Scribd Logo
Upload

Welcome to Scribd!

  • 90 views

    RP Poka Yoke

    Uploaded by

    Darvesh Singh
    Poka yoke is a Japanese technique for mistake-proofing manufacturing processes to prevent defects. There are three main types: shutdown poka yoke stops production when errors are detected, control poka yoke makes errors impossible, and warning poka yoke alerts operators to potential errors. Implementing poka yoke through techniques like part present sensors and vision systems can help identify problem causes using DMAIC and eliminate human error, reducing costs by decreasing defects. While an effective quality improvement method, poka yoke also faces challenges like limitations of existing systems and need for expert advice.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    RP Poka Yoke

    Uploaded by

    Darvesh Singh
    90 views17 pages
    Poka yoke is a Japanese technique for mistake-proofing manufacturing processes to prevent defects. There are three main types: shutdown poka yoke stops production when errors are detected, control poka yoke makes errors impossible, and warning poka yoke alerts operators to potential errors. Implementing poka yoke through techniques like part present sensors and vision systems can help identify problem causes using DMAIC and eliminate human error, reducing costs by decreasing defects. While an effective quality improvement method, poka yoke also faces challenges like limitations of existing systems and need for expert advice.

    Original Title

    rp poka yoke

    Copyright

    © © All Rights Reserved

    Available Formats

    DOCX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Poka yoke is a Japanese technique for mistake-proofing manufacturing processes to prevent defects. There are three main types: shutdown poka yoke stops production when errors are detected, control poka yoke makes errors impossible, and warning poka yoke alerts operators to potential errors. Implementing poka yoke through techniques like part present sensors and vision systems can help identify problem causes using DMAIC and eliminate human error, reducing costs by decreasing defects. While an effective quality improvement method, poka yoke also faces challenges like limitations of existing systems and need for expert advice.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    90 views17 pages

    RP Poka Yoke

    Uploaded by

    Darvesh Singh
    Poka yoke is a Japanese technique for mistake-proofing manufacturing processes to prevent defects. There are three main types: shutdown poka yoke stops production when errors are detected, control poka yoke makes errors impossible, and warning poka yoke alerts operators to potential errors. Implementing poka yoke through techniques like part present sensors and vision systems can help identify problem causes using DMAIC and eliminate human error, reducing costs by decreasing defects. While an effective quality improvement method, poka yoke also faces challenges like limitations of existing systems and need for expert advice.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 17

    QUALITY IMPRROVEMENT IN MANUFACTURING : POKA

    YOKE

    Introduction

    With the growing competition in the market in recent decades, it has


    become important for the manufacturing firms to adhere and enhance the
    quality of the products. And it is not just about quality management but
    managing it at optimum cost is also important so that customers get
    defect free products.

    Using various tools of TQM like Kaizen, Poka yoke, JIT, JIDCO, etc.
    can help companies to develop quality culture. This paper studies the
    practical usage of Poka yoke.

    Poka yoke refers to a japanese improvement technique for mistake


    proofing in order to prevent manufacturing defects. Initially it was
    known as idiot proofing but since it workers didn’t like the term it was
    changed to mistake proofing.

    A Method to build poka yoke for counter measures involved 3step:

     Identification of need
     Identifying Possible mistakes
     Management of mistakes before satisfying needs
    Poka yoke in long term saves time and releases pressure on theinds of
    workers. Creativity and special skills of workers can be used for
    decreasing pressure on workers.

    TYPES OF POKA YOKE

    Different methods of poka yoke: Poka Yoke is an innovative technique


    to check human error at work. Any defect or any imperfection exists in
    the either of of the states, The defect that has already occurred before in
    the defect detection or is about to occur in that particular case calling for
    defect prediction. The Poka yoke technique starts by analysing the
    process for potential problems, identifying parts by the characteristics of
    dimensions, size & weight and shape, detect process deviation from the
    nominal procedures and norms.

    It has three types:-

     Shutdown Poka Yoke


     Control Poka yoke
     Warning Poka yoke
    1. Shutdown Method : This method is also known as the prevention
    method, This method regularly checks critical process parameters
    of a device and shuts down the process when a situation moves out
    of the tolerance zone, this indicates that a defective product has
    either been produced or is about to be produced. By implementing
    this method we can assure that the product is 100% defect free. It
    has 0 % chances to produced defective products.
    For example :- Use of fuse in the electric circuit. When there is a
    short circuit in the electric circuit then the supply of electricity is
    cut down and the fuse is operated to avoid any further accidents.

