Dr Mohan Parameswaran – PhD

(www.waransgemba.in)

19.03.2021
 TPS – Toyota (Lean) Production System

TPS

First Time
Right
Quality

JIDOKA
TOYOTA PRODUCTION
JIT

SYSTEM
Right Quantity at
Right Time

19.03.2021
Waste Elimination by Kaizen
 JIDOKA

JAPANESE SCRIPT :

• HIRAGANA { Original script}

•KANJI { Pictorial }

•KATAKANA (CLOSER TO English)

19.03.2021
 In KANJI…JIDOKA

• JI …… SELF
• Dou …. Movement
• Ka …. Ization

IT IS NOT AUTOMATION …. IT IS AUTOMATION WITH AN HUMAN TOUCH…

UNDERSTAND THE “ PRIDE OF WORKMANSHIP”

19.03.2021
 The Confusion Over JIDOKA*

* Jidoka as practiced in Toyota has several Meaning

19.03.2021
 JIDOKA
• It is a quality control process used in TPS
which applies the following four principles
1. Detect abnormality
2. Stop
3. Fix or Correct the immediate condition
4. Investigate the ‘Root Cause’ and install
countermeasures
5. The required number of pieces have been
made
6. The mechanism is jammed
19.03.2021
 JIDOKA
• Jidoka also has a sub-title, "Quality built-in to the
process". This seems to mean that the process
inputs are controlled, and operators have
authority to make adjustments within certain
(control) limits. Variations outside control limits
(monitored by devices on the equipment) are
used to trigger a process 'stop'. This contrasts
with the Western approach which is to control
the outputs of the process (measure, inspect,
check, etc.) and then react to any non-
conformance in the product. In many cases, this
does not trigger a process 'stop'

19.03.2021
 Poka-Yoke Case Studies

1. Some of the Case Studies ,presented are shared with me

during my interaction with professionals , years ago . .

1.1 Source : Unknown

1.2 : No copyright intended
1.3 All rights and Credit reserved to respective owners
1.4 DM or tag us in the Comment for Credits/Removal

2. These Case Studies are Sharing for’ Learning ‘

8
 POKA-YOKE

DETECTION DEVICES

NON-CONTACT TYPE
PROXIMITY SWITCH INLINE TYPE
CONTACT TYPE
PHOTOELECTRIC
LIMIT SWITCH SWITCH PRESSURE TRANSDUCER
MICRO SWITCH BEAM SENSORS
FIBER OPTIC SENSORS
PRESSURE SWITCH
REED SWITCH
AREA SENSORS FLOW SENSORS
TOUCH SWITCH
POSITIONING SENSORS
LVDT’S RTD TEMP SENSORS
DISPLACEMENT SENSORS
COLOUR MARKING LOAD CELLS
SENSORS
ULTRASONIC SENSORS
VISION SYSTEMS
1
0

Case Study No.1

Classification: Contact Type and Control type.
Problem :
The Component does not rest properly on the rest pad
resulting in manufacturing of defective component
and hence rejection.

19.03.2021
1
1
POKA-YOKE

BORING
BAR

HYD.OPERATED HYD.OPERATE
CLAMP DCLAMP

GEAR
BORING CARRIER
BAR BORING
CASTING
BAR

FIXTURE REST
PADS
19.03.2021
1
2
POKA-YOKE

BORING AXES
COMPONENT GENERATED
GETS ARE SKEW
REJECTED WITH
RESTFACE
GAP
GEAR CARRIER
CASTING

METAL CUT
FIXTURE REST
PADS
19.03.2021
1
3

Solution Implemented
A air feedback system is implemented. The system is

designed to sense any gap between the rest pad and the
component.

Machine waits for the “OK” signal from the air

feedback system. If the job is rested properly only then

the back pressure is built and pressure switch gets

operated hence “Ok” signal is generated else not.

19.03.2021
1
4
POKA-YOKE

M/C BORING AUTO

CYCLE DOES NOT
START

ALARM

HYD.OP.CLAMPING
NOT DONE
DETECTION OF
GAP
GEAR CARRIER
CASTING

COMPR. AIR
SUPPLY &
FIXTURE REST
PRESSURE
PADS WITH AIR
FEEDBACK
VENTURIES
19.03.2021
1
5

Effect:
If the error occurs i.e. component (in this case it
was Gear Carrier) is not rested properly on the rest
pads then the error is detected before it turns in to
a defect . This is done by the air feedback
Pokayoke
system which restricts the hydraulic clamping of the
component as well as the start of auto cycle. Hence
system detects the error and the defect can not be
produced.
19.03.2021
1
6

Case Study No. 2

Classification: Contact Type and Warning type.

