Training module on POKA - YOKE Basics.pdf

Training module on POKA YOKE basics, which will help a Trainer to drive a theory on basics & conduct a workshop consecutively.

1. POKA YOKE
TRAINING
MISTAKE PROOFING
TECHNIQUES
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2. OBJECTIVES
•Understanding basics of pokayoke
•Examples of pokayoke in the daily life
•Types of pokayoke devices/techniques (case studies)
•Poka yoke implementation strategies
•Where to implement poka-yoke
•Benefits of pokayoke in the work place
•Games & rewards –identify & implement right poke yoke
in the given process
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3. WHAT IS POKA YOKE ???
•Poka yoke, pronounced “poh-kahyoh-keh,” is a japanese term that translates to
“mistake-proofing” or “inadvertent error prevention.”
•It was invented in the 1960s by industrial engineer shigeo shingo and applied to
thetoyotaproduction system to eliminate errors.
•Poka-yoke is a quality control process used within lean manufacturing to ensure that
products are in perfect condition. It ensures that products are manufactured right the
first time, reducing the cost of trial and error.
•The core principle of poka-yoke is designing the production process to make it
impossible for human error to occur.
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4. POKA-YOKE-EXAMPLE IN OUR DAILY LIFE
•One such example of this that is referred to in training that 99% of
people have come across without realizing it pokayoke is the SIM
card shape and SIM card tray.
•If the SIM card did not have that notch, it could be put into the
phone in eight different ways. However, by simply adding a notch
there is only one possible way to put a SIM card in the tray.
•A simple change has saved billions of people from stress and
confusion.
•The widespread use of ATMs has certainly made banking
more convenient and shows no signs of diminishing usage.
•However, early on, the banks encountered a very
inconvenient problem; customers regularly drove off from
the ATM leaving their debit cards in the card slot of the
ATM.
•A simple but effective poka-yoke has been incorporated in
the ATMs so that an alarm sounds and continues to sound
until you have taken your card from the slot.
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5. POKA-YOKE-EXAMPLE IN OUR DAILY LIFE
•Many plugs, such as 3-pin plugs and
USB plugs, are designed so that they
can only be inserted into the outlet in
one orientation
•A classic example of the “contact”
method of error-proofing, which uses
the object’s physical shapes to prevent
mistakes from being made.
•Wheelchair wheels are designed to lock
when the chair isn’t in motion.
•This ensures the occupant doesn’t slip
when moving in and out of the
wheelchair, or ends up in a dangerous
situation with a runaway chair.
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6. POKA-YOKE-EXAMPLE IN OUR DAILY LIFE
•In order to prevent leaded fuel
from being placed in unleaded
automobiles, the size of the fuel
inlet was changed so that the
leaded fuel dispense nozzle would
not insert.
•A very common poka-yoke is involved every time we purchase fuel for our
automobiles.
•When unleaded fuel was introduced, there were many automobiles on the
road that still used leaded fuel.
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7. POKA-YOKE-POP OUT YOUR OWN IDEAS
Idea 1, 2, 3 ……
Personal Life
At work place
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8. TYPES OF POKA YOKE DEVICES
Poka-yoke methods can be broadly categorized into two:
PREVENTION DEVICES:
Designed to prevent errors from occurring in the first place. Examples
include fixtures that only allow parts to be assembled in the correct orientation or sensors that detect
missing components before the next step in the process begins.DETECTION DEVICES:
Identify errors after they have occurred but before they proceed further in the
production process. For example, a sensor might detect if a component is missing or improperly
assembled and stop the machine until the issue is resolved.
Detection Poka Yoke:Detection Poka Yoke:
Relies on alarms & other
warnings to catch mistakes
before they result in a defect
Prevention Poka Yoke:
mistakes from happening
Prevention Poka Yoke:
Uses Sensors & other
means to prevent
mistakes from happening
PROCESS MISTAKE DEFECTS
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9. Within these categories, specific poka-yoke
techniques can be implemented:
•Contact methods:these methods rely on physical
attributes like shape, size, or colourto ensure that
parts fit together correctly or are processed in the
right sequence.
