UNIT 5

Modern Concepts in Operations Management

 POKA YOKE
(MISTAKE-PROOFING / ERROR-PROOFING)
• Tool or mechanism that keeps a person from being able to perform
an action in an incorrect manner
• Decreases the opportunities for a failure to occur
• Developed as a key component of the Toyota Production System
(TPS)
• Avoid waste by eliminating or minimizing quality mistakes that lead
to rework as well as eliminating potential safety issues
 POKA YOKE PROCEDURE
• Obtain or create a flowchart of the process. Review each step, thinking
about where and when human errors are likely to occur.
• For each error, think of potential ways to make it impossible for the error
to occur
• Choose the best mistake-proofing method or device for each error.
• Test it, then implement it.
• Three kinds of inspection methods provide rapid feedback:
• Successive inspection is done at the next step of the process by the next
worker
• Self-inspection means workers check their own work immediately after
doing it
• Source inspection checks, before the process step takes place, that
conditions are correct. Often it’s automatic and keeps the process from
proceeding until conditions are right
 5S
• Methodology that results in a workplace that is clean, uncluttered, safe,
and well organized to help reduce waste and optimize productivity
• 5S
• Seiri - To separate needed tools, parts, and instructions from
unneeded materials and to remove the unneeded ones
• Seiton - To neatly arrange and identify parts and tools for ease of
use
• Seiso - To conduct a cleanup campaign
• Seiketsu - To conduct seiri, seiton, and seiso daily to maintain a
workplace in perfect condition
• Shitsuke - To form the habit of always following the first four S’s
 5S
Japanes Translated English Definition
e
Seiri organize sort Eliminate whatever is not needed by separating
needed tools, parts, and instructions from
unneeded materials
Seiton orderliness set in order Organize whatever remains by neatly arranging
and identifying parts and tools for ease of use
Seiso cleanliness shine Clean the work area by conducting a cleanup
campaign
Seiketsu standardiz standardize Schedule regular cleaning and maintenance
e by conducting seiri, seiton, and seiso daily
Shitsuke discipline sustain Make 5S a way of life by forming the habit of
always following the first four S’s
 3M’S

• Waste (Muda)- an activity which does not add value

to the product
• Three main types of waste
• Mura (unevenness in production volume)
• Muri (overburden ie. overloading equipment,
facility or people resources beyond its capacity)
• Muda (waste)
TOYOTA WASTES (TAIICHI OHNO)
MUDA
 KAIZEN
• Change to become good or better
• Small improvements can yield big results
• Father of Kaizen, Masaaki Imai globally introduced kaizen as a systematic
management methodology in Kaizen: The Key to Japan’s Competitive
Success (1986)
• Continuous Improvement
• Kaizen is process of continuous improvements in small increments that make
process more efficient, effective and adaptable