Problem :
Assembly of BA-10 gear box is done manually .
Inadvertently a component called as spacer is missed out
while assembling. The resulting defect is detected at a
latter stage . This leads to FIELD COMPLAINT.
19.03.2021
1
7
POKA-YOKE

GEAR BOX
COVER

SPACER

GEAR BOX

19.03.2021
1
8
POKA-YOKE

FIXTURE GAUGE WITH L.V.D.T.

FOR BRG.PRELOADING SHIM
SELECTION

19.03.2021
1
9
Solution implemented

* The missing component is made up of metal ,hence a

metal sensor i.e. A inductive type proximity switch is
utilised for sensing the presence of spacer.
* A presence of spacer operation is clubbed with the
gauging operation which is carried out at the immediate
stage of spacer assembly stage.
* A proximity switch is used to sense if the gauge is
mounted on the gear box.
19.03.2021
2
0
POKA-YOKE

PROXIMITY PROXIMITY
SWITCH ‘ON’ SWITCH ‘OFF ‘

ALARM

OMISSION
OF
SPACER

GEAR BOX

19.03.2021
2
1

Effect:

* An alarm gets generated on occurrences of

inadvertent
error of missing a spacer. Thus it is brought to
operator’s notice that spacer is missing in the
assembly. Hence the operator immediately corrects
the
error. This prevents field complaint as the defect is
prevented .
19.03.2021
2
2
Case Study No.3

Classification: Counter Type and Control type.

Problem :
The Component has five bolts . Each of the bolt needs to
be torque and this operation is done manually. Some
times few of the bolts are left untorque. This inadvertent
error results in FIELD COMPLAINT of oil leakage.

19.03.2021
2
3 FIX VALUE METHOD POKA-YOKE

BEFORE AFTER

GEAR BOX BEFORE

CONVEYOR TORQUING

AFTER
TORQUING

TORQUING OF FIVE BOLTS

19.03.2021
AFTER 10 SEC DELAY
2
4
Solution implemented :
* A limit switch is mounted on the torque wrench which
operates every time when torque is applied on the bolt.
* Two pneumatic cylinder are used to restrict the job
movement.
* A counter is used with set point set to 5.
* Counter issues “OK” signal when , 5 pulses are received
from limit switch. This allows present job to exit the
stage
and next job to enter the stage.
19.03.2021
2
5
Effect:
* Once the component enters the torquing stage, the path
to move to the next stage is restricted by pneumatic
cylinder. After performing the torquing operation on
all the five bolts the exit path is open. This repeats for
every job which ensures that no error occurs.
Hence the heavy rework cost is eliminated.

19.03.2021
2
6

Case Study No.4

Classification: Counter Type and Warning type.

Problem :
Drilling , tapping of one hole and chamfering operation
on 8 holes is performed on the crankcase.
Few of the operations are some times missed ,resulting
in heavy rework.

19.03.2021
2
7 WARNING TYPE- POKAYOKE
BEFORE AFTER

A D B
CHAMFER
HOLES BUZZER
TAPPING HOLE

A- TAP PRESENT
B-CHAMFER TOOL PRESENCE
C- JOB PRESENCE
REST D-COUNTERWEIGHT STROKES
19.03.2021 PADS
2
8
Solution implemented :
* A photo sensor is used to sense the presence of new job.
* Tools presence is monitored using proximity switches.
* The status of the proximity sws. indicate which tool is
used at any instant.
*A counter issues “OK” signal for the respective tools, when
the required no of times the operation is performed.
* An alarm is generated in case missing operation occurs.

19.03.2021
2
9
Effect:
* The counter monitors the count for respective tools. If the
job is removed from the m/c.before performing all the
required operation, the alarm is continuously blown. Thus it
is brought to operator’s notice that particular operation
is missed. Hence the operator immediately corrects the
error. This prevents heavy rework .

19.03.2021
3
0

Case Study No.5

Classification: Standard operating procedure and

Control type.
Problem :
The Gear carrier assembly is done manually.
One of the component called as Oil seal is missed out
while performing the assembly. This error results
in FIELD COMPLAINT.

19.03.2021
3
1 POKA-YOKE-OIL SEAL MISSING

BEFORE AFTER HYDRAULIC

PRESS RAM
DUST COVER

A DOLLEYS I
OIL SEAL
SLINGER
SLINGER

PINION SHAFT B II
OIL SEAL

C III
DUST SEAL

19.03.2021
3
2
Solution implemented :
* Photo sensors are used to monitor the picking action.
* The tools are monitored using proximity switches.
* The status of the proximity sws. indicate which tool is
used at any instant.
* A Sequence of operation is monitored by a PLC.
* The access to the pressing operation is granted by
a pneumatic cylinder on following the proper sequence,
or else the access is denied and alarm is generated

19.03.2021
3
3
Effect:
* The system monitors the sequence of operation. The press
is operated with a hand lever. If the sequence is missed
,the lever gets restricted with a pneumatic cylinder and
alarm is blown. The error (missed component) is brought
to the notice of operator . Once the error is eliminated ,he
can proceed further. This ensures that the defect is made
Zero .

