle detectio! Polari;ed or Fi)er 9'tic

Tra!s'are!t material Polari;ed sca!

6a)el detectio! Ciff"se or Fi)er 9'tic

7i! or ho''er le$el Thr" whe! "si!% wi!dow Ciff"se from a)o$e

*old or die clear to close Thr" sca! or Fi)er 9'tic &hi%h tem'(

*a hei%ht mo!itor &i.e. For tr"cs( Thr" sca!

9'a"e material o! semitra!s'are!t carrier Thr" sca!

*otio! detectio! ll sca! ty'e

APP)ICATIONS FOR P&OTOE)ECTRIC SENSORS



EPREFER.PPT - 018

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(Poka-Yoke) CONCEPTAD$ANTA%ES DISAD$ANTA%ES APP)ICATIONS

*a%!et 9'erated - !e'e!si$e - *a%!et re"ired - +ec"rity a!d safety

&reed relay( - =ery selecti$e tar%et - +e!siti$e to weldi!% i!terloci!% ide!tificatio! fields - +e!si!% thr" metal

Aall Effect - om'lete switchi!% - *a%!etic tar%et o!ly - ey)oard

f"!ctio! is i! a si!%le - Etremely se!sit i$e to

i!te%rated circ"it i!d"strial e!$iro!me!t

- 9'erates "' to 150h;

- Ai%h tem'erat"re

&150 de%rees (

- <ood resol"tio!

@ltraso!ic - +e!ses all materials - Resol"tio! - !ti-collisio! o! <=

- Re'eata)ility Coors

- +e!siti$e to )ac%ro"!d

a!d e!$iro!me!t cha!%es

- Cista!ce limitatio! to

0mm

!d"cti$e - Resista!t to harsh - Prese!ce detectio! o! all

e!$iro!me!ts i!ds of machi!es

- Easy to i!stall - =ery 'o'"lar

- =ery 'redicta)le

a'aciti$e - +e!ses all materials - =ery se!siti$e to - 6e$el se!si!% with li"ids

- Cetects thro"%h walls e!$iro!me!t cha!%es a!d !o!-metall ic 'arts

Photoelectric - +e!ses all materials - +")ect to co!tami!atio! - Parts detectio!

- *aterial ha!dli!%

- Paca%i!%

- =ery 'o'"lar

Pie;o-electric - Tor"e &a"tomated or

ma!"al(



EPREFER.PPT - 020

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(Poka-Yoke) CONCEPT

NE- APP)ICATIONS:

• Press"re sensing

• Shape sensing

• -eight sensing

• Presence sensing

• Color sensing 8!ar1 #s light;

• Tor+"e sensing 8Pie>oelectric;

• Position sensing

• C"sto2 ? a!apti#e si>e parts

• $ac""2 sensing

• Flo* sensing 8e0g0 gallon ? 2in"te;



EPREFER.PPT - 021

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(Poka-Yoke) CONCEPT

PO<AYO<E Sensors at a De2ing Pri>e -inner 60 Mechanical @0 &eat Sensor

0 Magnetic 60 %as Sensor

0 Bea2 C"t 660 Force Sensor

0 S"per Sonic 60 Tor+"e Sensor

70 I2age Sensor 60 Meter Relay

0 Co"nter 60 $i3ration Sensor

0 Bea2 Re(lector 670 A"to2atic Meas"re2ent

0 Press"re Sensor



EPREFER.PPT - 022

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(Poka-Yoke) CONCEPT

T&E MOST EFFECTI$E TYPES OF ERROR NOTIFICATION MEANS

%etting the OperatorGs Attention:

• $is"al Signal 8(lashing light is 3est;• A"!io Signal 8lo"! an! persistent4 e0g0 3"rglar alar2;• Protecti#e Barrier 8to pre#ent !e(ect or operator inH"ry;• -hen "se!: lo* !e(ect occ"rrence rate an! *hen

repairs can 3e 2a!e0

Sh"tting Do*n the Operation:

• 'pon !etecting a ,noncon(or2ance/ the operation

is si2ply sh"t !o*n4 i0e0 the ne9t part *ill not 3e processe!0• -hen "se!: relati#ely higher occ"rrence rates an!

*hen repairs are not possi3le0



EPREFER.PPT - 023

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(Poka-Yoke) CONCEPT

Pro3le2 TypeError Proo(ing

Installe!

Type o(

Sensor 'se!

Type o(

Inter#ention 'se!

*issi!% 5om'o!e!ts o"!ter to $erify *icro-switch *achi!e i!terloc

correct !"m)er of

com'o!e!ts

Pre-co"!ti!% the :o!e :o!e

!"m)er of com'o!e!ts

Fit"re at the o'eratio! Proimity switch *achi!e i!terloc

to detect the 'rese!ce

of com'o!e!t from the

're$io"s o'eratio!

