PokeYoke KC1 PDF

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All Rights Reserved

Introduction to the Ebook
www.kaizenclub.co.in Copyright of Hash Management Services LLP, 2020. All Rights Reserved
Thank You
We are sure that this Ebook would add tremendous value to you in terms of
providing practical knowledge and implementation tips on various lean tools.
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Audience for this Ebook
Engineering Students Would be a great addition to your resume and help you get a Job in the
who are interested in Manufacturing Sector. You can become a champion in implementing Lean
Manufacturing Sector Concepts in the company where you are joining. Faster Career Growth and
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Professionals from the You can become a trainer and create a basic understanding for your team
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Possibilities of Higher Salary and Incentives.
Why this Ebook?
There are so many websites, books, videos on Lean manufacturing in the internet. In
that case, why we have created this Ebook?
20
20
, Jargons
1. Easy to understand & Less Jargons - We have created this Ebook with a
L P
s L
i ce
simple idea of explaining Lean in a simple and easy way and touch more than
v
r words
1,00,000 people. We have purposefully avoided jargons and Japanese
S e
n t
which may confuse people
m e Practical Tips for

Implementation Tips: The existing resources do not g e Implementation
2.
n a provide an in-depth /
M a
Step by Step approach of the Implementation Procedure. i.e. How do I start
sh
implementing Lean in my company?
H a
o f
3.
ht
Holistic Approach: The existing resources are focused on explaining the
Lean Tools in bits y

i g
r pieces. Except for some of the well-known books
and
o p Holistic
C only a very few articles discuss about the holistic philosophy.
written on Lean, Approach
About the Author
Ananth is the Managing Partner and Principal Consultant of Hash Management Services
LLP, a boutique business advisory firm working with manufacturing companies in
implementing Lean Manufacturing Initiatives.
Over the last 10 years, Hash had worked with more than 100 companies in helping them
in the Lean Journey and had trained more than 10,000 professionals on the Lean and
related topics.
Some of our clients are VKC Group, Venus Water Heaters, Paragon Footwear, JK Tyres,
Email: pananth@hashllp.com
Amaron Batteries, Farida Group, etc.
Linkedin: ananthpalaniappan
Twitter: pananth
About the Author
Hash helps in implementing Continuous Flow Production, 5S, Single Minute

Exchange of Dies (SMED), PokaYoke, Load Levelling, Kaizen, Kanban and other
Lean Tools.
Ananth holds a B.E. (Mech) degree and a PGDM in Marketing and Operations from
IFMR. Earlier, he had worked as a Senior Engineer in Titan Industries and as a
Consultant at Deloitte’s Strategy and Operations Practice.
My Mission:
1. Work with More than 100 Companies per year on implementing Lean
Email: pananth@hashllp.com
2. Train More than 1,00,000 people on Lean Manufacturing every year
Linkedin: ananthpalaniappan
Twitter: pananth 3. Touch More than 1 Million people through Social Media (Youtube, LinkedIn,
Facebook, etc.) every year
Inspection and it’s connection
with PokaYoke
Before we learn PokaYoke…
What is Inspection?
2 0
2 0
Before knowing about Poka-Yoke it is essential to know about Inspection and defects. P , Inspection is the process of checking
L L
whether a product meets the specifications. The products which do not meet the
e s specifications are termed as Defectives.
vi c
e r
Inspection is merely an activity to check / segregate the good products
t S and bad products.
e n
Inspection do not reduce Defects, because the defects originate e m in the processes. Strengthening inspection by following
g
a end equipments may lead to easy identification of defects, but will
stringent methods, adding more inspectors and other n high
M a
not result in reduction of defects.
s h
H a
So, to reduce defects, the processes must o f be designed in such a way that defects are identified immediately / not produced
ht
at all. r i g
p y
C o
Inspection is a Waste (NVA)
How to eliminate Inspection? 0

0 2
, 2
P
s
Pokayoke helps us in eliminating Inspection. As we saw in the earlier slide, Inspection
LL
helps in only segregation of Good and
c e
Bad products.
r vi
S e
n t
m e
ge the Defects, so we can gradually achieve ZERO QC (a stage
Pokayoke (along with Source Inspection) helps in eliminating
a
where there is no need for inspection)
a n
h M
a s
f H
o in detail and in the later part, we explain how pokayoke helps in achieving Zero QC
Now, let us look at the types of inspection
t
ig h
y r
o p
C
Inspection
Inspection
There are 3 types of Inspection
2 0
2 0
1. Judgemental inspection
P,
s LL
2. Informative inspection
i c e 1. Judgemental Inspection
e rv
t S
3. Source Inspection
e n
e m
a g
a n 2. Informative Inspection
h M
a s
f H
t o
ig h
p yr 3. Source Inspection
C o
1. Judgemental Inspection
What is Judgemental Inspection?

