PK1 PDF

… A TVS Group Company
POKA - YOKE
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POKA-YOKE
A Strategy for Performance Excellence
WHAT IS POKA YOKE
• Principle of mistake proofing first documented in the Toyoda loom works in

the early part of the 20th Century – looms with a self stop mechanism when
threads broke gave them a significant competitive edge.
• Definition : to avoid (Yokeru) inadvertent errors (Poka)
Toyoda G-loom circa 1924
WHAT IS POKA YOKE
• The Toyota company began in 1891 when the Japanese inventor Sakichi
Toyoda began as a manufacturer of the automatic loom, but it ended 100
years later as one of the biggest multinationals in the world today.
• The early success of the Toyoda company was built in textiles. At the beginning
of the century Britain was still the dominant power in cotton, but in less than
20 years Japan overtook Britain as the largest exporter. Much of the success
for this was because of the invention of Toyoda's G type loom which meant
one worker could operate 25 looms simultaneously a revolution in the
industry.
• This provided the springboard for the launch of the Toyota motor company in
1936 the name being changed because in Japanese Toyota requires eight
strokes to write and the number eight is associated with 'rising prosperity'.
WHAT IS POKA YOKE
What does it mean?
• It means designing quality in to the process or product
• It means guaranteeing 100% defect free products
WHAT IS POKA – YOKE
DEFECTS AND CAUSES
TO PREVENT THESE ERRORS
i.e,
• MAN ERROR
• MACHINE ERROR
• MATERIAL ERROR
• METHOD ERROR
&
• INFORMATION ERROR
POKA – YOKE SYSTEM …………….

TPS stands for Toyota Production System and it applies the “pull ” concept
They reduced the lead time drastically by eliminating seven type of losses ;
Transportation, Inventory, Motion, Waiting, Over production, Over processing,
Defect and rework.
What is TPM ?
TPM stands for Total Productive Maintenance & Management and it is defined as a
program that aims to create a culture and environment that constantly tries to maximize
the effectiveness of the entire production system.
TPM uses a hands –on shop floor approach to build a zero defect and zero breakdown &
Zero accident ’ system designed to pre-empt losses of all types throughout the life cycle of
the production system.
WHAT IS POKA – YOKE
POKA YOKE
POKA means INADVERTENT ERRORS
YOKE means TO AVOID
POKA -YOKE – TO AVOID INADVERTENT ERRORS
TERM COINED BY Dr. SHIGEO SHINGO
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POKA - YOKE
HINT LIST
ERRORS AND MISTAKES ARE INEVITABLE – BUT

DEFECTS ARE NOT.
THEY CAN BE PREVENTED AT THE SOURCE

THROUGH POKA – YOKE.
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WHY POKA YOKE
• In a modern Consumer driven company our aim must be
I. Zero Defects
II. Zero waste
III. Zero delays
• We know that 100% judgement inspection is costly and time consuming
• Sample inspection is of course an option but at a risk
• Poka-Yoke implementation providing 100% source inspection is really
the answer
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WHEN POKA YOKE
• Zero Defects
• Zero Waste QUALITY IMPROVEMENT
• Zero delays
is now the absolute minimum required to achieve customer satisfaction.
POSITIVE QUALITY
Customer Satisfaction
Customer Delights ZERO DEFECTS
NEGATIVE QUALITY
Customer Complaints
Service Information
Warranty & Product Returns
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COST IMPACTS
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POKA - YOKE
MURPHY’S LAW
IF ANYTHING CAN GO WRONG, IT WILL GO WRONG !
POKA - YOKE
REWRITES MURPHY’S LAW.
IF ANYTHING CAN GO WRONG, IT CAN BE PREVENTED !
MINDSET IS NECESSARY TO HAVE STRONG CONVICTION

THAT MISTAKES CAN BE ELIMINATED THERE BY ACHIEVE
ZERO DEFECTS.
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POKA - YOKE
APPROACH
WHEN A MISTAKE HAS OCCURRED WHICH WILL
LEAD TO DEFECT CREATION , WE MUST LOOK FOR
WAYS AND MEANS OF KNOWING IT IN ADVANCE
SO THAT IT ( MISTAKE ) CAN BE PREVENTED FROM
OCCURRING.
( PREVENTION – PROACTIVE )
IF THE ABOVE IS NOT POSSIBLE
WHEN A MISTAKE HAD TAKEN PLACE LEADING TO
DEFECT CREATION , WE MUST LOOK FOR WAYS
AND MEANS OF KNOWING IT SO THAT IT
( DEFECTIVE PIECE ) CAN BE PREVENTED FROM
MOVING TO THE NEXT OPERATION / CUSTOMER.
( DETECTION – REACTIVE )
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CONCEPTS FOR ZQC
A zero Quality Control system is build on the

following basic ideas
1, Use source inspection for preventing defects

2, Always use 100 % inspection rather than sampling
inspections
3,Minimize the time it takes to carry out corrective
actions
4, Human workers are not infallible – Recognize that
people are humans and set up a effective Poka - yoke
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WHAT IS PSP IN POKA YOKE
“There are 3 major types of techniques

Judgement in the field of quality control…..”
Inspection Shigeo Shingo
Informative
Inspection
Source
Inspection
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WHAT IS PSP IN POKA YOKE
• Judgement Inspection
– Separates defective products from good ones after processing. It
helps prevent defects from being delivered to customers, but does
not decrease a company’s defect rate.
• Informative Inspection
– Investigates the causes of defects and feeds back this information
to the ‘guilty’ process to implement remedial corrective action.
• Source Inspection
– A defect is typically a result of a simple mistake. Using the
techniques of Poka-Yoke, we can ‘inspect’ 100% at source so
leading to Zero Defects!
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• Judgment Inspection (Taylor’s)
› Inspection That Discovers Defects – 100 % inspection
• Informative Inspection (Shewhart’s)

