POKA YOKE OR MISTAKE PROOFING KİBAR YILDIRIM 2013432085 TOLGA YILDIZ 2015432115
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POKA YOKE OR MISTAKE PROOFING
KİBAR YILDIRIM 2013432085TOLGA YILDIZ 2015432115
WHAT CAUSES DEFECTS ?
Poor procedures and standards Machines Non-conforming materials Worn tooling Human mistakesThese conditions can be predicted and corrective action can be implemented to eliminate the cause of defects.
WHAT CAN WE DO ?
To avoid such mistakes here comes the tool that is called ;
Mistake-proofing systems Does not rely on operators catching mistakes Inexpensive Point of Origin inspection Quick feedback 100% of time.
WHAT IS IT ?
Poka-Yoke was coined in Japan during the 1960s by Shigeo Shingowho was on of the industrial engineers at Toyota.
The initial term was Baka-yoke which means fool proofing. This termbaka-yoke dishonorable and offensive connotation.Hence, the termwas changed to poka-yoke which means ‘mistake-proofing’.
WHAT IS THE POKA-YOKE ?
Techniques that help operators avoid mistakes in their work caused by choosingthe wrong part living out a part,installing a part backwards, etc.
It provides instant feedback and prevention of quality problems.Poka-Yoke as Prevention Device Poka-Yoke as Detection Device
Why is it important ?
Poka-yoke helps people and processes work right the firsttime.
Poka-yoke refers to techniques that make it impossible tomake mistakes.
Poka-yoke techniques can drive defects out of products andprocesses and substantially improve quality and reliability.
It can also be used to fine tune improvements and processdesigns from six-sigma Define-Measure-Analyze-Improve-Control (DMAIC) projects.
The use of simple Poka-yoke ideas and methods in productand process design can eliminate both human andmechanical errors.
WHEN TO USE IT ? It is a technique, a tool that can be applied to any type of
process be it in manufacturing or the service industry.
Poka-yoke can be used wherever something can go wrong oran error can be made.
Errors can be of any type ;
Processing Error Setup Error Missing part Improper part/item Operations Error Measurement Error
How to use it ?Step by step process in applying poka-yoke Identify the operation or process based on a Pareto Analysis. Analyze the 5-whys and understand the ways a process can fail. Decide the right poka-yoke approach, such as using a,
Shut out Type: Preventing an error being made, or an
Attention Type: Highlighting that an error has been made.
Determine whether a
Contact Method Constant Number or Counting Method Motion-Sequence Method2. Trial the method and see if it works.3. Train the operator , review performance and measure success.
Example of Poka Yoke
Simple Example
All the three pins need to fit perfectly within the three slots provided. the design phaseof the product needs to be executed perfectly as well. A slight error in the calculationof the slot-size or the pin-size can make the device redundant or faulty.
you place a dish in the microwave and forget all about it, the microwave switches off on its own. This is called 'auto cooking mode'.
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