2 0
2 0
Judgemental inspections is the basic level of inspection that categorises the P,
s LL
finished products as Good or Bad.
i c e
e rv
t S
The data regarding the inspection, Good and Bad etc are recorded e n in a database.
e
However this information is not shared with the previousgprocess
m where the
n a
defects are originating.
M a
s h
H a
f
oaction to reduce the defects in the future.
So there would not be any preventive
ht
r i g
p y
C o
2. Informative Inspection
What is Informative Inspection? Informative Inspection

2 0
2 0
The information regarding the defects are fed back to the processes
P,
involved, where the corrective and preventive actions are taken to s LL
i c e Statistical Quality Control
reduce the defect.
e rv (SQC)
S
If this method is followed, the defects rate will gradually reduce.
nt
m e
There are three categories in Informative inspection
g e
n a Successive check
1. Statistical Quality Control
M a
s h
2. Successive Check
Ha
of
ht Self Check
3. Self Check.
y rig
o p
C
Informative Inspection
What is Statistical Quality Control?

2 0200
2 0
P,
Statistical Quality Control (SQC) is a method of quality control which employss LL 150 UCL
i c e
statistical methods to monitor and reduce the defects. The data related to r v
S e 100
defects are analysed and corrective actions are taken.
n t
m e
g e
People use Quality Circles, 7 QC tools and other qualityaprinciples and do
50 LCL
a n
projects to reduce the defects.
h M
a s
Typically most of Indian companies follow f H
this SQC methods to reduce defects
t o
i g h
y r
o p
C
What is Successive check?

Process A
2 0
Successive check is when the products are checked by the next process (before
2 0
P,
LL
starting the work).
Inspects before
1. When A finishes the processing of an item, it is transferred to B

e s starting the
vi c process
2. B starts with an inspection of the process done by A and then starts e r

t S Process B
Processing and after that sends to C

e n
m
ethen processes and
3. C Starts with inspection of the process done by B and
a g
sends to D
a n
h M Inspects before
starting the
In this way, each operation is inspected by thea s Successive Person
process
f H
Benefits of Successive Checks
t o
i g h Process C
y r
1. Better than Sampling Inspections as this is 100% inspection
p
2. Faster communicationoto the previous processes
C
‘A’ Inspects before

What is self check? sending to ‘B’
Process A
2 0
2 0
P,
LL
Self check is the process in which the operator who performs the process
would check the product and only when the product meets the requirement e s
i c
rv
‘B’ Inspects before
e
sending to ‘C’
he/she moves the product to the subsequent downstream process.
t S
e n
m are done
Successive Check and Self Check are not Batch Inspections. They
e
Process B
a g
immediately after the process; for each piece.
a n
h M
s
By this method, we can reduce defects (but cannot
a eliminate, as the
f H
inspection is done after the process)
t o
ig h Process C
y r
o p
C
3. Source Inspection
What is Source inspection?

2 0
2 0 Error/
Defect
P, Mistakes
Before the operation is performed, all the process parameters are checked. In case
L L Source Effect
e
any deviations, they are fixed before the production. So Defects would notcarise.
s
r vi Mistake unidentified at the source
S e causing defects
n t
Identifying and rectifying errors that cause the defects is called Source Inspection.
If the errors continue, defects also arises.
m e Error/
g e Mistakes
Defect
n a
By Source Inspection, Defects can be completelyaEliminated. Source Effect
h M
a s
f H
t o Mistake identified at the source
i g h thereby feedback sent immediately
y r and defect prevented
o p
C
Zero QC
Source Inspection and PokaYoke together help in
achieving Zero QC
Errors that cause Defects
What are the 10 common errors that cause defects?

2 0
2 0
P,
s LL
1. Processing omissions (a step was forgotten)
i c e
e rv
2. Processing errors (something was done incorrectly)
t S
e n
e m
3. Error in setting up the work piece
a g
a n
4. Assembly omissions (a part was forgotten)
M
s h
Ha
5. A wrong part / item was includedo f
ht
y rig
o p
C
Errors that cause Defects
What are the 10 common errors that cause defects?

