Lets Understand Cost Of Defect Presently cost of poor quality is on very high. Company miserably failed to increase their profit. Each loss can be converted in to Profit Cost of internal rejection Cost of External rejection Cost of complaint Cost off Warranty claims Cost of inspection

What is Poka Yoke Error proofing is a structured approach to Ensuring Quality all the way through your work processes. enables you to Improve Your production or Business Processes to Prevent Specific Error / defects Focus of error proofing is Not on identifying and Counting Defect Elimination of their cause Error And Defect are Different. Poka -Yoke will not prevent Defect But Prevent Error.

What is Poka Yoke The success of poka-yoke is to provide some intervention device or procedure to catch the mistake before it is translated into nonconforming product In a “fat” system, any defects that are found can simply be discarded while operations continue. These defects are later counted, and if their numbers are high enough, root-cause analysis is done to prevent their recurrence. But in a lean enterprise, which concentrates on producing smaller batch sizes and producing to order versus adding to inventory, a single defect can significantly impact performance levels. When a defect occurs in a lean enterprise, operations must stop while immediate action is taken to resolve the situation. Obviously, such pauses in operations can be costly if defects occur often. Therefore, it is important to prevent defects before they can occur

Error Proofing Devices Elements of Error Proofing General Inspection 100 % inspection Error Proofing Devices Immediate Feedback

General Inspection Source Inspection Informative Inspection (RM CHECK) Informative Inspection (Line Inspection) Successive Inspection Self Inspection Judgement Inspection (Final Inspection)

Physical Contact Sensor Error Proofing Devices Guide Pin Limit Switch Physical Contact Sensor Counter Alarm Checklist / Graphics

Immediate Feedback Warning Method Control Method

Ways to Mistake Proofing Old Method New Method Reprimand Worker Remove Opportunity of Error -Improve Process - Make Wrong action more difficult Retrain worker If you can not remove opportunity of Error - Make it easier to remove error Motivational Talk Tell them to Pay them attention

First Poka Yoke Shingo Suggested – A solution that become the first Poka Yoke In the old Method a worker began by taking two springs, out of a large parts box and then assembled a switch. Problem – Some time worker Failed to put 2 springs in the switches New Approach – New Approach, two spring will be lifted and kept in empty plate, After assembly if any spring remain there, worker will came to know the thing.

Common Sources of Errors Human Lack of Knowledge/ Skill Mental Errors Sensory Overload Mechanical Process area Distraction Loss of Memory Loss of Emotional Control Process Step Transportation Material Machines Environment Lack of Effective Standard Rapid Repetition High Volume Adjustment Mixed Part Multiple Step Infrequent Process

Poka – Review of Human Error Mistake prevention in the work environment. Mistake detection (Shingo’s informative inspection). Mistake prevention (Shingo’s source inspection). Preventing the influence of mistakes. Mistake Prevention in the Work Environment

Elimination Replacement Prevention Facilitation Detection Mitigation Poka Yoke Principal Elimination Replacement Prevention Facilitation Detection Mitigation

Poka Yoke Principle Elimination – This seeks to eliminate the possibility of Mistake by redesigning the product or process so that the task or part is no longer necessary. Example : Product simplification or part consolidation that avoids a part defect or assembly Mistake in the first place Replacement – Substitute a more reliable process to improve consistency. Example : Use of robotics or automation that prevents a manual assembly Mistake, automatic dispensers or applicators to ensure the correct amount of material such as an adhesive is applied.

Poka Yoke Principle Prevention – Design the product or process so that it is impossible to make a mistakes at all. Example – Limit switches to assure a part correctly placed before process is performed; part features that only allow assembly the correct way, unique connectors to avoid misconnecting wire harnesses or cables, part symmetry that avoids incorrect insertion. Facilitation – Employ techniques and combining steps to make work easier to perform. Example – visual controls including colour coding, marketing or labeling parts to facilitate correct assembly ; exaggerated asymmetry to facilitate correct orientation of parts; a staging tray that provides a visual control that all parts were assembled, locating features on parts.

Poka Yoke Principle Detection – Identify a mistake before further processing so that the user can quickly correct the problem. Examples – sensors in the production process to identify when parts are incorrectly assembled built-in self-test (BIST) capabilities in products Mitigation – Minimizing the effects of Mistakes. Examples – fuses to prevent overloading circuits resulting from shorts, products designed with low – cost, simpler rework procedures when a Mistake is discovered, extra design margin or redundancy in products to compensate for the effects of Mistakes.

Identify at least 2 Poka Yoke