› Inspection That Reduces Defects – Sampling inspection
• Source Inspection (Shingo’s)

› Inspection That Eliminates Defects – Error proof inspection
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ZERO QC SYSTEM
• SOURCE INSPECTION
• 100 % INSPECTION ZERO DEFECT
• IMMEDIATE FEEDBACK
• ACTIONS
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INSPECTION METHODS
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SOURCE INSPECTION
Is of 2 Types
• Vertical Source inspection – The idea behind
the vertical source inspection is to try to
control or contain the causes of defects.
• Horizontal Source inspection – The idea
behind the horizontal source inspection is to
detect defect source within processes and
then conducting inspection to keep errors
from turning to defects
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POKA - YOKE
THERE ARE EIGHT BASIC RULES BEHIND THE ACHIEVEMENT OF
MISTAKE PROOFING AND ZERO DEFECTS
RULE - 1 INCORPORATE QUALITY IN TO THE PROCESS
RULE - 2 MISTAKES AND DEFECTS CAN BE ELIMINATED
RULE - 3 GO AHEAD WITH GOOD IDEA AND DISCARD IMMEDIATELY

IF ANY IDEA DID NOT WORK
RULE - 4 INSTEAD OF MAKING EXCUSES,THINK OF A WAY TO DEAL

WITH THE PROBLEM
RULE - 5 GET THE JOB DONE EVEN IF THE RESULT IS 50% OF YOUR TARGET
RULE - 6 IF EVERYONE WORKS TOGETHER IT IS POSSIBLE TO ACHIEVE

MISTAKE PROOFING AND ELIMINATE MISTAKES.
RULE - 7 THE WISDOM OF TEN IS BETTER THAN THE INSPIRATION OF ONE
RULE - 8 SEEKING THE TRUE / ROOT CAUSE – 5 WHYS AND 1 HOW

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WHY TO ADOPT POKA YOKA ?
COMPONENT RELIABILITY BATHTUB CURVE
Infant Mortality Useful Life

Wear Out
(Unbudgeted Costs) (Warranty Costs)
KEY DRIVER
Failure Rate
- Escapes due to:

* Poor/Changing designs KEY DRIVER * Beyond Warranty
* Poor manufacturing - Inherent Design component reliability
processes based on constant failure rate * Aftermarket sales
* Misunderstanding of spare parts
requirements
* Workmanship errors / No
poka yoke
* Supply Chain fluidity
* Control of sub-tiers
B787 TPRs initiated due

to key drivers above
Time
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INPUTS & OUTPUTS
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Shingo’s Method
A Poka Yoke System uses Poka Yoke Devices

Built into Source or Sequential Inspection
Methods. Properly Implemented, the System
can achieve
• Zero Defects
• Zero Waste
• Zero Delays
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WHAT ARE FUNCTIONS OF POKA YOKE
• We should consider that a defect exists in one of two states:

… About to Occur
…Already Occurred
• Recognising that a defect is about to occur is called PREDICTION

• Recognising that a defect has occurred is called DETECTION
• Mistake Proofing has 3 basic functions to use against defects, these can be
applied to judgement inspection, but ideally to source inspection
1. Warning
2. Shut down
3. Control
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FMEA – Detection Rating
Detection Explanation
Ranking
1 Prevention – Prevented by fixture design , machine design, part
design
2 Prevention – Error is detected part is not made

3 Detection - Locks the part in station
4 Detection - Locks the part from further processing
5 Detection – In station by variable gauging
6 Detection post processing by variable gauging
7 Detection in station by visuals
8 Detection post processing by visuals
9 Detection is not easy
10 No process control, cannot detect
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CAUSES OF DEFECTS
DEFECTIVE PRODUCTS
PROCESSING DEFECTS PRODUCT DEFECTS
Primary Causes
of Defects
Incoming
Processing Processing products Sub-Standard
Failures Errors (Missing Parts) Products
(Misassembled)
Causes of
defects
Adjustment Improper Work Setting Mistaken Unmaintained Other

Errors
errors Operation Errors Work Facilities
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WHAT ARE TYPE OF ERROR
• Forgetfulness – easy to miss a process step out

• Errors due to misunderstanding – lack of training
• Errors in identification – mistaken selection
• Wilful errors – sabotage
• Errors due to slowness – too slow to respond to
process
• Errors due to lack of standards – no clear guidelines

• Intentional errors – to try and make the process work
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HUMAN ERRORS DEFECTS
1) Forgetfulness 1) Omitted processing
2) Errors due to misunderstanding 2) Processing error
3) Errors in identification 3) Error in setting up work piece
4) Errors made by amateurs 4) Missing parts
5) Over confidence errors 5) Wrong parts
6) Inadvertent errors 6) Processing wrong work piece
7) Errors due to slowness 7) Adjustment error
8) Errors due to lack of standards 8) Miss-operation
9) Surprise error 9) Equipment not set up properly
10) Intentional errors. 10)Tools and jigs improperly prepared.
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POKA – YOKE HINTS
GET TO KNOW THE CHARACTERISTICS OF THE PARTS
BY WEIGHT BY DIMENSIONS BY SHAPE
DETECT DEVIATIONS FROM PROCEDURES
PROCESS SEQUENCE
DETECT DEVIATIONS FROM THEIR VALUES
USING A ODD – PART OUT CRITICAL CONDITION

