2. 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

3. 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.

4. 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

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

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

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

8. Immediate Feedback
Warning Method
Control Method

9. 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

10. 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.

11. 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

12. 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

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

14. 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.

15. 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.

17. 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.

18. Identify at least 2 Poka Yoke