Poka-Yoke Team 4

8/19/2019 Poka-Yoke Team 4

1/14


2/14

""

WORK DONE BY THE TEAM

Date and Time of the Meetings:

Topic Name: Introduction to Poka-Yoke

Date/Time of meeting: October-1-2012 19:00-21:00

Topic Name: Poka-Yoke in Manufacturing


Topic Name: Opportunities in Poka-Yoke


Topic Name: Strengths and weakness in Poka-Yoke


Topic Name: Case Study & Comparison in Poka-Yoke


Topic Name: Research & Development in Poka-Yoke


All members were present in above meetings.

(0167D1EFEGE8E01

Hitesh Sharma: Introduction of Poka-Yoke

Faraz Ahmad: Poka- Yoke in manufacturing

Robin Malik: Opportunities in Poka-Yoke

Satwinderpreet Singh Dhaliwal: Strengths and Weakness in Poka-Yoke

The rest of the report was completed in group discussions


3/14

#

Table Of Contents

1.INTRODUCTION .................................................................................................................... 2

2. MANUFACTURING ............................................................................................................... 3

2.1 Contact Method .................................................................................................................... 3

2.2 Constant Number or Fixed Value Method ........................................................................... 3

2.3 Sequence or Motion Step Method ........................................................................................ 3

3. STRENGHTS AND WEAKNESS IN POKA-YOKE .......................................................... 4

3.1 Strengths .............................................................................................................................. 4

3.2 Weakness ............................................................................................................................. 4

4. OPPORTUNITIES OR IMPLEMENTATION OF POKA-YOKE .................................... 5

4.1 Automotive industry ............................................................................................................ 5

4.2 Opportunities in Service Industry ........................................................................................ 5

4.3 Server based Poka-Yoke are divided into: ........................................................................... 5

4.4 Customer based Poka-Yoke are divided into: ...................................................................... 6

5. CASE STUDY OF YAMADA ELECTRICAL PLANT – 1961 .......................................... 6

6. COMPARISON OF POKA-YOKE WITH OTHER METHODS OF

MANUFACTURING ................................................................................................................... 7

7.RESEARCH AND DEVELOPMENT IN POKA-YOKE ..................................................... 8

7.1 Difficulty in Accepting change ............................................................................................ 9

7.2 Low investment Amount ...................................................................................................... 9

7.3 Difficulties in continuous processes .................................................................................... 9

7.4 Effect in Time ...................................................................................................................... 9

7.5 Complexity of the process ................................................................................................... 9

8.CONCLUSION: ...................................................................................................................... 10

REFERENCE ............................................................................................................................. 11


4/14

$

1.INTRODUCTION

Defects are the results or effects of mistakes. Errors are the sources or causes of mistakes. Inshort Error = Mistake = Defects. Therefore, the removal and control of errors eliminates

mistakes. This is basic principle behind the „POKA-YOKE!, a Japanese term means “FAIL-

SAFING” or “MISTAKE-PROOFING” which was first introduced by Shigeo Shingo (1909-

1990). Poka-Yoke makes sure that every process in an industry is free from defects or errors

at first place. Where this is not possible to find out defects at first place, it performs a

detective function, by eliminating the errors as soon as they are found. So, it’s a mechanism

that prevents a mistake from being made which is obvious at a glance. In this report, we are

going to discuss SWOT (Strength, Weakness, Opportunities, Threats) analysis on the Poka-

Yoke. This report will enhance our knowledge about Poka-Yoke and also reveal various

aspects which most of us are not aware of.

Fig 1. Three main rules for Poka Yoke


5/14

%

2. MANUFACTURING

Poka yoke can be implemented in any phase of manufacturing from the design of a part to the

assembly. For example a device can count the number of parts that are to be fixed to a body.

This counting will ensure that all the parts are attached to the body not missing any parts. The

Poka Yoke system uses three main methods as follows :-

• Contact Method

• Constant number or Fixed Value method

• Sequence or Motion-step method

2.1 Contact Method

This method detects any deviation in shape, dimensional

characteristics or other specific defects, through mechanisms that are

kept in direct contact with the part. The most common example for

this would be the AC power sockets found in most of the houses in

Canada. The three pin design ensures that the plug is fixed in the

proper way. It is shown in the picture on the side.