•Fixed-value methods:involve controlling or
limiting the number of operations performed,
such as using counters or sensors to ensure that a
specific number of parts are assembled.
•Motion-step methods:involve sequencing
operations so that an error in one step prevents
the next step from being performed, forcing the
operator to address the issue.
TYPES OF POKA YOKE
DEVICES
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10. POKA YOKE-
Example In
the Industry
•INTRODUCTION TO POKA-YOKE (LEAN SIX SIGMA)
(YOUTUBE.COM)
•EXAMPLES OF POKA YOKE (YOUTUBE.COM)
•TOYOTA FIXED VALUE POKAYOKE / MISTAKE
PROOFING / ERROR PROOFING; BOLTS DISPENSER
(YOUTUBE.COM)
•POKA YOKE (YOUTUBE.COM)
•LCA POKA YOKE TO ENSURE ONE PIECE FLOW
(YOUTUBE.COM)
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11. CASE STUDY -1
•The car manufacturing industry faces
challenges when loading cars into freight
cars.
•Loading the car into the carrier proves
difficult due to inappropriate height.
•Therefore, we need a method to prevent
damage and ensure safety during car
transportation.
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12. POKA YOKE
SOLUTION -1
To fix these problems, we
implement poka yoke in the
following ways:
•We cut the wood to the
right length and labeled
and color code it.
•We attach the chain to
the wood and position
the house.
•We updated the
standardized work to
include a check for level.
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13. CASE STUDY 2
•Previously, detecting unfilled boxes in the
consumer product industry posed a
challenge for companies.
•Occasionally, boxes would remain unfilled
due to machine errors, yet they were still
closed and sent for shipment.
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14. To address this issue,
companies employ poka yoke
through the following
measures:
•They install pedestal fans
near the conveyors.
•They blow off unfilled boxes
from the conveyor.
POKA YOKE
SOLUTION -2
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15. POKA-YOKE IMPLEMENTATION STRATEGIES
Implementing poka yoke is straightforward and logical. Here are some steps for
you to follow:
•Identify company operations or work processes.
•Analyze the causes of failures using the5-whysmethod.
•Determine the most suitable poka-yoke method.
•Test the chosen plan and evaluate the results.
•Train operators, assess performance, and measure the success of the
implemented poka-yoke.
Use Cases
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16. WHERE TO IMPLEMENT
POKA-YOKE
Once you've decided on which process could benefit from a poka-
yoke device, there are a few areas to consider placing the device or
method within the workflow.
•Thebest locationfor a poka-yoke device is before an operator or
the machine starts a task.In other words, it's best to prevent any
errors by not allowing the process to even begin until a certain set
of conditions are met.
•Thesecond-best locationfor a poka-yoke device is during a
particular step within a process.This way, an operator or machine
receives an alert in the event of an error and stops the part or
processfrom moving down the line.
•Finally, thethird-best locationfor a poka-yoke device is
downstream after the process step is finished, typically at an
inspection station.At this point, you're assuming errors or defects
may have occurred and are dependent on detection controls to
find the defects before
sending
the process down the line.
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17. BENEFITS OF
IMPLEMENTING POKA YOKE
•Reduced defects:by preventing errors at the source, the
incidence of defects is minimized, leading to higher quality
products and services.
•Cost savings:fewer defects translate to less rework,
reduced scrap, and lower material wastage, resulting in
significant cost savings.
•Improved efficiency: processes that incorporate pokayoke
mechanisms are more efficient as they experience fewer
disruptions caused by errors.
•Enhanced customer satisfaction:delivering high-quality
products consistently leads to better customer satisfaction
and loyalty.
•Operational excellence:pokayoke contributes to overall
operational excellence by promoting a culture of
continuous improvement and error prevention.
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