    2. Control Method : In this method the devices are regularly working


    which are installed on the equipment and work pieces which make
    it impossible to produce defects. Just like shutdown method this
    method also gives 100% defect free results in the process. It is
    insured that no defect reaches the end customer.
    3. Warning Method : This method gives the operator some signs that
    something wrong is occurring. The idea is simply generated in a
    way that Poke yoke devices indicate or shows to a worker that a
    defect has been produced. When operators get warnings then they
    should stop the interface immediately so that further process is not
    corrupted. Warning method depends on human nature and
    behaviour. The alert method gives 30% of the guarantee of good
    products. It tells about existence of defect but it does not assure
    and produce 100% quality. The most common indictor is the
    beeping of the light or any flashing light or sound alarm.
    Example:- Flashing of light in ATM machine after removing the
    card from the machine. It warns the operator that he is safe and
    ensure that the card in not in the machine.

    Once top management decides to implement TPM culture in the


    organization one should follow the methodology of Poka-yoke to
    compensate for defect free products successfully.

    What Causes defects?

    Errors lead to defects in any process


    1. Poor procedures or standards.
    2. Human Mistakes
    3. Machines
    4. Non- Conforming materials.
    5. Worn Tooling
    Poka Yoke as Prevention Device: Eg’s - Part Locators , Part
    present sensors.

    Poka Yoke as Detection Device: Eg’s – Vision system and limit


    sensors.
    Literature Review

    Study of S. Tkazzyk and M.Dudek (2009) states how in current


    scenarios all organizations need to implement quality tools and
    techniques to improve and enhance the preventation strategies. They
    must pay attention to improve quality and cutting the extra costs.

    Another study of Burlilowska and D. Szewiecczek (2009) quoted


    method of Poka- Yoka as an improving quality tool of operating in the
    manufacturing sector of an organisation.

    Moreover, Stewart (2002) learnt and found Poka- Yoka as a preventive


    method in error proofing.

    Many people concluded Poka Yoka to be a tool for Zero defects in


    mamufacturing process.

    Study of Dr kannan and Sangeetha  states that poka yoke is a "mistake


    proofing" . Poka yoke is a lean manufacturing process which is used to
    eliminate the product defects by correcting, preventing the errors when
    they occur. poke yoke was formalised and this term was made by Shigeo
    shingo
    In the each process of poka yoke we make sure that the mistake is
    eliminated from the starting of the process through which revokes are
    avoided.

    CLARIFY THE PROBLEM

    DMAIC is the problem solving method behind Siz Sigma. the Poka
    Yoke concept consists 5 DMAIC Phases : 
     Define
     measure 
     Analyse
     Improve
     Control

     1 Define : what problem is to be fixed ?

    The first phase is the Define phase of the six Sigma improvement
    process.
    In this process a high level blueprint of the process is created by the
    experts, it understands the need of the customers of the process.This is
    an important phase in which the team frames the project which focuses 
    for themo and for the leadership for the organisation.

     2 Measure : How will the process perform ?

    When the team starts collecting the data they focus on both the
    procedure and also they measure what customer wants.
    This shows that there are two main motives : Reducing the lead time and
    improving the quality.

     3 Analyse : cause of the problem ?

    In this phase the main focus is on the idea by which brainstorming is


    done to root causes, develop  hypothesis upon that as to why problems
    exist and then work to prove or disapprove their hypothesis.

     4 Improve : How to find the cause of the problem ? 

    Finding roots of the problem is crucial to find the solutions necessary.


    this is an improvement phase where expert teams find the solutions and
    eradicate the problem. 
     5 Sustaining the improvement ?
    When the solution is given it is important to see that problem is not
    repeated again. Team makes control plan to ensure where  success of the
    plan and solutions are there  without creating the downfall of the
    performance.
    RESEARCH OBJECTIVES

    OBJECTIVES-

    1. How PokA Yoka has evolved?


    2. Why it is called a tool for zero defects?
    3. How Poka Yoka removes human error in manufacturing process
    4. How it reduces cost by reducing errors?
    5. How Poka yoka is an efficient and effective method?

