Transcript
8/2/2019 Poka Yoke ASQ621-Presentation
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Diana Howard ASQ CA/RABQSA
Quality Tools
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1.Poka Yokea. Heat sink example
2. Four Up Charts3. Lean Sigma
a. Value Stream Mapping
4. Resources
Topics of Discussion
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What is Poka-Yoke?
The phrase Poka-Yoke originates from theJapanese words:
yokeru = to avoid
poka = inadvertent errors
It is a methodology that is used to strive
toward zero defects by either preventing orautomatically detecting defects.
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Mistake Proofing Devices
1. Guide/Reference/Interference Rodor Pin:
2. Template:3. Limit Switch/Microswitch:4. Counter:
5. Odd Part Out Method:
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Mistake Proofing Devices (p. 2)
6. Sequence Restriction:7. Standardize and Solve:
8. Critical Condition Indicator:9. Detect Delivery Chute:10.Stopper/Gate:11.Sensor:
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Other Prevention Techniques
Eliminate the Condition This method isolates the specific characteristic and removes it. For
example: Certain non-functional holes cause confusion about where toinsert parts during assembly. We simply plug the non-functional holes
and eliminate any possibility that they might be used and cause errors.
Redesign for Symmetry Redesign for symmetry means to revise or modify the appearance or
function of a part, tool or fixture so that its opposite sides are identical ornearly identical. In this way they become interchangeable.
Redesign for Asymmetry This involves revising or modifying the appearance or function of a part,
tool or fixture so that its opposite sides are no longer identical. In this waythey can no longer be confused and mistakenly interchanged. This isespecially useful when a particular orientation is critical.
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Four Ups charts
Used for Reporting to management
Graph of measurement over time
Analysis of quarterly data Issues/causes
Action Items
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Graph Ana lys is
Issues /Causes Action Items
Pre-Ship Acceptance
Hardware Missing: Developed UV/black light markercheck. Operator to use pen and Touch for Quality - QAto audit with black light. Due date: 2/3/06
PDC: 10 different refdes locations across 8 differentassemblies. No common trend.
Missing: Nozzle replacement program instituted andrefresher on operator training.
Great improvement!
Customer intro during quarter( XXXXX volumes rampedduring qtr)
Hardware Missing: XXXXXX 9131-0031-0004 Screws PDC: Misc customers and locations.
Missing: No Common locations or assemblies.
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Lean Sigma
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What is Value Stream Mapping?A tool used to create a material and information
flow of a product or process
The value stream includes the following:
People Tools
Technologies
Physical facilities
Material and Information flows
Policies and procedures
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Why Value Stream Maps?
It helps visualize what may beotherwise un-seen
Find the sources of waste andquantifies those wastes so thatefforts for reduction can be
prioritized
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Target Waste with Value Stream Maps
LeanManufacturing/Enterprise
Excess Inventory
Apply linebalancing (Lean) and Kanban toreduce or eliminate inventory
Long Setup Apply lean tools(SMED) to reduce set up time
Value Add
Non-Value Add
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Summary
Poka Yoke Make it fool proof
4-Ups Picture representation forManagement
Combine Lean and Six Sigma to reducelead time, increase productivity,reduceWIP, better utilize space.
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Resources
http:isixsigma.com
http://en.wikipedia.org
Sasa Todorovic Quality Engineer, Black Belt Master
Learning to See by Mike Rother and John Shook
Available at www.lean.org
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