2 0
2 0
P,
s LL
6. Wrong work piece
i c e
e rv
t
7. Operations errors (incomplete information, procedures not followed)
S
e n
e m
8. Adjustment, measurement, dimensional errors
a g
a n
9. Equipment maintenance errors
h M
a s
H
10. Errors in preparation of tools, fixtures,f blades, etc
t o
i g h
y r
o p
C
Introduction to PokaYoke
PokaYoke
Pokayoke are devices/systems that helps in eliminating

errors (thereby eliminating defects)
POKA-YOKE is a Japanese term that means mistake proofing. Poka-Yoke is any mechanism/system (in the process)
that helps the operator in avoiding mistakes/ errors.
Mistakes/ errors in any process will lead to defects, Poka-Yoke is the mechanism which prevents the defects from
happening.
What is PokaYoke and what is not?
2 00
Poka-yoke is 2200 2
Poka-yoke is NOT
PP,,
L LL
• Poka-Yoke and Source Inspections focus on
• Creating Automation sat L
c ee s the final inspection stage to
• Eliminating the “Cause” of the Defect

filter out v
rrvi
defects
i c
S e
e
tt S
• eInnnthis case, Only labor costs are reduced
• No Defective Products are produced

e
e m
m
• Works together in Source Inspection Stage. a g
g e • Defects will not be reduced / eliminated
a n
n a
M
M a
s hh
Haa s
o ff H
h tt o
r i g
i g h
p yy r
CCoo p
How PokaYoke device works?
A PokaYoke Device has 2 steps in its working…
2 0
2 0
P,
• How the device identifies errors - called “Setting Methods” s LL
i c e
• How the device communicates to user - called “Regulatory v
Function”
er S
n t
m e
g e
n a
M a
s h
Ha
of
ht
y rig
o p
C
Setting methods
How the device identifies the errors? Setting Methods

2 0
2 0
P,
LL
Setting methods can be further classified into 3 types.
e s Contact method
i c
1. Contact method
e rv
t S
e n
2. Fixed value method
e m
a g
a n Fixed value Method
3. Motion step method
h M
a s
f H
t o
ig h Motion step method
y r
o p
C
Contact - Setting Methods
Using Physical contact or Sensors for SIM card Slot SIM card
identifying errors 2 0
2 0
P,
The device senses the error through physical contact or through sensors. s LL
i c e
e rv
t S
n can not
Physical Contact: Sim Card can be used only in one direction. You
e Tyre Pressure Monitor - in Automobiles
e wrong
insert in the other way (there is a 45 Degree slot which prevents m
a g
insertion)
a n
M
Ha s h !
Sensors: A Tyre Pressure Monitor alarm o f senses the low pressure inside
ht
the tyre and indicates to the user.
r i g
p y
C o
Fixed Value Method
Device monitors the count / value for identifying errors
User can set a value before the operation. The PokaYoke device would count and errors
are detected by checking against the set value and indication is provided in case there is
an error.
This method is best suited for a single operator performing an activity where there are
repeated number of operations.
For e.g. an assembly station where 8 screws have to be tightened. In this case the poke
yoke device can monitor the count (Set value = 8) and determine if the work is completed
or not such that the operator cannot miss any screws. Only if all the 8 screws are
completed the green signal will be turned on
Motion Step Method
Device will monitor the sequence of operation

2 0
Errors are detected when the sequence of operation is not followed.
1 20 2 3
P,
Imagine an assembly process where:
s LL
i c e
e rv
1. Bolt to be tightened
t S
e n
2. A warranty card has to be inserted
e m
a g
3. QC Check sticker has to be pasted
a n
h M
a s
f H
Frequent customer complaints are that warranty cards are missing / QC 1 3
o
sticker is missing. We can develop a tpokayoke in such a way that the boxes
i g h
r and QC Stickers open only in that order.
containing the bolts, warranty ycards
o p
C
Motion Step Method
Boxes open according to the sequence Box Open Box Closed

Box Closed
2 0
2 0 Warranty
P, 1 Bolts
cards
QC Sticker
In the same example, Once the process starts, the box containing the bolts openLL
e s
(and the remaining boxes are closed), then the box containing the warrantyiccards
r v Box Closed Box Open Box Closed
S e
open (remaining boxes are closed) and finally the QC sticker box is opened.
n t Warranty
m e 2 Bolts
cards
QC Sticker
g e
During the process, only box will be in open condition. n aSo the operator can only
M a Box Closed Box Closed Box Open
proceed in a sequence. This is called Motion Step
s h method.
Ha
o f 3 Bolts
Warranty
QC Sticker
ht cards
r i g
p y
C o
Regulatory Functions
How the device communicates to the user?

