Poka-Yoke

TOTAL QUALITY MANAGEMENT

Poka-Yoke
WHAT IS POKA-YOKE?

THIS IS KNOWN AS MISTAKE-
PROOFING

FROM JAPANESE:
YOKERU (AVOID)
POKA (INADVERTENT ERRORS)
WHAT DOES POKA-YOKE
DO?
ELIMINATES THE CAUSE OF AN
ERROR AT THE SOURCE;

DETECTS AN ERROR AS IT IS BEING
MADE;

DETECTS AN ERROR SOON AFTER
IT HAS BEEN MADE BUT BEFORE IT
REACHES THE NEXT OPERATION.
ARE ERRORS
UNAVOIDABLE?

THERE ARE TWO APPROACHES TO
DEALING WITH ERRORS:

1. ERRORS ARE INEVITABLE!
2. ERRORS CAN BE ELIMINATED!
1. ERRORS ARE
INEVITABLE
PEOPLE ALWAYS MAKE MISTAKES.
WHILE WE ACCEPT THE MISTAKES AS
NATURAL, WE BLAME THE PEOPLE WHO
MAKE THEM.
WITH THIS ATTITUDE, WE ARE LIKELY TO
OVERLOOK DEFECTS AS THEY OCCUR IN
PRODUCTION.
THEY MAY BE DETECTED AT FINAL
INSPECTION, OR WORSE STILL, BY THE
CUSTOMER.
2. ERRORS CAN BE
ELIMINATED
ANY KIND OF MISTAKE PEOPLE MAKE
CAN BE REDUCED OR EVEN
ELIMINATED.

PEOPLE MAKE FEWER MISTAKES IF
THEY ARE SUPPORTED BY PROPER
TRAINING AND BY A PRODUCTION
SYSTEM BASED ON THE PRINCIPLE
THAT ERRORS CAN BE AVOIDED.
INSPECTION
ONE METHOD OF DETECTING
ERRORS IS INSPECTION.
THERE ARE TWO MAJOR TYPES OF
INSPECTION.

1. SAMPLING INSPECTION.
2. 100% INSPECTION.
SAMPLING
INSPECTION
IN SOME FACTORIES, THE
ATTITUDE IS:

IT MAY TAKE ALL DAY TO INSPECT
ALL PRODUCT.
THERE MAY BE A FEW DEFECTS,
BUT SAMPLING IS THE MOST
PRACTICAL WAY TO CHECK.
SAMPLING INSPECTION -
REFLECTION
THINK ABOUT SAMPLING.

WITH SAMPLING, THERE IS A
CHANCE THAT AN ERROR MAY GO
UNDETECTED.

EVEN IF 1 PART IN 1000 IS
DEFECTIVE, THE CUSTOMER WHO
BUYS THAT PART HAS A 100%
DEFECTIVE PRODUCT!
SAMPLING INSPECTION -
REFLECTION
SAMPLING INSPECTION MAKES
SENSE ONLY FROM THE
MANUFACTURERS VIEW, NOT FROM
THE CUSTOMERS!
2. 100% INSPECTION
IN THE BEST FACTORIES, THE
ATTITUDE IS:

WE WONT TOLERATE A SINGLE
DEFECT!
WE WILL ORGANIZE PRODUCTION SO
THAT 100% OF THE PRODUCT CAN BE
EASILY INSPECTED.
THAT MAKES THE MOST SENSE.
100% INSPECTION -
REFLECTION
THINK ABOUT 100% INSPECTION.
EVEN ONE DEFECTIVE PRODUCT IS
ENOUGH TO DESTROY A CUSTOMERS
CONFIDENCE IN A COMPANY.
TO STAY COMPETITIVE A COMPANY
MUST SUPPLY GOOD PRODUCT IN
THOUSANDS.
THE BEST WAY TO ACHIEVE THIS IS TO
ORGANIZE PRODUCTION TO INSPECT
100% OF THE PRODUCTS.
THE USER IS THE BEST
INSPECTOR
NO ONE INTENDS TO MAKE
MISTAKES.
WHILE WE ARE WORKING, ERRORS
CAN SHOW UP WITHOUT US
NOTICING.
HOW CAN WE CATCH THESE
ERRORS BEFORE THEY TURN INTO
DEFECTIVE PRODUCTS?
FINDING DEFECTS IN THE
SUBSEQUENT PROCESS
Wedontexpecttofinddefects,butifa
productweusedoesntdowhatitis
supposedtodo,thenweknowitis
defective.

Usersarethebestatdiscovering
defects!
FINDING DEFECTS IN THE
SUBSEQUENT PROCESS
Sincesubsequentprocessesarealso
usersoftheproductbeing
manufactured,theyarealsoexpertat
findingdefects.
Ifproductsareproducedinaflow,each
productissenttothenextprocessas
soonasitisfinishedanddefectsare
thereforefoundimmediately.
TWO STRATEGIES FOR
ZERO DEFECTS

1.DONTMAKEIT!
1. DONT MAKE IT!
Dontmakeproductyoudontneed.

Themoreyoumake,thegreaterthe
opportunityfordefects.

Followjust-in-timeprinciplesbyonly
makingwhatisneeded,whenitis
neededintheamountneeded.
TWO STRATEGIES FOR
ZERO DEFECTS

2.BuildSafeguards
2. BUILD
SAFEGUARDS
Theuserisanexpertinfindingdefects.

Thereforebuildsafeguardsintothe
productionprocess.

Qualitycanbebuiltintoproductsby
implementationofPoka-Yoke.
POKA-YOKE
DEVICES
Humanerrorsareusuallyinadvertent.

Poka-yokedeviceshelpusavoid
defects,evenwheninadvertenterrors
aremade.

Poka-yokehelpsbuildqualityinto
processes.
POKA-YOKE DEVICES
ERROR DETECTION AND ALARMS
POKA-YOKE DEVICES
CHECKLISTS
POKA-YOKE
EXAMPLE
Itispossibletomounttheblankthe
wrongwayontothepiercetool.
BLANK PIERCED BLANK INCORRECT
Astheblankcanfitthepiercetoolin
manyways,howcanthisbeprevented?
POKA-YOKE
EXAMPLE
Byfittingablockintothepiercetooling,
theblankplatecanonlygoononeway.

BLOCK
POKA-YOKE
POKA-YOKE
MEANS
ZERO DEFECTS