Fig 2.1 Plug can be put into

socket only one way

2.2 Constant Number or Fixed Value Method

This type of method is used when a process has a fixed

number of steps or has a fixed number of parts attached to

it. A sensor counts all the parts or the step so that none of

them go missing. If an operator finds the number less he

will know that some step or part is missing. The device on

the right has a screw counting feature!

Fig 2.2 Screw-driver with screw

counting feature

2.3 Sequence or Motion Step Method

#$%& '()* +, -*'$+. %& /&*. '+ 0$*01 %, 2 )23'%0/423 &'*) %& 0+-)4*'*. +3 5+' 6%'$ '$* $*4) +,

&*5&+3&! 7, 2 )23'%0/423 &'*) %& 5+' 0+-)4*'* '$* )3+0*&& %& &$/' .+65! #$* *82-)4* +, '$%& %&

%5 4%9$' %5.%02'+3 :+23.& +, -20$%5*&! 7, '$* )3+0*&& %& 5+' 0+-)4*'*. %5 '$* 9%;*5 '%-* 25.

&*


6/14

&

3. STRENGHTS AND WEAKNESS IN POKA-YOKE

3.1 Strengths

1. Poka-Yoke make use of those techniques to identify the errors in which mistakes are

impossible to make.

2. The keen strength of Poka-Yoke is that it can eliminate both human and mechanical

errors in each step of the process.

3.

In manufacturing industry its main concern is to reduce the waste and associated

machining, by inspecting each stage for the excess material and machining rather than

after several stages.

4.

Poka-Yoke also contributes to reduce the inventory holdings.

5. It yields more customer satisfaction because they are served with a best quality

product.

6. Poka-Yoke encourages better employee relationships by involving them in support

teams who identifies the processes which are causing problems.

7.

It always tends to enhance the productivity of plant, it is its prime concern to increasethe productivity by decreasing the number of errors.

8. It lowers the quality cost because numbers of errors in a process are decreased.

Moreover, it tends to lower the quality cost by minimizing the waste produced during

the process. Poka-Yoke is a part of quality and continual effort such as KAIZEN.

3.2 Weakness

1. Poka-Yoke increases the operators inspecting time as compared to the time taken by

operation in usual process.

2. It sharply increases the scrap material for a short period of time.

3. It sometimes gives an error in indentifying any type of error.

4. Usually it responds very fast in some cases and relatively very slow in some cases.

5. Poka-Yoke does not give full information sometimes.

It does not process completely in some cases or we can say incorrect processing


7/14

'

4. OPPORTUNITIES OR IMPLEMENTATION OF POKA-YOKE

Manufacturing is a business where one small error in a system can lead to thousands of

dollars in damaged goods, twisted machine parts, and even endanger human lives. Poka-Yoke

can be implemented at any step where the possibility of error is there or something can go

wrong. Poka-Yoke is mainly used to improve the quality of the process by taking out the

defects or prevent causes which can cause errors.

4.1 Automotive industry

Purpose is to manufacture the elements of high quality which

meet the quality standard in accordance with the principle

process of continuous improvement (Kaizen).

Example: car seat belt indicator. If one forgets to put the seat

belt, then you will get an indicator sign as warning that you

forgot to wear seat belt.

4.2 Opportunities in Service Industry

In manufacturing errors made by producers are considered, whereas service industry

considers errors made by both server and the customer.

In call centres Poka-Yoke is used to deal issues with compliances. Poor training, fatigue and

limits of human consistency can lead to agent skipping key steps in process.

In software designing there are very compelling reasons to use Poka-Yoke for the benefits of

end user and creating high quality software in sorter frame of time. Eg: Gmail attachment

checks and password indicators.

4.3 Server based Poka-Yoke are divided into!

• Task Poka-Yoke: focus on common mistake that server makes while performing task

for the customer.

