Yazaki - 9.0 Mistake Proofing NYS Training - V4 2011

Pok
a Yok
e
Kanban
5S 7 MUDA SMED
Problem
Value Stream Standardised
Solving
Mapping Work
Just In Time Heijunka
Mistake Proofing
Ray Hayter
2010 © COPYRIGHT BY YAZAKI EUROPE LTD. ANY REPRODUCTION OR DISCLOSURE IS PROHIBITED WITHOUT PRIOR WRITTEN CONSENT OF YAZAKI
Pok
aY
Definition & Philosophy
oke
Mistake Proofing/Poka-Yoke
The use of process or design features to prevent

manufacture of non-conforming products.
Techniques that can drive you to build defect free
products and processes and improve their quality and
reliability.
The question here is:

Can the error that causes defects be minimised?
Can it be eliminated?
Pok
aY
oke
Poka-yoke helps people and processes work right

the first time. Poka-yoke refers to techniques that
make it impossible to make mistakes. It can be
thought of as an extension of FMEA. It can also be
used to fine tune improvements and process
designs from six-sigma Define - Measure - Analyse
- Improve - Control (DMAIC projects). The use of
simple poka-yoke ideas and methods in product
and process design can eliminate both human and
mechanical errors.
Pok
aY
oke
By applying Mistake Proofing/Poka-Yoke

devices to your processes, will:
Ensure that the proper conditions exist before
executing a process step, avoiding defects to be
generated in the first place. Where this is not
applicable, poka-yokes will act as a detective function
so that defects are eliminated as soon as possible in
the process.
This will lead to a work environment where you’ll be
allowed to make your processes
100% defect-free, 100% of the time
Pok
aY
oke
Historical Mindset
We must meet our delivery, whatever the cost
We have no time to address the root cause, we have a

shipment to make
Management, not taking visible ownership
We have been doing this at Yazaki forever, why is today

going to be any different
Most of our processes are manual, we work with people

and people make mistakes, so defects are a normal thing
Pok
aY
oke
Desired Mindset
Quality comes first, it is Priority 1
Management must be actively involved to show

commitment and give the example
We learn by sharing our successes with others
We must eliminate defects by improving our product

design or improving the process
Adding more inspections is not a solution
Working together to build reliable and sustainable processes

and a trusting Quality Environment
Pok
aY
Errors vs. Defects
oke
Errors are not the same as defects. Errors cause defects
Pok
aY
Reasons for errors and defects
oke
There are several reasons for errors to appear as:

Missing or inaccurate/wrong procedure
Process operation missed or not performed according with

standards
Using the wrong tooling or setting machine adjustments

incorrectly
Process not stable (with variations)
Variations on the raw materials
Inaccurate measuring devices
Incorrect equipments usage
Human error
Pok
aY
Reasons for errors and defects
oke
The last items on our list (and because people commit

mistakes), can be further broken-down:
Forgetfulness, missing concentration
Misunderstanding or jumping to conclusions without having

all information
Training or lack of it
Wilful errors where the human ignores the rules
Inadvertent errors involving fatigue and/or distraction
Lack of standards
Intentional errors such as sabotage
Pok
aY
Responsibilities
oke
If we analyse these problems deeper, we will see that quite

often we use these arguments as excuses (mainly people and
equipment errors), but in truth these are Management issues
Management employ the people
Management train the people
Management define the process
Management select the machines
Management maintain the machines
Management set the standards

Pok
aY
Why apply Mistake Proofing/Poka-Yoke
oke
Do you think that Defect-free products/processes can be

achieved through inspection methods such as:
100% Visual Inspection ?
Sampling Techniques ?
Measurement Gauge Inspection ?
First-Off / Last-Off Inspection?
Let’s see through some practical examples

Pok
aY
oke
100% Visual Inspection ?
Visual Inspection Test
Pok
aY
oke
“f” Test
Please find and count all the “f”s on this page:
“In the final analysis, finished files are the result of

years of scientific study combined with the experience
of the years.”
Result = 12 “f”s
Pok
aY
oke
“C” Test
Please find and count all the “c”s included on the
board below:
ooooocooooooooooo
ooooocoooocoooooo
oocoooooccoooocoo
ooooooocooooooooo
oooooooooooooooco
oocoooooooooocooo
oooooooocoocooooo
Result = 13 “C”s
Pok
aY
oke
For those that think 100% visual sorting is 100% effective.
It has been our experience at Yazaki and taking into account trustable
data collected along these years, that visual inspection is usually only 85
to 90% effective, and that making 200% visual sorting is only rising this
accuracy to 95%.
Pok
aY
oke
Sampling Techniques ?
Sample Inspection Test