E!correct Processi!% Process se"e!ce :o!e &all fit"res :o!e

fit"ri!% s'ecially desi%!ed(

.ro!% 5om'o!e!ts =erifyi!% com'o!e!t 6i%ht tra!smissio! =ideo or a"dio alarms

sha'e# wei%ht# or

dime!sio! switches

EAMP)ES OF PO<AYO<EGS

FOR T&E T&REE MOST COMMON PROB)EMS



EPREFER.PPT - 024

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(Poka-Yoke) CONCEPT

-hat is the 3est 2etho! (or sensing (l"i! le#els

(or a 2achine.

-hat is the 3est 2etho! (or sensing 2agnets (or

electric 2otors.

-hat are three possi3le 2etho!s (or sensing 3"rs

on a cylin!er 3ore.

-hat is the 3est 2etho! (or !etecting the presence

o( an Oring.

BEST SENSIN% IDEAS



EPREFER.PPT - 025

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Fo"r Categories o( Errors ="estions to As1....

Missing Parts s there a model mi s"ch that some models re"ire a 'art

while others re"ire !othi!% at all i! that locatio!?

s the 'art assem)led as a small 'art after some mai!

acti$ity?

s the 'art diffic"lt to see after )ei!% assem)led?



EPREFER.PPT - 02

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Missing PartsMissing Parts

s the 'art G

@!see! or "!to"ched i!

s")se"e!t 'rocess ste's? Ciffic"lt to see d"ri!% assem)ly?

Ciffic"lt to assem)le?

Ciffic"lt to see after assem)ly?

Ciffic"lt to differe!tiate )etwee! 're

a!d 'ost assem)ly?

s the 'art G

@!see! or "!to"ched i!

s")se"e!t 'rocess ste's? Ciffic"lt to see d"ri!% assem)ly?

Ciffic"lt to assem)le?

Ciffic"lt to see after assem)ly?


a!d 'ost assem)ly?

a! a!ythi!% )e do!e to resol$e this

i! desi%! of 'rod"ct/'rocess?

a! the 'art )e com)i!ed with

a!other 'art?

a! the 'art )e elimi!ated?



a! the 'art )e com)i!ed witha!other 'art?


hat ca! )e do!e to detect whether

the 'art has )ee! assem)led?

Detection device - tor"e

co"!ter# 'hotoelectric eye o$er

co!tai!er# limit switch atdis'e!ser#....


the 'art has )ee! assem)led?

Detection device - tor"e

co"!ter# 'hotoelectric eye o$er

co!tai!er# limit switch at

dis'e!ser#....

6oc o"t s")se"e!t o'eratio! if 'art

is missi!%.

Lock out device - limit switch#

co!d"cti$ity se!sor...


is missi!%.



m'leme!t o'erator i!str"ctio!s#$is"al aids a!d trai!i!% as mi!im"m

re"ireme!t

HE+

:9

:9

Implement Error Proofing

(process/design change and/or

detect/lock out device)

Verify results

HE+



EPREFER.PPT - 02

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Brainstor2 Error Proo(ing Mechanis2

*ae $isi)le/o)$io"s if missi!%

olor co!trast

=isi)le at !"mero"s o'eratio!s a!d 'ac

@se mirrors

Positio! of 'art as mo$es dow! li!e

=is"al aid/'ict"re 'osted with 'art 'rese!t a!d hi%hli%hted

Redefi!e 'rocess ssem)le early i! 'rocess

+"ccessi$e chec

Rearra!%e m"lti'le write-"' to elimi!ate Isometimes do/sometimes do!>tJ

*o!itor 'art s"''ly

9!ly s"''ly 'arts !eeded for that model &!o "estio!s-if there are 'arts 'rese!t#

"se them(

6ot co!trol# co"!t 'arts-m"st e"al K 'ieces 'rod"ced

+e!sors

Photoelectric eyes to detect# loc o"t "!til corrected

6imit switch to detect# loc o"t "!til corrected

*odify desi%!

Elimi!ate 'art

Missing Parts - Thought Starters



EPREFER.PPT - 02

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Misasse23le! Parts s the o'eratio! diffic"lt for the o'erator to see as they

'erform the o)?

s there a! assem)ly or 'ositio!i!% o'eratio! that ca! )e

com'leted i!correctly?

Fo"r Categories o( Errors="estions to As1....



EPREFER.PPT - 028

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Misasse23le! PartsMisasse23le! Parts

s the 'art G

Ciffic"lt to see d"ri!% assem)ly?

Ciffic"lt to assem)le? Ciffic"lt to see after assem)ly?


a!d 'ost assem)ly?

6aci!% %"ides or fit"res for 'ro'er

assem)ly or 'ro'er ali%!me!t?

s the 'art G

Ciffic"lt to see d"ri!% assem)ly?