• Treatment Poka-Yoke: puts stress on interaction between customer and the server.


8/14

(

Example: Burger king utilizes warning-oriented by placing cue cards at the service

• Tangible Poka-Yoke: improves the physical impression and experience for the

customer. Example: Motorola uses control oriented pok yoke in the legal department

by having a second lawyer inspect all legal work for spelling, presentation, and

arithmetic.

4.4 Customer based Poka-Yoke are divided into!

• Preparation Poka-Yoke: helps in preparing the customer before entering the

service. Example: usually Universities send emails to students prior for registration to

next semester.

• Resolution Poka-Yoke: basically reminds the customers of the value of their input to

continuous improvement of the service. Exapmle: Hotels use automated check-out

system through the television in each room.

• Encounter Poka-Yoke: attempt to fail-safe a customer at a service who may

misunderstand, ignore, or forget the nature of the service or their role in it. Example:

selection system used in used in gas and oil station to direct customer so that they

do not pull wrong thing in the station.

5. CASE STUDY OF YAMADA ELECTRICAL PLANT – 1961

Shigeo Shingo was visiting the Yamada electric plant in 1961. Where, management told him

about a problem which the company was facing from several years. This problem was in a small

switch with two push buttons. To work properly, this switch should be supported by two

springs. But sometimes, workers assembling these switches forget to put the second spring.

Occasionally, this defect was not discovered during the testing of the switches in the plant. But,

when the customers start using the product they send the complaints to the company that their

switches are not working properly. This was very embarrassing to the company. Because, due to

this, company was affected in two ways:

6.1 Cost Wise: Company has to send an engineer at the site to repair or change the

switch, which adds more expenses in products manufacturing cost.

6.2

Reputation Wise: Because, Now in the market, people are talking about the

companies defines switches. Which ruined the companies several years of reputation

in a very awful way.


9/14

)

Fig 5: Start Stop Button

Management was trying its best to overcome this problem by warning its employees and

workers, but results weren’t so impressive. So, Shigeo Shingo suggested the management a verysimple solution.

In the old assembly method of switches, a worker has to pick two springs from a box containing

springs. But, what he suggested that, every worker should have a dish containing two springs

instead of a box containing springs. If any of the dish, contains the spring then that will remind

the worker that he has not installed the second spring.

By implementing this technique, company has solved its problem of missing springs.

6. COMPARISON OF POKA-YOKE WITH OTHER METHODS OF

MANUFACTURING

'H! ?, 9>/?54909 E"01

@"-/70=/4- 278

/=89=B

G2"A97 "- 2

H25279-9

E/=8 :/=

51"4/-/516

0120 89:"79

?272;9?970-=/49 "7

>/70"79"@98

E"44 0=";;9=

=95497"-1?970

/: 0120

5=/80J 52=0

/= "7@970/=6B

3/F2 L/F9 "-

2 09>17"D21//-"7; 019

E=/7; 52=0J

492@"7; /FE2=8-J

90>B


10/14

M

*+, C0278-

:/= N

*/024O,289

/70=/44"7;J

8"=9>0"7; 27

/=;27"A20"/7B

'C =9:9=- 0/N

CRISIO >492=

9--2=6

"09?- :=/?

E/=F 2=92

CRI*TUO

/=;27"A9 E/=F

2=92 "7 27

/=89=46

?2779=

CRICTO >4927

E/=F 2=92

CRIGRC*VO

?2"702"7

E/=F 2=92

>49274"79--

CWI*CVGRO

?2"702"7 -94:8"->"54"79 "7

E/=F 2=92B

I7 GKIXRU N

GKI =9:9=-

Y127;9J

XRU =9:9=-

Z9009= "B9

>127;9- :/=

.9009= /=

>/70"7


11/14

_

7.1 Difficulty in Accepting change

When there is a complete change in the manufacturing process in order to implement error

saving methods, there is a lot of training that will be required to be given to the workers, forthem to accept the change. Some of them will find this very difficult to adapt. Thus maximum

research should be carried out so that there is least amount of change in the system. And

training should be carried out at regular intervals so that the workers are updated with the latest

trends.

