Monozukuri Adam Arif 2015

CONTENTS  INTRODUCTION  WHAT IS ERROR ?  POKA YOKE OVER ERRORS  IMPORTANCE  WHEN TO USE  HOW TO USE  METHODS  DAY 2 DAY EXAMPLES 2

NO WHAT IS POKA YOKE ??? 3 a) Brother of PIKACHU b) A new Chinese action hero c) A disease It’s a mistake proofing technique used by each of us

 Pronunciation POH-KAH-YOH-KAY  YOKERU Avoid  POKA Mistakes  Coined in Japan during the 1960s by as part of the Toyota Production System INTRODUCTION 4 Shigeo Shingo

 Initially ‘BAKA-YOKE’ ‘fool-proofing’  Dishonorable and offensive  Changed to ‘POKA-YOKE’ ‘mistake-proofing’ 5 INTRODUCTION (Cont.)

WHAT IS ERROR ???  A mistake : deviation from what is correct, right, or true  How to prevent error  Old way Scold people Retrain them Tell them to be more careful…  New wayTraining and motivation Easy way to do a job  The potential for human error can be dramatically reduced 6

What Causes Defects?  Errors lead to defects 1. Poor procedures or standards 2. Machines 3. Non-conforming material 4. Worn tooling 5. Human Mistakes 7

8 TEN TYPES OF HUMAN MISTAKES n Forgetfulness n Misunderstanding n Wrong identification n Lack of experience n Willful (ignoring rules or procedure) n Inadvertent or sloppiness n Slowliness n Lack of standardization n Surprise (unexpected machine operation, etc.) n Intentional (sabotage)

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 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 10 Poka Yoke over Errors

11 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

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13 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.  Thought of as an extension of FMEA.

14 Contd…  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.

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. 15

Contd…  Errors can be of any type- i. Processing Error: Process operation missed or not performed per the SOP. ii. Setup Error: Using the wrong tooling or setting machine adjustments incorrectly. iii. Missing Part: Not all parts included in the assembly, welding, or other processes. iv. Improper part/item: Wrong part used in the process. v. Operations Error: Carrying out an operation incorrectly; having the incorrect version of the specification. vi. Measurement Error: Errors in machine adjustment, test measurement or dimensions of a part coming in from a supplier. 16

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 an  Attention Type: Highlighting that an error has been made. 17

Contd… 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. 18

Methods in Detail Contact Methods:- “Do not have to be high tech!”  These can be as simple as blocks that do not allow parts to be seated in the wrong position prior to processing. 19

Methods in Detail  Take advantage of parts designed with an uneven shape.  This method signals to the operator right away that the part is not in proper position. 20

Methods in Detail Constant Number or Counting Method:-  Used when a fixed number of operations are required within a process.  When a product has a fixed number of parts that are attached to it.  A sensor counts the number of times a part is used or a process is completed and releases the part only when the right count is reached. 21

Methods in Detail Motion-Sequence Method:-  The third poka yoke method uses sensors to determine if a motion or a step in a process has occurred.  If the step has not occurred or has occurred out of sequence, the sensor signals a timer or other device to stop the machine and signal the operator. 22

Day 2 Day Examples of Poka-Yoke 23

Disk 24

File cabinets, opening one drawer locks all the rest, reducing the chance of the file cabinet tipping. 25

Sinks 26

 Microwaves  Washing machines  Central locking in modern cars  Key locks in mobiles  Refrigerators  Beeps in automobiles if key is left in ignition 27

Okay, So This Is Not An Everyday Example For Anybody. I Hope You'll Find It Interesting … 28

Submarine The bathyscaph is a deep water submarine used to explore the very lowest parts of the ocean. It is electrically powered. Once at the bottom, if the batteries or electrical system fail the best outcome would be for the sub to return to the surface. The designers made this outcome occur by holding the ballast in place with electromagnets. When power is lost, the ballast drops off automatically and the sub starts its ascent. 29

John Grout Mistake-Proofing IS NOT Rocket science. A stand-alone technique that will obviate the need for any other responses to error. Widely known and practiced in manufacturing (even less in services generally, or healthcare specifically).

Characteristics of PokaYoke 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  A detection device cannot provide a complete error proof solution 31

32 TO ERR IS HUMAN NATURE BUT INTELLIGENCE IS ALSO HUMAN NATURE SO NEVER STOP FINDING WAYS OF NOT MAKING MISTAKES REMEMBER

Thanks For Keeping Patience 33

Which dial turns on the burner? Knowledge in the World: Stove A Stove B

John R. Grout 35 How would you operate these doors? B A C Push or pull? left side or right? How did you know? Knowledge in the World:

John Grout Whose signature is required? Before: After: Knowledge in the World:

Invalid Credit Card Customer (supplier): Online Customer Potential Error: Entering a wrong credit card Poka-Yoke: An error message

File Cabinet Customer (supplier): Office equipment user Potential Error: File cabinet tipping over due to multiple top drawers open Poka-Yoke: Only one drawer can be opened at a time

Automobiles Customer (supplier): Automobile Drivers Potential Error: Leave gas cap at gas station Poka-Yoke: Fastened Gas gap

Clearance Signs Customer (supplier): Drivers of tall vehicles Potential Error: Vehicles crashing into bridge, tunnel, parking facility, etc Poka-Yoke: Signs or devices to inform driver of vehicle height restrictions

Clearance Signs

Tugas presentasi minggu depan  Buatlah desain suatu alat dengan konsep kaizen dan poke yoke  Topik apa saja 42