COUNTER METHOD DETECTION
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Prevention : Poka - Yoke
 Control Method: This method senses a problem and stops a line or process,
so that corrective action can take place immediately. Thereby it avoids serial defect
generation.
An example of this is an assembly operation wherein, if one of the components is found
to be missing before the actual assembly step takes place, the process shuts down
automatically.
 Warning Method: This method signals the occurrence of a deviation or trend of

deviations through an escalating series of buzzers, lights or other warning
devices. However, unlike the control method, the warning method does not shut
down the process on every occurrence.
It is used when a bandwidth of acceptance exists, for a process. An example could be
pressurizing a vessel or a filling operation, in which the results need not be exactly the
same. Although the process continues to run, the Poka-Yoke signals the operator to
remove a defect from the line, or make necessary adjustments to keep the process
under control.
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Detection : Poka - Yoke
Methods Examples Examples
A device on a drill counts the
number of holes drilled in a
work piece; a buzzer sounds if
A steel pin on a fixture keeps
the work piece is removed
Contact Method incorrectly placed parts from
before the correct number of
fitting properly.
holes have been drilled.
Example : Shapes , Dimensions

Bolts are tightened with a
Light sensors determine if each
wrench dipped in paint. Bolts
crayon is present in each box; if
with no paint on them are still
Fixed method a crayon is missing, the
untightened.
machines will stop
automatically.
Example : Weight
A device detects when each
component is removed from a
dispenser; if a component is not
A simple proximity switch opens
removed, the device alerts the
Motion-Step Method after all components are loaded
assembler before he can move
in the proper order.
on to another unit.
Example : Progressive method
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Contact Method
A contact method functions by detecting whether a sensing
device makes contact with a part or object within the process.
An example of a physical contact

method is limit switches that are Cylinder present Missing cylinder;piston fully
pressed when cylinders are driven into extended alarm sounds
a piston. The switches are connected

to pistons that hold the part in place.
In this example, a cylinder is missing
and the part is not released to the next
process.
Cannot proceed
to next step.
Contact Method using limit

switches identifies missing
cylinder.
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Contact Method
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Contact Method
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Contact Method
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Contact Method
Guide pins
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Contact Method
Prevention :- The figure 1 - A shows that holes are wrongly
drilled due to incorrect positioning of plate.
Figure 1 - B shows that incorrect positioning of the plate is
Prevented by locating 4 reference pins. The cause of
Incorrect Drilling ( incorrect position ) is prevented.
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Contact Method
Detection :- Figure 2 - A shows that plate with 4 holes is drilled , is to
be dispatched to the Customer. Customer complaint show many plates
with 3 holes drilled.
Figure 2-B shows the mistake of less drilled holes is Detected

through a check by using 4 locator pins on a gauge.
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FIXED VALUE METHOD
• Fixed value Methods are used when

• A fixed number of parts must be attached to the
product when fixed repeats of operations needs
to be done at some process station.
• Counting devices count the number of times
something is done & Signals or releases the
product from its clamping when the required
number is reached.
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Example :- Fixed Method
Before
A tip of spot welding machine Welding tips needs to

wears with the use and should be replaced after 200
be replaced after certain number Nos.
of welds. Operator used to forget
changing the tip, resulting in
defective product
After
A counter , tracking the number

of welds, stops the machines
and flashes a light as a signal
to change the tip.
Counter
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Fixed Method
Used when
• A fixed number of operations are required within a process.
• When a product has a fixed number of parts that are attached to
it.
• A sensor counts the number of times a part is used or a process is
completed and releases the part only when the right count is
reached.
In the example to the right a limit switch

is used to detect and count when the
required amount of holes are drilled.
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Fixed Method
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Fixed Method
Counter counts the no of weld made & light

after six welds
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Fixed Method
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Motion-Sequence Method
The third poka-yoke method uses sensors to determine if a motion
or a step in a process has occurred. If the step has not occurred or
has occurred out of sequence, the sensor signals a timer or other
device to stop the machine and signal the operator.
This method uses sensors and photo-electric

devices connected to a timer. If movement does
not occur when required, the switch signals to
stop the process or warn the operator.
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Motion Sequence method
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Motion Sequence Method
The Shingo System:

Example
Exhibit 8.10
Poka-Yoke Example
(Placing labels on parts
coming down a conveyor)
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INSPECTION
METHODS TYPES
METHODS
Contact method Control type
Contact method Warning type
Fixed value method Control type
Source Inspection
Fixed value method Warning type
Motion step method Control type
Motion step method Warning type
Fixed value method Control type
Informative Inspection
Fixed value method Warning type
Motion step method Control type
Motion step method Warning type
Informative inspection
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POKA - YOKE
3 POINT CHECK OF CURRENT STATE
FREQUENCY OF 1 POINT - NO DEFECTS
OCCURRENCE
2 POINTS – LIKELY TO OCCUR INFREQUENTLY
3 POINTS – LIKELY TO OCCUR FREQUENTLY
DEGREE OF EFFECT 1 POINT - NO INFLUENCE
ON THE PROCESS 2 POINT – SOME DEGREE OF EFFECT,BUT RESTORATION

POSSIBLE THROUGH MODIFICATION.
3 POINT – OTHER PROCESSES,PARTICULARLY DOWNSTREAM
PROCESSES ARE THROWN IN TO CONFUSION.
DEGREE OF EFFECT 1 POINT - NO INFLUENCE
ON THE COMPANY 2 POINT – LIKELY TO RECEIVE COMPLAINTS,BUT POSSIBLE TO

SOLVE THROUGH REPAIR OR AFTER CARE.
3 POINT – COULD LEAD TO DISASTER. IT WOULD TAKE LOT OF
TIME AND COST LARGE MONEY TO RESTORE PUBLIC
CONFIDENCE IN THE COMPANY.
FREQUENCY OF DEGREE OF EFFECT DEGREE OF EFFECT

OVERALL POINTS = OCCURRENCE X ON PROCESSES X
ON THE COMPANY
OVER ALL POINTS : 4 – 9 – MISTAKE – PROOFING MEASURES NECESSARY

12 – 27 : PY SYSTEMS SHOULD BE IMPLIMENTED IMMEDIATELY
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POKA - YOKE
3 POINT CHECK OF COUNTERMEASURE
DEGREE OF 1 POINT - NO URGENCY
URGENCY
2 POINTS - A CERTAIN DEGREE OF URGENCY IS REQUIRED
3 POINTS - COUNTER MEASURES MUST BE IMPLEMENTED IMMEDIATELY.
DEGREE OF 1 POINT – DEFECT CAN BE EASILY PREVENTED BY USE OF JIG / FIXTURES.

