The concept and The philosophy

Objectives

Application fields
Submitted by
Miruna Poienaru N 41275 Antonia Clain N 41274 David Dragomir N 41300

The Process

Prof. Ana Paula Ferreira Barroso Prof. Maria Celeste Rodrigues Jacinto

Limitations and Advantages

Conclusions

The concept and The philosophy The concept

Poka-yoke is a quality assurance technique developed by Japanese manufacturing engineer Shigeo Shingo.

The aim of poka-yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible.
Poka-yoke has been used most frequently in manufacturing environments.

The concept and The philosophy

The philosophy A Poka-yoke device is any mechanism that either prevents a mistake or defect occurring or makes any mistake or defect obvious at a glance. It is the concentration on removing the causes of defects that is important. (Shingo,page 186; 1987) Poka-yoke was invented by Shigeo Shingo in the 1960s. The term "poka-yoke" comes from the Japanese words "poka" (inadvertent mistake) and "yoke" (prevent) .

The essential idea of poka-yoke is to design your process so that mistakes are impossible or at least easily detected and corrected.

Objectives of Poka-yoke

Implementing poka-yoke methods have both short and longterm objectives. Thus, the benefits can be direct and indirect. Usually, the most obvious benefits are seen in the assembly floor. Objectives for implementing poka-yokes:
Competitive advantage: Cost of quality is an important part of companys competitive advantage in the global markets; it costs far less to prevent defects occurring in the first place Knowledgeable workers: Understanding the principles of mistakeproofing helps to participate defect elimination Predictability: Poka-yoke devices and methods assures defect-free products and services and thus reduce the need for traditional inspection and rework operations Reduced variation: Mistake-proofing devices ensure that all subassemblies and completed assemblies are exactly the same. There will be little chance of part-to-part variation

Application fields

Guide Pins to assure alignment Sensors to validate presence or alignment Proximity switches to validate presence or alignment Limit switches to assure parts are seated properly Inspection templates for visual validation of presence or polarities Counters for validating the correct number of parts Color code components for fast visual validation of correct parts Warning lights for part seating, timed requirements or low materials Alarms Checklists

Application fields Error types

1. Processing error Process operation missed or not performed per the standard operating procedure. 2. 3. 4. Setup error Using the wrong tooling or setting machine adjustments incorrectly. Missing part Not all parts included in the assembly, welding, or other processes Improper part/item Wrong part used in the process

5.

Operations error Carrying out an operation incorrectly Having the incorrect version of the specification.

6. Measurement error Errors in machine adjustment, test measurement or dimensions of a part coming in from a supplier. 7. Guide pins of varying sizes that ensure the upper and lower portions of a stamping die are correctly aligned and centered. 8. Error-detection alarms that alert workers when a defective part has been produced 9. Limit switches that ensure correct placement of workpieces in machines and processing equipment. 10. Counters used to ensure that all processing operations have been completed before transferring a part to the next process. 11. Checklists filled out to ensure that all components in an assembly have been installed.

Two types of error proofing devices POKAYOKE Control - eliminates the possibility of a mistake to occur (automatic machine shutdown) Warning - signals that a mistake can occur (blinking light, alarm, etc.)

The Process

Essentially poka-yoke devices are installed upon process equipment to eliminate or reduce the possibility of error.
The specific devices that are employed will depend upon the nature of the process they are used on, but the most common types of poka-yoke devices are inexpensive modifications to process equipment, including such things as locator pins, limit switches and interference pins. Their purpose is to reduce the variability that exists in processing and to ensure consistent, defect-free production. Poka-yoke devices work because a nonconformity can only be in one of two states: it is about to occur or has already happened.

Poka-yoke devices employ three basic methods to prevent product defects:

1. Shutdown. Poka-yoke devices monitor critical process conditions and shut down the process when a parameter moves out of the desirable range, indicating that a defective product has either been produced or is about to be produced. 2. Control. Poka-yoke devices are installed on process equipment and/or work pieces, making it impossible to produce defects and/or to flow a non- conforming product onto the next process. 3. Warning. Poka-yoke devices signal to a worker that a defect has been produced. The worker must intervene to correct the processes responsible for causing the defect, since otherwise the processes will output further nonconforming product.

In most of places when people want to park their cars, they usually park horizontally along the road; however in some places people park somehow vertically and it helps them to have more chances for finding a place for parking. This is usual for busy areas and the road should be wide enough for such an arrangement.

When stores put the price label on goods, buyers do not need to ask the price and it helps the sales person to deliver services in a more organized manner.

In some places after the customer have food, the waiter put his/her bill on the table. It prevents the counter to be crowd and customers need not to stay in queue for paying the food bill (e.g. a restaurant of a 5 star hotel versus the long queues of McDonalds food stors).

In many services such as a conference, the organizers are usually asked to wear uniforms with different colors or to use representation cards in different colors. Therefore, the audiences could easily access the responsible persons. Other examples include personnel in banks, hotels, etc.

Using double doors in building to avoid noise (e.g. hospitals and libraries).

In some supermarkets when people want to use trolleys, they should put a coin in a small box on them to release one. Once their shopping is finished and they want to leave there, they turn back the trolley to the specific area outside the supermarket and by locking it to other trolleys, they could collect their coin back. This helps the supermarket to better manage the internal space.

Most of airports use some flexible tunnels instead of stairs for transferring passengers to the airplane. This case example reduces the needed space for movement of facilities.

Poka-yoke Homemade

Limitations and Advantages

Characteristics of good poka-yoke devices

they are simple and cheap

they are part of the process

they are placed close to where the mistakes occur, providing quick feedback to the workers so that the mistakes can be corrected

References

Newspapers
Shingo, S. (1987). The Sayings of Shigeo Shingo: Key Strategies for Plant Improvement. Portland, OR: Productivity Press. The informed, Poka-Yoke: Mistake-Proofing as a Preventive Action By Stewart Anderson, march 2002 International Journal of Marketing Studies, Service Poka Yoke, Arash Shahin &Maryam Ghasemaghaei