Note: Our Supplier has 2% Defect rate
Pok
aY
oke
Measurement Gauge Inspection ?
Measurement Gauge Inspection Test
Pok
aY
oke
39.20 ±0.2
Pok
aY
oke
First-Off / Last-Off Inspection?
Pok
aY
oke
First or Last Piece Inspection
Rejects
LSL USL
Actual Result of First Piece or

Last Piece Inspection
Pok
aY
oke
First or Last Piece Inspection
Tells You – What ??
You are making a correct part

You made one piece (the first or last) to drawing specification
That’s all it tells you
Pok
aY
oke
Some commonly held beliefs . . . “About Inspection”
Defects are inevitable that’s why we need inspection
Inspection reduces defects
100% Inspection ensures defect free shipments
YEL Quality Performance
90 83
80 75
70
60
50
40 36
30 24
18
20 15
9
10
0
2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09
Pok
aY
Calculating PPM’s oke
How to measure Quality – Defective Parts/Million pieces shipped
Percentage % Parts Per Million (Ppm)
100 1,000,000
10 100,000
1 10,000
0.1 1,000
0.01 100
0.001% 10
0.0009% 9 YEL 2008/9 Performance
Pok
aY
How to measure Quality – Parts Per Million pieces shipped
Percentage % Parts Per Million (Ppm)
0.0009% 9
9 Ppm or 0.0009% defect rate equals
99.9991% Good Parts Shipped
Pok
aY
Considering that last year YEL Operations Shipped 37

Million Parts
9 ppm Quality level multiplied by 37
Equals
333 Defective Parts delivered to our customers
THEREFORE ONLY A ZERO DEFECT

PHILOSOPHY IS ACCEPTABLE
Pok
aY
Comparison with other daily life numbers oke
If 99.9% success rate were acceptable, would you care if.....
Heathrow International Airport would only have 900 unsafe

arrivals or departures per year
Pharmaceutical companies would only kill 200 people per year

with the launch of a new anti-heart disease drug
Koln post-offices would only loose 10,271 letters a day
Customers of Toyota would only experience 26 electrical circuit

concerns per vehicle in the aftermarket
Pok
aY
Zero-Defect Standard
oke
DO's
Recognise that people, machines and processes make errors!
Respect intelligence of workers by removing the judgement from
respective tasks or actions where errors are likely to occur
DONT’s
Accept “operator error” or “retrain the operator” as an excuse for
the root cause of the defect
It is Managements responsibility to establish a

Zero Defect Standard & Implement the Philosophy
Pok
aY
Types of Mistake-Proofing Devices
oke
Pok
aY
When you can’t Mistake Proof
oke
When you can not apply or find the adequate Mistake Proofing device
for your process, there are still some strategies that can be used to
minimise mistakes, or that can make them easier to detect.
Colours & colour coding (i.e. credit cards manual receipts are always
designed so that customer gets the coloured copy and the dealer gets the
white one.
Use of Shapes (i.e. traffic signals are different colours and shapes according
with the info to pass, danger, information, obligation, etc)
Auto-detection (i.e. Word processors come with spell checkers that when
used reduces errors considerably
Checklists, work flows, that make it easier to make things right by giving
instruction steps that follows the process
Pok
aY
oke
Workshop
Pok
aY
Workshop
oke
STEP 1
Brainstorm to provide a list of mistake-proofing devices, that you
use in everyday life. Insert your list in the left hand column
“Mistake Proofing Devices”
STEP 2
Identify the human or mechanical defect that the mistake proofing
device prevents. List in middle column “Error or Defect that is
prevented”
STEP 3
Identify the Type of the Mistake Device that prevents the error
State or Malfunction and list in “Mistake Proofing Type”.
Pok
aY
Workshop - Form
oke
Mistake-Proofing Error or Defect that Mistake Proofing

Device is prevented Type
Pok
aY
Mistake Proofing Examples
oke
Contact Warning
Pok
aY
Mistake Proofing Examples
oke
Control Motion Step Method
Shutdown
Fixed Value Method
Pok
aY
Implemented Example
oke
Problem :Common standard and visual aids displayed on the same
working step, for Diesel and Gasoline suffixes
Diesel and gasoline suffixes
Common visual aids for

Diesel and Gasoline
Common standard for
Diesel and Gasoline
No mistake proof system.
Pok
aY
Implemented Example
oke
Solution: Individual work stations with Poka Yoke system that will
only accept correct part and layout.
Pok
aY
Implementation
oke
MISTAKE -PROOFING PROCESS
Walk the process
Involve the Operator (they normally know best!)
Check process is inline with original concept
Document the facts.
Pok
aY
Problem Solving Pyramid
oke
Level 1: Biggest efficiency, best detection/prevention