DIFFICULTY 2 POINTS – REQUIRES PY DEVICES INCORPORATED IN TO THE WORK
PROCESS.
3 POINTS – ELIMINATING THE DEFECT IS POSSIBLE ONLY WITH HEAVY
INVESTMENT , IF AT ALL.
COUNTER 1 POINT – THE DESIGN STAGE

MEASURE 2 POINTS – DURING THE WORK PROCESS.
METHOD
3 POINTS – DURING THE FOLLOWING PROCESSES OR THE INSPECTION
PROCESS.
DEGREE OF X DEGREE OF X COUNTER MEASURE

OVERALL POINTS = URGENCY DIFFICULTY METHOD
OVER ALL POINTS : 4 – 9 : EASY TO DEAL WITH THE PROBLEM

12 – 27 : DIFFICULT TO EMPLOY COUNTER MEASURES
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Types of Sensing Devices
1. Physical contact devices
2. Energy sensing devices
3. Warning Sensors
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Physical Contact Sensors
These devices work by

physically touching
something. This can be a
machine part or an actual
piece being manufactured.
In most cases these devices
send an electronic signal
when they are touched.
Depending on the process,
this signal can shut down
the operation or give an
operator a warning signal.
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Touch Switch
Used to physically detect the presence or absence of an
object or item-prevents missing parts.
Used to physically detect the height of a part or
dimension.
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Energy Sensors
These devices work by

using energy to detect
whether or not an defect
has occurred.
Fiber optic
Vibration
Photoelectric
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POKA - YOKE
POKA – YOKE DEVICES

MECHANISMS THAT EITHER PREVENT A MISTAKE
FROM BEING MADE OR MAKE THE MISTAKES OBVIOUS AT A GLANCE.
LEVEL – 1 - DEVICES
A DEVICE THAT PREVENTS A MISTAKE FROM BEING MADE.
A DEVICE THAT DETECTS A MISTAKE OR
ERROR AFTER IT OCCURS,BUT BEFORE IT TURNS IN TO A DEFECT.
( SOURCE INSPECTION )
A DEVICE THAT DETECTS A DEFECT, AT THE
INSTANT, IT OCCURRED.
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POKA - YOKE
WORK PIECE IN
CORRECT LOADING
MACHINE SPINDLE
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POKA - YOKE
BEFORE STATUS
WORK PIECE
IN REVERSE
PROBLEM :
WORK PIECE COULD BE
REVERSED WHILE LOADING.
MACHINE SPINDLE WHEN PROCESSED BECOMES
TOTAL SCRAP.
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POKA - YOKE
Proximity Switch – Signal

To interlock with machine
WORK PIECE
IN REVERSE
Signal from Proximity switch

due to wrong Loading prevents
the machine from operating.
MACHINE SPINDLE
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POKA - YOKE
LEVEL - 2
Proximity Switch – Signal

To interlock with machine
No Signal from Proximity

MACHINE
Switch, the machine Operates.
SPINDLE
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POKA - YOKE
Level - 1
PY BLOCK THAT
PREVENTS
REVERSE LOADING
MACHINE NORMAL LOADING

SPINDLE
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Processing errors including safety errors.
Processing error Section consists of examples where due to
operators mistake some process step is partially or incorrectly
done.
For Example :-
Sometimes the drill is raised back before drilling the required depth (thru). A
proximity Switch has been provided to sense the coming through of drill
to indicate completion of drill operation.
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THE MISTAKE – PROOFING TOP 5
MISTAKE PROOFING PINS ; BLOCKS AND GUIDES
ERROR DETECTION EQUIPMENTS ; LIMIT SWITCHES

WARNING LAMPS, ALARMS.
SPECIALISED MISTAKE – PROOFING JIGS TO

DETECT DEFECTIVE PARTS
COUNTERS, TIMERS
POSTING AND CHECKING, PROSEDURE CHARTS
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POKA - YOKE
BEFORE IMPROVEMENT AFTER IMPROVEMENT
JIG WITHOUT PY BLOCK JIG WITH PY BLOCK
PY BLOCK
HOLE
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POKA - YOKE
BEFORE INTRODUCTION OF PY
WELDER
PROBLEM :
This automatic welding machine welds a
ring on to an assembly. Sometimes, an
assembly comes along that is missing a
Ring.
RING TO BE WELDED
WORK
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POKA - YOKE
AFTER INTRODUCTION
OF PY SYSTEM
WELDER
RING
TO BE WELDED LAMP
TO THE WORK
INTERLOCKED
WITH MACHINE
BUZZER
WORK
STOP
BUTTON
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Five Best Poka-Yoke
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Assembly Error
This selection consists of examples where operator by mistake does

partial or incorrect assembly.
For Example :-
During assembly of a gear on the shaft for two similar models , Gear ‘B’
is assembled on the shaft ‘a’ instead of Gear ‘A’. Gear A & B are similar
looking gear differing only in the number of teeth.
To eliminate this error a mating part is installed on the assembly fixture
corresponding to ‘A’ to ensure that only gear ‘A’ is loaded.
Mating Part with Gear ,A
Gear, B
Gear,A
Shaft a
Before
Gear B Installed Wrongly.