Ciffic"lt to assem)le? Ciffic"lt to see after assem)ly?


a!d 'ost assem)ly?

6aci!% %"ides or fit"res for 'ro'er

assem)ly or 'ro'er ali%!me!t?



&%"ides# fit"res# a"tomatio!(


a!other 'art?




&%"ides# fit"res# a"tomatio!(a! the 'art )e com)i!ed with

a!other 'art?



the 'art has )ee! misassem)led?

Detection device - tor"e co"!ter#

'hotoelectric eye# limit switch


the 'art has )ee! misassem)led?

Detection device - tor"e co"!ter#



is misassem)led.




is misassem)led.




re"ireme!t

HE+

:9

:9




Verify results

HE+



EPREFER.PPT - 030

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=is"al aids

=is"al aid/'ict"re 'osted with correct 'ositio! hi%hli%hted

Redefi!e 'rocess

ssem)le early i! 'rocess

+"ccessi$e chec or'lace or%a!i;atio!

9r%a!i;e for maim"m ease a!d $isi)ility

+e!sors



*odify/desi%! fit"re @!a)le to assem)le i!correctly

*odify desi%!

Elimi!ate 'art

Pre$e!t misassem)ly - e.%. two si;es of st"ds

Pro$ide %"ides or refere!ces

Misassembled Parts- Thought Starters



EPREFER.PPT - 031

2/13/00

Incorrect Processing s there a! o'eratio! that re"ires a reco%!itio! of some

characteristic to determi!e what to do with the 'art !et?

REJECTSGOOD




EPREFER.PPT - 032

2/13/00

Incorrect ProcessingIncorrect Processing

Coes the o'eratio! re"ire reco%!itio!

of some characteristic to determi!e

what to do with the 'art?

(e.g. ed light indicates place in re!ect

pile" visual inspection #or pre-de#ined

de#ects)

Coes the o'eratio! re"ire reco%!itio!

of some characteristic to determi!e

what to do with the 'art?

(e.g. ed light indicates place in re!ect

pile" visual inspection #or pre-de#ined

de#ects)



&fit"res# a"tomatio!(


a!other 'art?




&fit"res# a"tomatio!(




the 'art has )ee! i!correctly

'rocessed?

Detection device - reset )"tto!#



the 'art has )ee! i!correctly

'rocessed?

Detection device - reset )"tto!#



is i!correctly 'rocessed.




is i!correctly 'rocessed.




re"ireme!t

HE+

:9

:9




Verify results

HE+



EPREFER.PPT - 033

2/13/00


=is"al aids

L"ality alert i!dicati!% hi%h 'ote!tial for error

Fit"re or tem'late o"tli!i!% 're-defi!ed defects

7o%ey or sam'le )oards for $is"al i!s'ectio!

Redefi!e 'rocess

Reset or ac!owled%e )"t at the a''ro'riate !et o'eratio!

"tomate

or'lace or%a!i;atio!

+e'arate a!d clearly la)el reect locatio!s/co!tai!ers

+e!sors



$ncorrect Processing- Thought Starters



EPREFER.PPT - 034

2/13/00

Incorrect Parts s there a selectio! of 'arts i! fro!t of the o'erator that

wo"ld allow for the wro!% 'art to )e chose! a!d assem)led?




EPREFER.PPT - 035

2/13/00

Incorrect PartsIncorrect Parts

s there a selectio! of 'arts a$aila)le

at the worstatio!?

re similar 'arts assem)led o!to the'rod"ct at the same locatio!?

s there a selectio! of 'arts a$aila)le

at the worstatio!?

re similar 'arts assem)led o!to the'rod"ct at the same locatio!?



&o!solidatio!# se'arate o'eratio!s(


a!other 'art?




&o!solidatio!# se'arate o'eratio!s(




the i!correct 'art has )ee!

assem)led?

Detection device - )ar code#



the i!correct 'art has )ee!

assem)led?

Detection device - )ar code#


6oc o"t s")se"e!t o'eratio! if the

i!correct 'art is detected



6oc o"t s")se"e!t o'eratio! if the

i!correct 'art is detected




re"ireme!t

HE+

:9

:9




Verify results

HE+



EPREFER.PPT - 03

2/13/00


*ae $isi)le/o)$io"s if i!correct 'art

olor code - match 'art to 'rod"ct

=isi)le at !"mero"s o'eratio!s a!d 'ac

Positio! of 'art as mo$es dow! li!e

=is"al aid/'ict"re 'osted with correct 'art 'rese!t a!d hi%hli%hted

Redefi!e 'rocess

ssem)le early i! 'rocess

+"ccessi$e chec

Rearra!%e m"lti'le write-"' to se'arate assem)ly of lie 'arts

*o!itor 'art s"''ly

9!ly s"''ly 'arts !eeded for that model

+e!sors



*odify/desi%! fit"re

@!a)le to assem)le i!correct 'art

*odify desi%!