    TYPE OF RESEARCH-

    It is a Descriptive research. Descriptive research refers to the research


    wherein we study the characteristics of the problem. In this paper, we
    are examining the various factors and features of the method of Poka
    Yoka in manufacturing sector.

    We have used Secondary Data for the paper. Secondar data refers to the
    data that has already been published in the forms of articles, books etc
    and has been collected by some one else earlier.
    CHALLENGES AND LIMITATIONS OF POKA YOKE

    Poka yoke is one of the best tool of Total quality Management but also
    have to take in view about its obstacles and challenges that is faced by
    Poka yoke.

    Some of challenges are listed below-

     Process parameter does not allow change in the existing system.

     Practical implementation of the solution is not possible.

     Expert advice is needed for new creative and challenging tasks, It


    does not occur in all the MSME’S as they don’t have an financial
    expert available.

     Poka yoke is not always cost saver.

     Interdepartmental relations between two different departments are


    not good so each one think that I don’t have to do anything with
    that issue
    Characteristics of a good Poka Yoke devices.

    Poka-yoke devices,regardless of their implementation, share many


    common characteristics, some of them are :-

     Simple and Cheap to use. It is not complicated to use otherwise it


    would have been expensive and not cost beneficiary.

     It provides immediate feedback about the quality of work and the


    corrections could be made on the spot.

     They are placed close to work where the mistakes occur mostly,
    quick feedback is provided to the workers to correct the mistake
    that occurred

     They are part of the work process, implementing what Shingo calls
    “100%” inspection.
    Qualities of a Good Poka Yoke

    A good Poka Yoke must meet the following qualities:-

    Simple: The poka yoke should be simple as to develop and maintain the
    work. This is quite important to reduce time and effort in maintaining
    poka yokes and to work efficiently and effectively.

    Precise: It should be precise, so that it is easy to diagnose and identify


    what mistakes are occurring in the process

    Early: A good poka yoke must be early in the process, so that it can
    provide quick feedback to the mistake occurred and help in detecting the
    mistakes at the moment they occur.

    Light: Poka yoke needs to be transparent. If a poka yoke itself becomes


    an overhead to the process, then it will drive the end users crazy and
    they will find different ways to avoid it all together.
    Analysis

    It has been analyzed that Poka yoke technology can be implemented at


    any step of the manufacturing department where something might go
    wrong or the error can be occurred. Poka yoke is a lean manufacturing
    process which is used to eliminate the product defects by correcting,
    preventing the errors when they occur. poke yoke was formalised and
    this term was made by Shigeo shingo

    In the each process of poka yoke we make sure that the mistake is
    eliminated from the starting of the process through which revokes are
    avoided.

    There is a very good example to know the right analysis of Poka yoke in
    the manufacturing Industry – Sim card slot in the mobile phones which
    are designed in a way so that the user is allowed to insert SIM card in
    the slot in a correct way only that is in the direction that has been
    provided by setting a small picture beside the slot. There is no chance
    for the user to make any mistake while putting the sim card on the
    mobile phone . This makes the design mistake proof

    Poka yoke helps people and processes to work right in the first time. It
    refers to the technique that makes impossible to make mistakes. These
    can drive the defects out of the products and processes and improves the
    quality and reliability. It can also be used for improvements and process
    designs from six-sigma Define - Measure - Analyze – Improve &
    Control (DMAIC) projects. The poka yoke ideas can eliminate both the
    human and machine errors.
    Findings
    There has been significant increase in the usage of Poka yoke technique
    in the past as it is necessary for removing errors and saving time by
    assuring 100% defects.

    It has found that Defect Prevention and Defect Detection is being widely
    used.

    The Defect prevention method is the most important activity in SDLC.


    This method is used to identify all the possible issues and actions that
    are required to eliminate the errors. There is a quality assurance team
    which helps in preventing these defects by reviewing the software
    requirement specifications document. The issues and related errors are
    addresses in this stage in the software coding phase and prevented from
    carrying it to the later stage.

    The software and the manufacturing industry are the examples of defect
    prevention technique.

    The Defect detection is the other common method that is widely used for
    mistake proofing in the industries. It uses various approaches and
    strategies for executing test cases effectively. There are other method
    also that have started coming into light as now there is higher
    requirement for the mistake proofing , These are Smoke and
    Exploratory testings.
    Mostly 80% of the industries and companies have started using this
    technique to eliminate the errors

    You might also like