Only Gear A can Be Installed.
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Inspection Errors
Section on Inspection error consists of examples which are related to rejected
components going down the line or to the Customer. These errors are due to
monotony and fatigue faced by the Inspector.
The operator is not sure of the completion of leakage test and passes them to
the bin meant for keeping jobs that have passed leakage test.
Operator sometimes not sure of leakage testing test completion and keeps
NOT OK products in OK bin
Now, head for stamping added at leakage testing station , only after
leakage has been tested OK job will be stamped by the Head for
stamping
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Processing Omissions
This section consists of example where due to mistake , the operator
MISSES out few steps of the process.
For Example :-
4 holes to be drilled 3 holes drilled

because of mistake
Now , the drilling operation has been provided with counter

and the job will not be unclamped unless, the counter with
drilling machine reads four.
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Assembly omissions
The section on Assembly Omissions consists of examples
where an assembly part is not assembled by the operator by
mistake and the assembly goes to next
For Example :-
In an assembly operation washer were missed before
providing nut. To remove this problem washer picking
was sensed to give a start to nut runner.
Proximity
which senses
picking of
Picking washer gives
Nut signal to nut
Nut runner
runner
Washer sometimes missed
Picking of washer will be sensed to allow the start of nut runner
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Packing / pasting / labeling error
As the name suggest this section includes examples on
Errors in Packing / Pasting / Labeling.
For Example :
A Cartoon going without the medicine bottle inside as packer

missed to keep the bottles inside the cartoon
Now , a draft of fan has been

provided below the conveyor ,
carrying cartoons with bottle ,
which is strong enough to blow
an empty cartoon.
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POKA - YOKE
Poka – yoke - exercise Before
improvement
List of Materials to be packed
1.Maintenance&Service manuals
2.Instruction Manuals
3.Handles
6
4.Cords 5
5.Clips 4
6.PVC Sheets 3
2
1
Problem: Omission of
Accessories
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POKA - YOKE
Poka – yoke - exercise After
improvement
List of Materials to be packed
1. Maintenance & Service manuals

2. Instruction Manuals
3. Handles
6
4. Cords 5
5. Clips 4
6. PVC Sheets 3
2
1
Stopper
Limit Switch
Photoelectric
switches
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POKA - YOKE
Poka – yoke - exercise After further
improvement
List of Materials to be packed Light

( Bulbs )
1.Maintenance&Service manuals
2.Instruction Manuals
3.Handles
6
4.Cords 5
5.Clips 4
6.PVC Sheets 3
2
1
Stopper
Limit Switch
Photoelectric
switches
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Dimensional Error / Miss orientation /
misalignment
This section consists of errors because of misaligned / miss oriented
job loaded on a process leading to slightly offset operations.
For Example :-
Before After
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POKA - YOKE
EVERY DAY EXAMPLES
3 PIN ADOPTER / PIN IN ELECTRICAL FITTINGS

FLOPPY LOADING IN P.C
CASSETTE LOADING IN TAPE RECORDER / VCR / VCP
AUTOMOBILE CONTROLS
LAWN MOWERS
WASHING MACHINES / REFRIGIRATORS / IRON BOX
HOTEL ROOMS
FLUSHING TOILET – WATER FILLING & LEVEL MAINTCE.
PETROL IN PETROL TANKS - AUTOMOBILES

92 / 139 (LEONARD. R)
Mistake Proofing.. Daily Life examples
You can have number of Mistake proofing examples such as :-
- ATM transactions
- Remote locking of car door
- Computer turns off if unattended for set time
- Computer peripherals
- Gas cylinder valve
- Refrigerator lamp turns on when door is

opened and so on……………..
93 / 139 (LEONARD. R)
Mistake Proofing.. How ?
If you re-look in to these examples carefully you will notice that a
- small sensor,
- switch ,
- timer ,
- shape ,
- visual signal ,
- thickness ,
- hole , are used to PREVENT MISTAKES
94 / 139 (LEONARD. R)
POKA - YOKE
ELECTRONIC
DOOR LOCKS
NO DOOR IS LEFT DOORS AUTOMATICALY LOCKED LOCK WON’T OPERATE WHEN

UNLOCKED WHEN SPEED EXCEEDS 18 mph DOOR IS OPENAND THE
95 / 139 (LEONARD. R) ENGINE IS RUNNING

POKA - YOKE
NEW LAWN MOWERS ARE REQUIRED
TO HAVE SAFETY BAR ON THE HANDLE
THAT MUST BE PULLED BACK IN ORDER
TO START THE ENGINE.
IF YOU LET GO, THE MOWER BLADE
STOPS WITHIN 3 SECONDS.
( WHY ? )
96 / 139 (LEONARD. R)
POKA - YOKE
IRON TURNS OFF AUTOMATICALLY
WHEN IT IS LEFT UNATTENDED. OR
WHEN IT IS RETURNED TO ITS
HOLDER.
97 / 139 (LEONARD. R)
POKA - YOKE
FILING CABINET
OPENING ONE DRAWER LOCKS
ALL THE REST, REDUCING
THE CHANCE OF THE FILE
CABINET TIPPING.
98 / 139 (LEONARD. R)
POKA - YOKE
FILLING GAS FOR VEHICLE.
THE PY DEVICE, DOES NOT ALLOW
THE MOTORIST TO DRIVE OFF
WITHOUT THE GAS CAP IS FITTED
WITH RATCHED TO SIGNAL PROPER
TIGHTNESS AND PREVENT OVER –
TIGHTENING.
99 / 139 (LEONARD. R)
POKA - YOKE
ANTILOCK BRAKING SYSTEM
( ABS )COMPENSATE FOR
DRIVERS WHO STOMP ON THE
BRAKE. WHAT USED TO BE
A DRIVING ERROR IS NOW
THE PROPER BRAKING
PRESSURE.
100 / 139 (LEONARD. R)