& lowest Cost Approach
Design
Level 2: Can effect cycle time and bigger
Process investment
Level 3: Defects are detected not
prevented, costs are higher
Automatic due to rework procedures
Inspection
Level 4: Highest risk of Errors, risk
of defects to pass to the
Operator Control
customer.
Visual Inspection
Instructions/Training
Pok
aY
Cost Impact of Defect Pyramid
oke
1 Euro
Design
10 Euro
Supplier
Proces
Process
s 100 Euro
Automatic
Yazaki Process
Inspection 1,000 Euro
Customer Rejections
10,000 Euro
Warranty Claim
Pok
aY
Benefits of Mistake Proofing
oke
It will lead us to a Zero-Defects Philosophy, which

will also support...
Productivity / Efficiency Improvements
Lean Manufacturing / Pull Strategy (NYS)
Customer Satisfaction and Loyalty
Cost Reduction
To truly and really serve our customers, our processes have

to be both stable and capable. It can't just be one or the
other.
Stable - control charts are in control (no unstable conditions)
Capable - histograms fit inside specification limits (USL,LSL)
Pok
aY
Taguchi Loss Function
oke
Stabilising our processes and reducing its variation will also reduce the cost of the Taguchi
Loss function. This will save us and our customers time and money (rework, waste, and
delays). Customers can see the difference in quality between us and our competitors.
Time
Money
Upper Resources
Specification Energy
Limit Materials
Lower
Specification
Limit
If our data fits between the upper and If the control charts shows an unstable
lower spec limits, then we are meeting process we may not be able to meet our
our customer's requirements. customers requirements consistently and
predictably.
Pok
aY
Summary
oke
Management Responsibility
Do's
People, machines and processes make errors!
Respect the intelligence of operators that perform repetitive

tasks.
Remove the judgement from repetitive tasks or actions where

errors are likely to occur
Do Not’s
Accept “operator error”, “retrained operator” as excuse for root
cause.
Pok
aY
Summary
oke
Mistakes and Errors are an inherent part of processes
Mistakes and Errors can be controlled

Therefore Zero Defect targets can be realised
We all must be committed to the Zero Defects philosophy
(Management to Shop floor)
We must change the culture to the new spirit of management
Set the ZERO DEFECT standard

Implement it Now!

Yazaki - 9.0 Mistake Proofing NYS Training - V4 2011

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yazaki - 9.0 Mistake Proofing NYS Training - V4 2011

Uploaded by

Copyright:

Available Formats

Pok

Just In Time Heijunka

The use of process or design features to prevent

The question here is:

Poka-yoke helps people and processes work right

By applying Mistake Proofing/Poka-Yoke

We must meet our delivery, whatever the cost

We have no time to address the root cause, we have a

Management, not taking visible ownership

We have been doing this at Yazaki forever, why is today

Most of our processes are manual, we work with people

Management must be actively involved to show

We learn by sharing our successes with others

We must eliminate defects by improving our product

Adding more inspections is not a solution

Working together to build reliable and sustainable processes

There are several reasons for errors to appear as:

Process operation missed or not performed according with

Using the wrong tooling or setting machine adjustments

Process not stable (with variations)

Variations on the raw materials

Inaccurate measuring devices

Incorrect equipments usage

The last items on our list (and because people commit

Misunderstanding or jumping to conclusions without having

Wilful errors where the human ignores the rules

Inadvertent errors involving fatigue and/or distraction

Intentional errors such as sabotage

If we analyse these problems deeper, we will see that quite

Management employ the people

Management train the people

Management define the process

Management select the machines

Management maintain the machines

Management set the standards

Do you think that Defect-free products/processes can be

Measurement Gauge Inspection ?

First-Off / Last-Off Inspection?

Let’s see through some practical examples

100% Visual Inspection ?

Visual Inspection Test

“In the final analysis, finished files are the result of

For those that think 100% visual sorting is 100% effective.

Sample Inspection Test

Measurement Gauge Inspection ?

Measurement Gauge Inspection Test

First-Off / Last-Off Inspection?

First or Last Piece Inspection

Actual Result of First Piece or

First or Last Piece Inspection

Tells You – What ??

You are making a correct part

That’s all it tells you

Some commonly held beliefs . . . “About Inspection”

Defects are inevitable that’s why we need inspection

Inspection reduces defects

100% Inspection ensures defect free shipments

How to measure Quality – Defective Parts/Million pieces shipped

Percentage % Parts Per Million (Ppm)

How to measure Quality – Parts Per Million pieces shipped

Percentage % Parts Per Million (Ppm)

9 Ppm or 0.0009% defect rate equals

99.9991% Good Parts Shipped