19.03.2021
3
4

Case Study No.6

Classification: Standard operating procedure and

Control type.
Problem :
The Cylinder head drilling and reaming operation is
carried out at stage1 and stage 2 respectively on the same
m/c. Some times job is directly loaded to stage2 before
undergoing stage 1 operation, resulting in tool breakage
and rejection.
19.03.2021
3
5 SOP RELATED POKA-YOKE

NOT FOLLOWS FOLLOWS PATH

PATH- A D B A C B PATH- A D B A C B

FIXTURE FINISH FIXTURE

FINISH
STAGE STAGE

A A
D B D B

UNFINISH UNFINISH
STAGE STAGE

C C
19.03.2021
3
6
Solution implemented :
* Proximity switches are placed at each stage to sense
the presence of job.
* A photo sensor is used to sense the movement of job.
* The path for taking the job to the m/c is restricted by
a gate which is operated by a pneumatic cylinder
* The sequence of operation is monitored by the sensors.
* The gate grants the access to load and unload job
only if proper sequence is maintained.
19.03.2021
3
7
Effect:
* Access for loading , unloading the finished and unfinished
component is granted when proper sequence is followed to
the respective m/c. station.
* This ensures prevention of accident and m/c. misalignment
as well as the component and tool rejection.

19.03.2021
3
8
Case Study No.7

Classification: Standard operating procedure and

warning type.
Problem :
10 Lt. of diesel is to be dispensed in every vehicle.
Inadvertently some of the vehicles are missed out at the
dispensing stage and some times diesel was dispensed
twice in same vehicle. The quantity of diesel dispensed
was not consistent. These problems result in loss to the
company.
19.03.2021
3
9
POKA-YOKE

MOVING CONVEYOR
DIESEL FILLING ASSLY LINE.
STAGE
PITCH

VEHICLE FUEL
TANK 10 Ltrs FUEL
FILLED
DIESEL STORAGE
TANK.

19.03.2021
4
0
POKA-YOKE

MOVING CONVEYOR
DIESEL FILLING ASSLY LINE.
STAGE
PITCH

VEHICLE FUEL MISSING FUEL

TANK
FILLING
OPERATION.
DIESEL STORAGE
TANK.

19.03.2021
4
1
POKA-YOKE

MOVING CONVEYOR
DIESEL FILLING ASSLY LINE.
STAGE

VEHICLE FUEL EXCESS FUEL

TANK
FILLED..

DIESEL STORAGE
TANK.

19.03.2021
4
2
Solution implemented :

* A transparent tank is designed with sensors which

consistently dispenses 10 Lt. of diesel.
* A limit switch is mounted to sense the arrival of new vehicle.
* Once the vehicle enters the stage and if the operation is not
started with in specified time ,the alarm starts blowing .
It continues till the operation is completed.
* The Operator can not dispense till next vehicle enters.

19.03.2021
4
3
POKA-YOKE

MOVING CONVEYOR
DIESEL FILLING ASSLY LINE.
LIMIT SWITCH
STAGE

VEHICLE FUEL
TANK
AUDIO-
VISUALAL
DIESEL STORAGE ARM
TANK.

19.03.2021
4
4
Effect:
* The sequence of operation is monitored by the relay logic.
Every time when a vehicle arrives at the dispensing stage,
the status of dispensing unit is monitored. If filling cycle is
not started then alarm starts blowing. This intimates the
operator of the missing operation. The interlock takes care
that the next cycle can be started only at the arrival of next
vehicle.The quantity consistency error is eliminated by
the newly designed dispensing unit.
19.03.2021
 WHERE DO I START…? – PDCA >>SDCA>>P*D*C*A*

1. Invite your departments/staff form ‘CFT’ (Cross Functional

Easier Team)
2. Present Concept of ‘ Poka-Yoke’
3. Collect existing examples of mistake-proofing in your
facilities
4. Determine where additional mistake-proofing is needed
5. Look for examples in other industries that are applicable to
the ‘Project’
6. Invite suppliers to include/develop mistake-proof products
7. Invent and perform trials on new mistake-proofing devices
..PDCA
Harder
8. Declare ‘ Result ‘
9. Celebrate
10. Do It Again