POKA - YOKE
CIRCUIT BREAKERS PREVENT ELECTRICAL
OVER LOADS AND THE FIRES THAT RESULT.
WHEN THE LOAD BECOMES TOO GREAT THE
CIRCUIT IS BROKEN.
101 / 139 (LEONARD. R)

POKA - YOKE
LOCATION FOR TAPPING
WORK
ABNORMAL
FIXTURE
NORMAL
FIXTURE
102 / 139 (LEONARD. R)
POKA - YOKE
WORK PY BLOCK
FIXTURE
NORMAL
103 / 139 (LEONARD. R)

POKA - YOKE
INJECTION MOULDINGS
PROBLEM DEFECTIVE PIECE COULD BE IDENTIFIED ONLY AT FINAL STAGE
INSPECTIONAT FINAL ASSEMBLY.
PERFECT
COMPONENT
DEFECTIVE PIECE
WITH FLASHINGS
104 / 139 (LEONARD. R)

POKA - YOKE
FLASHINGS REMOVED FLASHINGS
PY BLOCK
PY BLOCK
105 / 139 (LEONARD. R)
POKA - YOKE
ALARM
AS THE TRAIN APPROACHES,THE ALARM

SIGNAL ALERTS PEDESTRIANS AND
DRIVERS.
106 / 139 (LEONARD. R)

POKA - YOKE
ALARM A BARRIER IS INSTALLED ON BOTH
SIDES AS A PHYSICAL HAZARD
WARNING,BLOCKING PASSAGE
ACROSS THE TRACK.
107 / 139 (LEONARD. R)

POKA - YOKE
A RAILROAD PASSES OVER A BRIDGE OR THROUGH A TUNNEL UNDER
THE ROAD, A MORE RELIABLE WAY OF PREVENTING ACCIDENTS
108 / 139 (LEONARD. R)

POKA - YOKE
BEFORE PY CONCEPT APPROACH.
COMPONENT
PILLAR PILLAR
DIA 25 mm DIA 25 mm
PROBLEM : IF BY MISTAKE TOP TOOL IS REVERSED, DAMAGE TO TOOL.
109 / 139 (LEONARD. R)

POKA - YOKE
AFTER PY CONCEPT IMPLEMENTATION
COMPONENT
PILLAR PILLAR
DIA 25 mm DIA 35 mm
110 / 139 (LEONARD. R)

TEN COMMANDMENTS
TO ACHIEVE
COMPANY WIDE ZERO DEFECTS.
BUILD QUALITY IN TO THE PROCESS.
EDUCATION TO EMPLOYEES TO HAVE A CONVICTION THAT

MISTAKES AND DEFECTS CAN BE ELIMINATED.
NO HESITATION TO GO AHEAD WITH GOOD IDEAS.
DISCARD IMMEDIATELY AN IDEA THAT DID NOT WORK.
ENCULCATE THE HABIT OF FINDING A WAY OUT TO SOLVE THE

PROBLEM RATHER THAN OFFERING EXCUSES.
111 / 139 (LEONARD. R)

TEN COMMANDMENTS
TO ACHIEVE
COMPANY WIDE ZERO DEFECTS.
TRY THING WITHOUT DELAY. CONVERT PAPER

PROJECTS INTO REALITY QUICKLY.
FOR WHOLESOME SUCCESS,INVOLVEMENT OF EVERY ONE IS

ESSENTIAL. CREATE ENTHUSIASM AMONG ALL.
THE WISDOM OF TEN PEOPLE IS BETTER THAN THE

INSPIRATION OF ONE MAN
GIVE AN ANALYTICAL TREATMENT TO THE PROBLEM

TO FINDOUT THE TRUE / ROOT CAUSE.
WORKOUT A STRUCTURED PLAN FOR PROMOTING THE SPRIT

AND FOR IMPLEMENTATION.
112 / 139 (LEONARD. R)

POKA - YOKE
SEVEN STEP METHODOLOGY
STEP - 1 WHAT’S WRONG ?
STEP - 2 WHERE WAS THE DEFECT DISCOVERED ?
STEP - 3 WHAT WAS SUPPOSED TO HAPPEN ?
STEP - 4 WHAT HAPPENED THAT WAS NOT SUPPOSED TO HAPPEN ?
STEP - 5 WHY DID THE MISTAKE ( NSE ) HAPPEN ?
STEP - 6 HOW CAN EACH ( NSE ) MISTAKE CAN BE ELIMINATED ?
STEP - 7 DOES IT WORK ?
113 / 139NSE – NON STANDARD ELEMENT

(LEONARD. R)
POKA - YOKE
THERE ARE EIGHT BASIC RULES BEHIND THE ACHIEVEMENT OF
MISTAKE PROOFING AND ZERO DEFECTS
RULE - 1 INCORPORATE QUALITY IN TO THE PROCESS
RULE - 2 MISTAKES AND DEFECTS CAN BE ELIMINATED
RULE - 3 GO AHEAD WITH GOOD IDEA AND DISCARD IMMEDIATELY

IF ANY IDEA DID NOT WORK
RULE - 4 INSTEAD OF MAKING EXCUSES,THINK OF A WAY TO DEAL

WITH THE PROBLEM
RULE - 5 GET THE JOB DONE EVEN IF THE RESULT IS 50% OF YOUR TARGET
RULE - 6 IF EVERYONE WORKS TOGETHER IT IS POSSIBLE TO ACHIEVE

MISTAKE PROOFING AND ELIMINATE MISTAKES.
RULE - 7 THE WISDOM OF TEN IS BETTER THAN THE INSPIRATION OF ONE
RULE - 8 SEEKING THE TRUE / ROOT CAUSE – 5 WHYS AND 1 HOW

