Poka Yoke & Mistake Proofing

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Presentation transcript:

Poka Yoke & Mistake Proofing Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

© 2007 Superfactory™. All Rights Reserved. Contents Introduction Background and History Components and Implementation Knowledge Check © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Introduction Mistake proofing and poka yoke is the use of process or design features to prevent errors or their negative impact. The term Poka yoke is Japanese slang for “avoiding inadvertent errors” which was formalized by Shigeo Shingo. Inexpensive. Very effective. Based on simplicity and ingenuity. © 2007 Superfactory™. All Rights Reserved.

Background and History 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. In the new approach, a small dish 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 dish. Then the worker assembles the switch. If any spring remains on the dish, then the worker knows that he or she has forgotten to insert it. The new procedure completely eliminated the problem of the missing springs. © 2007 Superfactory™. All Rights Reserved.

Components and Implementation Everyday Examples Error Proofing and SPC Inspection Techniques Types of Poka Yokes © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Everyday Examples 3.5 inch diskettes cannot be inserted unless diskette is oriented correctly. This is as far as a disk can be inserted upside-down. The beveled corner of the diskette along with the fact that the diskette is not square, prohibit incorrect orientation. Fueling area of car has three error-proofing devices: 1. insert keeps leaded-fuel nozzle from being inserted 2. tether does not allow loss of gas cap 3. gas cap has ratchet to signal proper tightness and prevent overtightening. New lawn mowers are required to have a safety bar on the handle that must be pulled back in order to start the engine. If you let go of the safety bar, the mower blade stops in 3 seconds or less. © 2007 Superfactory™. All Rights Reserved.

Everyday Examples: Whose signature is required? Before: After: © 2007 Superfactory™. All Rights Reserved.

Ten Types of Human Mistakes Forgetfulness Misunderstanding Wrong identification Lack of experience Willful (ignoring rules or procedure) Inadvertent or sloppiness Slowliness Lack of standardization Surprise (unexpected machine operation, etc.) Intentional (sabotage) © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. 3 Rules of Poka Yoke Don’t wait for the perfect poka yoke. Do it now! If your poka yoke idea has better than 50% chance to succeed…Do it! Do it now….improve later! © 2007 Superfactory™. All Rights Reserved.