2 0Regulatory
2 0
P, Functions
s LL
ic is no
Control Method - Stops the machine / process when the error occurs. There e
r v
way to run the machine without attending the error.
S e Control method
n t
m e
Warning Method - sends an alarm / light / noise etc.wheneerror is detected. This
a g
n
method will not stop the process. The operator canabypass the warning and still
Warning method
h M
can run the process.
a s
f H
t o
ig h
y r
o p
C
Control Method
The device shuts down the machine in case of error

2 0
2 0
P,
When errors occur, these systems shut down machines or lock clamps to halt s LL
i c e
operations, thereby preventing the occurrence of defects. This method has r v
S e
maximum efficiency in achieving zero defects.
n t
m e
The simplest example in our daily life is the Overload signal g ein Lifts. In case of
n a
overloading, the lift stops. There is no way to bypass M athis overload signal. Only if
the load is reduced the lift can be operated. a
h
s is called Control Method
This
f H
t o
i g h
y r
o p
C
Warning Method
The device gives a warning if error occurs

2 0
2 0
P,
s attention
When abnormalities occur, these systems escalates the abnormalities to workers’ LL
c e
i not notice
by activating a buzzer or a light. Defects will continue to occur if workersrv do
S e
these signals, this approach provides a less powerful regulatory action
n t than control
m e
methods.
g e
n a
M a
Example - Fuel level indicator is an example ofsh warning method of Poka-Yoke. It only
Ha
indicates the people that bike might stop,
o f but doesn’t stop the vehicle.
ht
r i g
p y
C o
PokaYoke in a Nutshell
Regulatory Function (How the device communicates?)

2 0
0
PokaYoke in a Nutshell
Control Warning
, 2
L P
Lifts would stop if there is overloading. Only if
s L
Setting Method (How the device works?)
Seat Belt Warning signal in cars. If the seat belt is

Contact Method
the load is below the limit, the device allows the
i c e
not used, the device creates an alarm. However the
rv
lift to operate. There is no bypassing this
user can ignore this and continue to drive the car.
mechanism.
S e
n t
Packing machines in a food processing
m e
Fixed Value
company where we can fix the weight of the
e
Fuel Gauge Indicator in cars where the Low Fuel
g
Method
pack (e.g. 250gm). The device monitors the
n aWarning signal glows and makes a sound to alert the
above 250gm.
M a
pack weight and stops filling once the weight is driver to fill the fuel.
s h
Order Processing pages
H a in E-commerce sites.
o f
e.g. There are 3 pages in a sequence. In first Creating a new registration in email or a software.
Motion Step
h t contains your shipping address
page, you select the product, quantity etc. The user is asked to follow certain steps (like
Method
i
andrthe glast page has payment details. These
second page uploading profile pic, address, and credit card
p y
pages are shown in sequence only
details), but the user can also choose to do it later.
C o
How to implement PokaYoke?
What are the 7 steps in Implementing Poka-Yoke?
1. Describe the Defect (Potential Defect)
2 0
2 0
2. Define where the defect is discovered (or) where it is made
P,
s LL
3. Detail the sequence of events in the documented standard
i c e
e rv
S
4. Observe the process and detail the steps that differ from the Standard
t
e n
5. Identify the Errors (Tools, Method, Training, etc)
e m
a g
n
a / Root Cause Analysis
a. Refer Step 4 Observations - Use 5-Why Analysis

h M
as to prevent the Defect
6. Identify the Poka-Yoke method necessary

H
f
t o to implement
a. Brainstorm and work as a team

h
y r ig
7. Implement Poka-Yoke p
Immediately
C o
What are the uses of PokaYoke?
PokaYoke can be used in 6 ways