Elimi!ate 'art

Pre$e!t assem)ly of i!correct 'art

$ncorrect Parts- Thought Starters



EPREFER.PPT - 03

2/13/00

The Error Proofng Process:– Utilizes a multi-unctional aroach

–!s "ri#en $% Customer Satisaction an"allo&s or 'uic( resonse an"imlementation o solutions

– !s use" to )*ill+ ro$lems– !s "ocumente" in the ,Pro$lem Sol#ing

Document .PSD/– Suorts Continuous !mro#ement

0etho"olog%– !s the ,Contain ste in the 1 Ste Pro$lem

Sol#ing Process

People&

Teamwork

12 E#aluate 32 !"enti%

42 5nal%ze

62 Plan

72 !mlement

Prevent Select

ContainCorrect

Error-Proofing Process“Quick Response / Quick Implementation”

!nstitutionalize

the Solutionan" the Ongoing

Control

InstitutionalizeContinuousImprovement

Opportunity

Pro$lem Sol#ing Documentation

8irst Time

'ualit%

.82T2'2/

at

Oeration

Deartmental

Containment

Station

9et&or(

!nternal

Plant

5u"it

Customer

Reects

.PP0/

S%stematic

Pro$lem

Sol#ing

Process

Candidates for Error Proofing

;arrant%

!normation



EPREFER.PPT - 03

2/13/00

6J DEFECT RATE 899% YIELD;

OF A)) STATIONS

RES')TS IN J

CONFORMIN% PROD'CTS

ell 1

ell 3

ell 2

ell 4

1M

Cefect

Rate1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1MCefect

Rate

1M

Cefect

Rate1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate

1M

Cefect

Rate



EPREFER.PPT - 038

2/13/00

PROCESS FA))O'T TAB)E

%entered Process

Process capa3ility ratio Parts per 2illion !e(ecti#e

0.50 133#00.00

0.5 24#400.00

1.00 2#00.001.10 8.00

1.20 31.00

1.30 8.00

1.40 2.00

1.50 .0

1.0 1.01.0 0.34

1.0 0.0

2.00 0.001



EPREFER.PPT - 040

2/13/00

DIDN’T WASHDIDN’T WASH

HANDSHANDS

DIDN’T WASHDIDN’T WASHHANDSHANDS



EPREFER.PPT - 041

2/13/00

Implementation Procedure:

• Product Tooling Design Phase

N Predict Potential &ualit' De#ects during

Product Tooling Design Stage.se DM to modi#' Tooling Design to

Prevent Potential De#ects #rom *ccurring inProduction based on Potential De#ects$denti#ied.

+uild Poka-,oke Devices into the Processhere Design ies0 can not be$ncorporated.

ERROR PROOFIN%



EPREFER.PPT - 042

2/13/00

• Production Phase

N etro-#it Poka-,oke Devices into 1isting

Tooling se &ualit' 2istor' to Target Potential 1rror

Proo#ing 3pplication Sites

*btain Set-p *perator $nput as to 4here to

3ppl' 1rror Proo#ing0 Devices as ell as the T'pe o# Devices to se.

Implementation Procedure (ontinued!:

ERROR PROOFIN%



EPREFER.PPT - 043

2/13/00

"ome Error Proofing #uidelines:• Standardi5e Press Shut 2eights

• tili5e Digital Process Parameter 6ages

• 3ppl' Locating Devices to Dies" itures" 1tc.

• 6ages Pre-calibrated prior to Start o# Set-p

• tili5e %ommon/0&uick %onnect ittings and%lamping 2ardare

• *ne 4a'0 Loading • 7889 %omponent Presence %heck

• :eri#' Machine %'cle %ompleted0

• Detected 1rror0 Stops Process

ERROR PROOFIN%

CAS'A) CONNECTIONS BET-EEN



CAS'A) CONNECTIONS BET-EENDEFECTS AND &'MAN ERRORS

Ca"ses

o( De(ects

Omitted Processing

Processing ErrorsErrors Setting Up Workpieces

Missing Parts

Wrong Parts

Processing Wrong Workpiece

Misoperation

Adjustment Error

Improper Equipment Setup

Improper Tools and Jigs

&"2an

Errors

I n t e r n a t i o n a l

M i s u n d e r s t a n d i n g

F o r g e u l

M i s i d e n t i i c a t i o n

A m a t e u r s

W i l l u l

I n a d ! e r t e n t

S l o " n e s s

# o n $ S u p e r ! i s i o n

S u r p r i s e

Strongly Connecte! Connecte!

SOURCE: NKS/Factory Magazine “Poka-Yoke”

Documents

Errorproofingtechnique Pokayoke 100605213544 Phpapp02