114 / 139 (LEONARD. R)
PROCESS FLOW DIAGRAM. REFERENCE NO
POKA YOKE
CQED NPIT POKA YOKE TMDO TR WED METHODS PU

PROCESS APQP CFT
CUSTOMER
FMEA
P COMPLAINT
FINDING
LINE REJECTION
WARRANTY.
DEFECTS IDENTIFICATION
&
DEFECTS CLASSIFICATION
D
POKA YOKE SELECTION
INTEGRATE OK
PREPARE TRYOUT
MANUFACTURE M/C. & TOOL
DESIGN
MODIFY NOT OK
PY.MASTER
STANDARDISATION
C
MAINTAIN
&
AUDIT
READ ACROSS
A
115 / 139 (LEONARD. R)
REFERENCE :
UNIT :
IMPLEMENTED ON :
MODULE :
OPERATION : POKA - YOKE PREVENT ERROR :
STATION / DETECT ERROR :
MACHINE NO :
ALARM :
PROBLEM :
KEY IMPROVEMENT :
BEFORE AFTER
BENEFIT:
116 / 139 (LEONARD. R)
POKA - YOKE
UNIT : AUDIT CHECK SHEET OWNERSHIP :
DATE OF
OPERATION PY MASTER PY SYSTEM AUDITED BY REMARKS
AUDIT A / NA
CONDITION
117 / 139 (LEONARD. R) SLIDE NO 17

Effectiveness of POKA YOKE
Visual Display
To ensure effectiveness of POKA YOKE we need to…. - Stickers
Have Visual Control on all POKA YOKE Stations like

• Lights
• Stickers
or any other visuals
Conduct Audits to validate the functioning of PY using Good Master

and Bad Samples Samples
• Daily - start of the shift audit by operator
• Mid-day audit by Quality inspectors
• Random audit by Production supervisors, Managers etc….
The daily audit by operators have to be recorded in the
Daily check Daily

Check sheet
sheet displayed in the work station
118 / 139 (LEONARD. R)

POKA - YOKE
WHERE MISTAKE – PROOFING WORK WELL
Manual operations where worker vigilance is needed
Where miss positioning can occur
Where adjustment is required
Where Teams need commonsense tools and not another buzz word.
Where SPC is difficult to apply or apparently ineffective.
Where attribute and not measurements are important.
Where Training Cost and Employee turnover are high
Where mixed model production occurs
Where special causes can re occur
Where external failure costs dramatically exceed
Where customers make mistakes and blame the service provider

119 / 139 (LEONARD. R)
Quality
Poka yoke implementation Vs Customer end rejection
80 5000
Customer end
4500
4300 rejection ( PPM)
4100 4000
63
60 58
3400 53
3002 3000
2390 43
40
2590
2100 Poka -yoke
1890 32 2000
27 implemented ( nos )
20 21 1300 1230
13 1089
15 1000
789
9 578
7
1 3
0 0 0
02
01
m 1
1
1
1
01
01
02
01
1
01
01
01
0
'0
l '0
'0
t'0
r'
n'
n'
n'
b'
b'
g'
c'
v'
p'
ar
ay
ju
ap
oc
ja
ja
ju
au
fe
fe
de
no
se
m
Poka yoke Customer end rejection
120 / 139 (LEONARD. R)

HOW POKA YOKE
Level 1: Defects
Operations
leave company
Errors
Level 2: Defects
do not leave company
Defects
Operations
Level 3: Defects
Improve
Processes
decrease
Defects Errors
Level 4: Defects
Inspections
do not leave the process
Level 5: Zero Defects Non-defective

items
121 / 139 (LEONARD. R)

HOW POKA YOKE
• Andon board in BCE
122 / 139 (LEONARD. R)

•
• BeforeImprovement
• 1. Previously produced items involved bolts of different lengths and very rarely such
bolts would find their way into theprocess.
• 2. Such problems were difficult to uncover anddefectiveitemsmoved on to
subsequent processes.
• After lmp;ovement
•An adjustable stopper was provided on a chute leading to subsequent processes

to prevent defectiveitems from moving forward shown below, the stopper is set so
that a bolt of normallengthcan just barely pass through. Longer bolts are stopped
and a buzzer sounds.
•
123 / 139 (LEONARD. R)

HOW POKA YOKE
• Machining production line
Before: After machine start

up some products are left
machined. Could go
unnoticed and result in die
damage in next process.
After: Limit switch installed

to detect height
differences. When switch is
actuated, alarm lamp is lit
to alert operator.
124 / 139 (LEONARD. R)

HOW POKA YOKE
• Treadmill
This treadmill has a clip that attaches to the user’s clothes.

If the user moves too far back away from the machine, a safety peg is
pulled from the machine turning the motor off.
125 / 139 (LEONARD. R)

HOW POKA YOKE
• Nut tightening process
Before: If air pressure dropped,
bolts were tightened with
insufficient torque
After: An air pressure meter

was installed in the air line. A
lamp blinks, an alarm sounds
and the conveyor stops if the air
pressure drops below a critical
point.
126 / 139 (LEONARD. R)

HOW POKA YOKE
• Go/No Go systems
127 / 139 (LEONARD. R)

HOW POKA YOKE
• Sorting process
Before: Operator could mix up which box the defects were placed
After: Sorting device developed. The gate to the defective and good boxes
moved depending on the test result of the gauge
128 / 139 (LEONARD. R)

HOW POKA YOKE
Hair drier
Switch
If you forget to switch off
What will happen?
Energy loss , Motor overheat ,
life is reduced
How to avoid ?
129 / 139 (LEONARD. R)