Elimination: Removal of unwanted processes /
2 0
Replacement: Replace the step with a more reliable
2 0
Mistakes. Example - downloading machine data ,
process. Example - scanning the barcode of a product
P
rather than entering manually, which is prone to instead of manual entry LL
e s
errors
v i c
e r the correct process easier to
Prevention: Change the process in such a way Facilitation:
t S Make
e
that mistakes are not possible to make. Example follow, n Example - Colour coding of wires in assembly
- USB pen drive can not be inserted in the wrong e m
processes
a g
way
a n
Detection: Make Mistakes obvious to
h Msee. Mitigation: Minimise the effect of defects when it
a s
f H
Example - use lights, sound for malfunction of cannot be eliminated. Example, Using Fuses where
any device (if the car isoswitched off with the
h t there are power fluctuations
r
lights turned on,i gan alarm would be activated to
p y
C o
alert the driver to turn the lights off)
Conclusion of this section
1. A regular inspection would only classify / categorise defects. Defects cannot be eliminated through
2 0
Inspection
2 0
P,
s
2. Informative Inspection can reduce the defects whereas Source Inspection can eliminate Defects
LL
c e
r
3. The ultimate aim of Source Inspection is to make Zero QCe(eliminate
vi
QC), since defects will not originate
t S
4. PokaYoke would help in achieving Zero QC. PokaYoke e n can be used in Source Inspection Stage or
e m
a g
Successive Check or Self Check stage
a n
h M
5. Setting Methods - How the device operates
a s (Three types - Contact, Fixed Value and Motion Step)
f H
6. Regulatory Function - how the t odevice communicates to the user (Two types - Control and Warning)
i g h
y r
o p
C
Thank You
I am sure that this Ebook was useful and informative. We request you to take Action,
by implementing what you have learnt so far. You can write to us in case of any
doubts / support required in implementation.
You can enrol in “Lean Master Course” - an Online Video based Training program
that overs all the lean tools and help you to become a Master of Lean in your
organization.
Please visit www.kaizenclub.co.in to enrol in the video course at an Unbelievable

Price.
Sources for this Ebook
Everything in this Ebook is from our experience and various

sources. Some of the sources are listed below.
• The Machine That Changed the World - James Womack
• Learning to See - John Shook
• A Revolution in Manufacturing - Shigeo Shingo
• Zero QC and Pokayoke - Shigeo Shingo
• The Toyota Way - Jeff Liker
• And so many articles and books
Thank You
You can reach us through following ways:
pananth@hashllp.com
www.kaizenclub.co.in www.hashllp.com
Feel free to refer this ebook
to your Friends, Relatives and
http://www.youtube.com/c/HashManagementServicesLLP Team Members
https://in.linkedin.com/in/ananthpalaniappan
Join kaizenclub.co.in community in LinkedIn to get ebooks,

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All Rights Reserved

We recommend you to:

1. Provide your honest opinion

3. You can subscribe our YouTube channel and also be a part of

that case, why we have created this Ebook?

m e Practical Tips for

Lean Tools in bits y

Hash helps in implementing Continuous Flow Production, 5S, Single Minute

2. Train More than 1,00,000 people on Lean Manufacturing every year

How to eliminate Inspection? 0

What is Judgemental Inspection?

What is Informative Inspection? Informative Inspection

What is Statistical Quality Control?

What is Successive check?

1. When A finishes the processing of an item, it is transferred to B

2. B starts with an inspection of the process done by A and then starts e r

Processing and after that sends to C

‘A’ Inspects before

What is Source inspection?

i g h thereby feedback sent immediately

y r and defect prevented

Source Inspection and PokaYoke together help in

What are the 10 common errors that cause defects?

What are the 10 common errors that cause defects?

Pokayoke are devices/systems that helps in eliminating

• Eliminating the “Cause” of the Defect

• No Defective Products are produced

A PokaYoke Device has 2 steps in its working…

How the device identifies the errors? Setting Methods

Device monitors the count / value for identifying errors

Device will monitor the sequence of operation

Boxes open according to the sequence Box Open Box Closed

How the device communicates to the user?

The device shuts down the machine in case of error

The device gives a warning if error occurs

Regulatory Function (How the device communicates?)

Seat Belt Warning signal in cars. If the seat belt is

a. Refer Step 4 Observations - Use 5-Why Analysis

6. Identify the Poka-Yoke method necessary

a. Brainstorm and work as a team

PokaYoke can be used in 6 ways

Please visit www.kaizenclub.co.in to enrol in the video course at an Unbelievable

Everything in this Ebook is from our experience and various

• The Machine That Changed the World - James Womack

• Learning to See - John Shook

• A Revolution in Manufacturing - Shigeo Shingo

• Zero QC and Pokayoke - Shigeo Shingo

• The Toyota Way - Jeﬀ Liker

• And so many articles and books

You can reach us through following ways:

Join kaizenclub.co.in community in LinkedIn to get ebooks,

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