7.2 Low investment Amount

The amount that has to be invested in implementing error-proofing methods should be justified.

If the amount is very large and increases the overall cost of manufacturing, that will intern

increase the cost of the final product. This will increase their competition in the market and will

affect the number of people buying the product. Thus development should be carried out in a

way that minimum amount is spent and better Poka-Yoke is implemented.

7.3 Difficulties in continuous processes

If manufacturing of a product involves a number of processes, a change in any process would

affect the other processes also, which would add to the cost, training of the workers, time, etc.

We should strive to achieve that the change made in a particular process does not affect the

other process.

7.4 Effect in Time

Poka-Yoke should be implemented in a way that the time used for manufacturing a product

does not increase. If the time used for manufacturing increases the number of products produced

will decrease, which will intern increase the price of the final goods. The best option will be that

the poka-yoke is implemented and the time for manufacturing is decreased. This will bring

more profit to the company.

7.5 Complexity of the process

Poka-Yoke should not add to the complexity of the process, the optimum implication should be

that the process becomes easy to manufacture and reduces error in manufacturing.


12/14

#`

8.CONCLUSION:

Poka-Yoke is simple but quality assurance method which prevents errors. To implement Poke-

Yoke, we need to understand as to why people make errors and we have to analyze the process

to know where errors are likely to occur and what root causes contribute to them. But by taking

broader view point of failure, we can use Poka-Yoke during the design phases of products and

services to find where we can incorporate low cost features that improve the customer’s

experience.


13/14

##

REFERENCE

• >;+321= ?2/4! @?+12AB+1* >*&%95& C21* D&&*-:4%*& C%&'21*A)3++,!@ C20$%5* >*&%95

•

E*F/3/'*3225 G%&'*- ?*-:/2'25= C25/,20'/3%59 &(&'*- *59%5**3%59=

$'')HII)/'32A.*&%95!:4+9&)+'!02IJKKLIMJI)+12A(+1*!$'-4

• D3'%04* +5 N#$* C2529%59 C*5'+3O

$'')HII666!'$*-2529*-*5'+3!0+-I*54%9$'*5-*5'+323*2&I-,9IPCI)+12(+1*!$'-

• D3'%04* +5 ND #*0$%*Q& R+'*:++1O $'')HII'*0$%*A5+'*:++1!:4+9&)+'!02IJKMJIKSI)+12A

(+1*A2))4(%59A-%&'21*A)3++,%59A'+!$'-4

• $'')HII666!9++94*!02I%-93*&T%-9/34U$'')VWDVJXVJXY!:)!:4+9&)+'!0+-VJXA

9ZR[-3S6\3+VJX#]-0B2J[^X7VJXDDDDDDDDD.7VJXD_`2;%&0$VJa':+VW>/bd++-UMbb.+0%.U`/EEi4(dW-5c:Cb&2Ueb*%

U4[fYnm-a\+]R(9[MW+>Y\9b;*.UK\\6P`P_6D6

• $'')HII666!'$*-2529*-*5'+3!0+-I*54%9$'*5-*5'+323*2&I-,9IPCI)+12(+1*!$'-

• $'')HII666!&0$++4A,+3A0$2-)%+5&!0+-I'


14/14

#$

• 1005NaaEEEB;//;49B>2a"?;=9-cDd51f0.7"8d(WCVMKYF\.4/?,Nf"?;=

9:1OhK]O

Z$#%a%&%M``#%'B10?4f8/>"8d-KWVh@"DVY%U$,f"?;/?a"

?;a5.a'()aM)_a$)$a$)$M)_'()g__MBb5;fEd'`$f1d%##f9"d8>8_V333Z&GQ6EiT

/LWKY;fA//?d#f"2>0d1>f@5Qd)`$f@56d_Mf8

Poka-Yoke Team 4

Documents

Transcript of Poka-Yoke Team 4