Poka-Yoke (Mistake Proofing)

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Presentation transcript:

Poka-Yoke (Mistake Proofing) 5/22/05 Fixed repeated note on slides 24-28. 050316 Added slide 2 with quotation from Douglas Adams Added Sean’s Law to slide 4 Slide 24, added instructor note, “May be performed as a group or in break-out groups of 4-5 ea.”

“A common mistake of people who try to make things completely fool-proof is to underestimate the ingenuity of complete fools.” -- Douglas Adams

Module Outline Background Introduction First poka-yoke device Categories of poka-yoke Examples Tips and techniques Summary Practical exercises References

Background The real world People make mistakes People are human Mistakes are inevitable Murphy’s Law: “If something can go wrong it will” Sean’s Law: “Murphy was an optimist”

Background The old way to prevent mistakes Reprimand worker Retrain worker Motivational talks Tell them to “be more careful” Tell them to “pay attention”

Background A better way to prevent mistakes Remove the opportunity for error Improve the process Make wrong actions more difficult If you can’t remove the opportunity for error Make it easier to discover the errors that do occur

Introduction Shigeo Shingo invented the Japanese concept called Poka-Yoke (pronounced POH-kah YOH-kay) Poka-Yoke means to mistake proof the process The essential idea of poka-yoke is to design your process so that mistakes are impossible or at least easily detected and corrected

First Poka-Yoke Device Shingo suggested a solution that became the first Poka-Yoke device In the old method, a worker began by taking two springs out of a large parts box and then assembled a switch Problem: Sometimes the worker failed to put both springs in the switch

First Poka-Yoke Device In the new approach, a small plate is placed in front of the parts box and the worker's first task is to take two springs out of the box and place them on the plate Then the worker assembles the switch. If any spring remains on the plate, then the worker knows that he or she has forgotten to insert it The new procedure completely eliminated the problem of the missing springs Empty plate

Categories of Poka-Yoke Poka-yoke devices fall into two major categories: Prevention Detection A prevention device engineers the process so that it is impossible to make a mistake at all

Prevention Example A classic example of a prevention device is the design of a 3.5 inch computer diskette Impossible to put in upside down

Categories of Poka-Yoke A detection device signals the user when a mistake has been made, so that the user can quickly correct the problem

My car beeps if I leave the key in the ignition Detection Example My car beeps if I leave the key in the ignition

Other Poka-Yoke Examples Locking devices on filing cabinet prevents opening multiple drawers which would lead to tipping

Other Poka-Yoke Examples Gas pumps are equipped with hose couplings that break-away and quickly shut-off the flow of gasoline

Other Poka-Yoke Examples This rental truck has a door latch which will not allow the loading ramp to slide out while the latch is in the closed position

Other Poka-Yoke Examples The Saf-T-Smart valve kit detects when the washing machine is operating and opens the valves allowing water to flow freely. When the washing machine is off the valves are closed, reducing pressure on the hoses and avoiding serious water damage (and returning to a flooded house).

Other Poka-Yoke Examples The U.S. Consumer Product Safety Commission has recorded 105 deaths that were caused by wheelchairs rolling away from the person. The response? A mistake- proofing device that locks the wheelchair when no one is sitting in it. An unlocking lever on the handle allows the wheelchair to be moved when empty.

Other Poka-Yoke Examples When pipes are likely to freeze, the common practice is to open faucets slightly and let them drip. This device automatically opens a valve that discharges just enough water to avoid pipes freezing.

Other Poka-Yoke Examples Limit switches Interlocks Jigs Alignment marks Go/no-go devices Electronic eyes Checklists

Tips and Techniques Eliminate unnecessary or duplicate steps Use flow charts to visualize the process Keep it simple You don’t have to spend a lot of money Use many Poka-Yoke devices in a process There isn’t a quota on how many you can use

Summary Poka-Yoke means to mistake proof the process Remove the opportunity for error Improve the process Make wrong actions more difficult If you can’t remove the opportunity for error Make it easier to discover the errors that do occur

Each table or group is to list other examples of Class Exercise Each table or group is to list other examples of Poka-Yoke (mistake proofing) devices Brainstorming!! Examples: Treadmill with safety kill switch on a string Iron with automatic cut-off Lawnmower will cut-off if you get off Bathroom sink with overflow hole Circuit breaker will trip before overheating Garage door opener Door-a-jar light on car Fluid indicator on car Window on envelope prevents letter from going to the wrong person

Class Exercise Mistake-Proof This: I always end up putting slides into the carousel projector up-side-down, backwards, or sideways. Propose a change that will ensure the correct orientation or make incorrect orientation obvious. Suggested answer: Mark the top left or right corner with a bright marker. May be performed as a group or in break-out groups of 4-5 ea.

Class Exercise Mistake-Proof This: A local countertop company makes and then loads the countertop pieces on to a truck and goes to the customer’s home and installs the countertop. More than 15% of all installation jobs have to be done with more than one trip to the customer’s 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.

Class Exercise 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.

Class Exercise 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.

References John Grout Other authors www.campbell.berry.edu/pokayoke www.mistakeproofing.com "Mistake-Proofing Production." Production and Inventory Management Journal Vol. 38, No. 3, pp. 33-37. "Failsafing and Measurement Control Charts" with Brian T. Downs. Quality Management Journal. Vol. 5, No.2, pp. 67-75. Other authors Services: Make your service fail-safe. Chase, R. B., and D. M. Stewart. 1994.Sloan Management Review (Spring): 35-44. Links to design:The role of variation, mistakes, and complexity in producing nonconformities. Hinckley, C.M. and Barkan, P. 1995. Journal of Quality Technology 27(3):242-249. The design of everyday things: Norman, D.A. 1989. New York: Doubleday. (“poka-yoke” not discussed, still applies, very cool.). IMPROVE Poka Yoke rwk.ppt Module - Knight 05/07/02.

QUESTIONS