1. Visual Control and Failsafing
GEOP 4316

2. Outline Visual Controls / Management
Definitions and Objectives
Examples
Fail-safing (error proofing, poka yoke)

3. Visual Controls/ Management

4. Visual Controls / Management
Definitions
Technique whereby control of an activity or process is made easier or more effective by deliberate use of visual signals.
These signals can be of many forms (examples already and later on)
Visual control communicates very effectively the information needed for decision making.
Visual control is very often about replacing textual or numeric data displays with carefully designed graphical displays whose meaning can be understood at a glance and are therefore more likely to be effective at communicating the required message.

5. Visual Controls / Management
Visual control are means, devices, or mechanisms that are designed to manage or control the operations (processes) so as to meet the following purposes:
make the problems, abnormalities, or deviation from standards visible to everyone and thus corrective action can be taken immediately,
display the operating or progress status in an easy to see format.
provide instruction.
convey information.
provide immediate feedback to people.

6. Visual Controls / Management
Some common visual applications
color-coded pipes and wires
painted floor areas for good stock, scrap, trash, (5S)
shadow boards for parts and tools (5S)
indicator lights/ production status boards (Andon)
workgroup display boards with charts, metrics, procedures, etc. (will discuss more on the KPI section)
process flowcharts, work instructions, photos of good parts

7. Visual Controls / Management
A place that uses VC/VM
is safe, clean and organized
is easily understood and managed through involvement by all
creates high quality products using standardized processes
communicates progress
In the visual workplace, anyone will easily know the who, what, when, where, why, and how of an area within 5 minutes

8. Visual Controls / Management
Andon boards: real time production and line status

9. Visual Controls

10. Visual Controls / Management

11. Visual Controls / Management

12. Visual Controls / Management

13. Fail-safing (Poka Yoke)

14. Fail-safing (error proofing, Poka Yoke)
Definition
Poka-yoke (ポカヨケ) is a Japanese term that means "fail-safing" or "mistake-proofing".
A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka).
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the Toyota Production System.

15. Fail-safing (Poka Yoke)
Basic Elements
Shigeo Shingo recognized three types of poka-yoke:
The contact method identifies product defects by testing the product's shape, size, color, or other physical attributes.
The fixed-value (or constant number) method alerts the operator if a certain number of movements are not made.
The motion-step (or sequence) method determines whether the prescribed steps of the process have been followed.

16. Fail-safing (Poka Yoke)
Either the operator is alerted when a mistake is about to be made (warning poka-yoke), or the poka-yoke device actually prevents the mistake from being made (control poka-yoke).
Shingo argued that errors are inevitable in any manufacturing process, but that if appropriate poka-yokes are implemented, then mistakes can be caught quickly and prevented from resulting in defects.
By eliminating defects at the source, the cost of mistakes within a company is reduced.

17. Fail safing Component of Quality at the Source
Each step responsible for its quality
be sure raw materials are defect free
do work
be sure result is defect free
The quality of the process/ system is not the responsibility of the QA/QC department
Slogans:
Right first time
Zero defects

18. Fail safing
Why?
If it takes 1 hour to fix a problem where it occurs, it may take 100 hours downstream, and it may take 1000 hours at the customer
What are cost implications?

19. Fail safing A version of contingency planning and defensive design
Brainstorm of possible misuses, errors, failures …
Develop ways during the design/ planning of a system to
prevent errors, ….
once they happen, have that knowledge quickly
develop mitigation actions

20. Fail safing
Examples

21. Fail safing Examples outside manufacturing/ physical products
Warning when deleting a file or closing without saving (software)
Devices that shutdown when opened (drier) or released (lawnmower)
Checklists at the end of an application/ form
Different organizations have developed industry specific methods