HOW POKA YOKE
Limit switch trigger
Auto off after keeping on holder
Poka – Yoke
130 / 139 (LEONARD. R)
HOW POKA YOKE
Story
Letter delivered to wrong person
To
R. Suresh
To D.No-86 II nd cross ,
Rajesh M.G Road,
M/s R.K Industry Hosur - 635109
Bangalore - 35
How to avoid ?
131 / 139 (LEONARD. R)

HOW POKA YOKE
Post cover
Provide Window cover for address
Avoids wrong posting , time saving.
To
R. Suresh
D.No.86, II nd cross ,
M.G Road,
Hosur - 635109
Poka – Yoke
132 / 139 (LEONARD. R)
HOW POKA YOKE
CAR PARKING
133 / 139 (LEONARD. R)

HOW POKA YOKE
134 / 139 (LEONARD. R)

HOW POKA YOKE
135 / 139 (LEONARD. R)

HOW POKA YOKE
136 / 139 (LEONARD. R)

HOW POKA YOKE
137 / 139 (LEONARD. R)

HOW POKA YOKE
Simple Design change
Before Improvement: After Improvement:

Cassette covers were frequently The cause of the trouble was scrutinized
scratched when the screwdriver slipped and a change was made in the shape of
out the screw slot and slid against the the screw slot to prevent the
plastic covers. screwdriver from slipping. Scratches
caused by the screwdriver slipping have
been completely eliminated.
138 / 139 (LEONARD. R)

MACHINE VISION
139 / 139 (LEONARD. R)

140 / 139 (LEONARD. R)
141 / 139 (LEONARD. R)
142 / 139 (LEONARD. R)
ARTIFICIAL INTELLIGENCE
143 / 139 (LEONARD. R)

Artificial intelligence (AI, also machine intelligence, MI) is intelligence
demonstrated by machines, in contrast to the natural intelligence (NI)
displayed by humans and other animals.
In computer science AI research is defined as the study of "intelligent agents:

any device that perceives its environment and takes actions that maximize its
chance of successfully achieving its goals. Colloquially, the term "artificial
intelligence" is applied when a machine mimics "cognitive" functions that
humans associate with other human minds, such as "learning" and "problem
solving".
144 / 139 (LEONARD. R)

145 / 139 (LEONARD. R)

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… A TVS Group Company

A Strategy for Performance Excellence

• Principle of mistake proofing first documented in the Toyoda loom works in

• Definition : to avoid (Yokeru) inadvertent errors (Poka)

Toyoda G-loom circa 1924

TO PREVENT THESE ERRORS

POKA – YOKE SYSTEM …………….

POKA means INADVERTENT ERRORS

YOKE means TO AVOID

POKA -YOKE – TO AVOID INADVERTENT ERRORS

TERM COINED BY Dr. SHIGEO SHINGO

ERRORS AND MISTAKES ARE INEVITABLE – BUT

THEY CAN BE PREVENTED AT THE SOURCE

IF ANYTHING CAN GO WRONG, IT WILL GO WRONG !

MINDSET IS NECESSARY TO HAVE STRONG CONVICTION

A zero Quality Control system is build on the

1, Use source inspection for preventing defects

“There are 3 major types of techniques

• Informative Inspection (Shewhart’s)

• Source Inspection (Shingo’s)

MISTAKE PROOFING AND ZERO DEFECTS

RULE - 1 INCORPORATE QUALITY IN TO THE PROCESS

RULE - 2 MISTAKES AND DEFECTS CAN BE ELIMINATED

RULE - 3 GO AHEAD WITH GOOD IDEA AND DISCARD IMMEDIATELY

RULE - 4 INSTEAD OF MAKING EXCUSES,THINK OF A WAY TO DEAL

RULE - 6 IF EVERYONE WORKS TOGETHER IT IS POSSIBLE TO ACHIEVE

RULE - 7 THE WISDOM OF TEN IS BETTER THAN THE INSPIRATION OF ONE

RULE - 8 SEEKING THE TRUE / ROOT CAUSE – 5 WHYS AND 1 HOW

Infant Mortality Useful Life

- Escapes due to:

B787 TPRs initiated due

A Poka Yoke System uses Poka Yoke Devices

• We should consider that a defect exists in one of two states:

• Recognising that a defect is about to occur is called PREDICTION

2 Prevention – Error is detected part is not made

PROCESSING DEFECTS PRODUCT DEFECTS

Adjustment Improper Work Setting Mistaken Unmaintained Other

• Forgetfulness – easy to miss a process step out

• Errors due to lack of standards – no clear guidelines

GET TO KNOW THE CHARACTERISTICS OF THE PARTS

BY WEIGHT BY DIMENSIONS BY SHAPE

DETECT DEVIATIONS FROM PROCEDURES

DETECT DEVIATIONS FROM THEIR VALUES

USING A ODD – PART OUT CRITICAL CONDITION

 Warning Method: This method signals the occurrence of a deviation or trend of

Example : Shapes , Dimensions

Example : Progressive method

An example of a physical contact

a piston. The switches are connected

Contact Method using limit

Figure 2-B shows the mistake of less drilled holes is Detected

• Fixed value Methods are used when

A tip of spot welding machine Welding tips needs to

A counter , tracking the number

In the example to the right a limit switch

Counter counts the no of weld made & light

This method uses sensors and photo-electric

The Shingo System:

DEGREE OF EFFECT 1 POINT - NO INFLUENCE

ON THE PROCESS 2 POINT – SOME DEGREE OF EFFECT,BUT RESTORATION

DEGREE OF EFFECT 1 POINT - NO INFLUENCE

ON THE COMPANY 2 POINT – LIKELY TO RECEIVE COMPLAINTS,BUT POSSIBLE TO

FREQUENCY OF DEGREE OF EFFECT DEGREE OF EFFECT