Poka yoke lean tool

mistake proofing tools in lean manufacturing

1. “ Poka - Yoke” (Mistake Proofing) Presented by Ariful Islam Industrial and Production Engineering (IPE) Jessore University of Science and Technology(JUST) A Presentation On:

2. What is Poka Yoke ? Mistake-proofing is the use of process or design features to prevent errors or their negative impact. It is also known as mistake proofing.

3. Origin Poka Yoke, Japanese slang means “avoiding inadvertent errors” Poka Yoke concept was first applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent human errors.Initially it was described as Baka -Yoke, meaning fool proofing or idiot proofing .But the name later changed to the milder Poka -Yoke.

4. Benefit of Poka -yoke Improves quality and customer satisfaction. Prevents causing error,defect . Cost effective . Easy to implement.

5. Costs of Defects Making processes better leads to reduced, Rework Scrap Warranty costs Inspection costs

6. 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)

7. How poka -yoke works? Prevention Detection in Process Detection After Mistake Elimination of issues at the source, or prevention of errors from occurring Catch errors during processing before becoming a problem Detect defects before they move to next step

8. Poke yoke devices should have the following characteristics Usable by all workers S imple to install Does not require continuous attention from the operator Provides instantaneous feedback, prevention, or correction .  

9. Some poka -yoke devices Error Detection and Alarms Tem p lates Checklists Slot in the conveyor line

10. Example of using Poka yoke concept Stove-A

11. Example of using Poka yoke concept Stove-A Stove-B

12. Conclusion A simple Poka -yoke device can creat a great influence.But these devices are not so expensive even a lot of Shingo's poke yoke devices cost less than $50. So it will be wise decision to implement Poka-yoka strategy to eliminate mistakes that often occurs due to losing concentration on it.

13. Thank you

14. Any question ?