Zero Quality Control: Source

Inspection and the Poka-Yoke

System
Introduction of Shigeo Shingo
Shigeo Shingo

 Shigeo Shingo (Shigeo Shingō; 1909 – 1990) was a Japanese

industrial engineer specialized in quality control. He is known
for various quality techniques concepts such as Poka-Yoke,
Mistake Proofing, SMED, Just in Time Production, and
Jidoka. His contributions to quality improvements have
significantly influenced western manufacturing approaches.
Shigeo Shingo quotes

 1.“There are four purposes of improvement: easier, better, faster, and cheaper. These four goals appear in the order of priority.”
 2.“Improvement usually means doing something that we have never done before.”
 3.“The most dangerous kind of waste is the waste we do not recognize.
 4.“Lean is a way of thinking- not a list of things to do.”
 5.“Those who are not dissatisfied will never make any progress.”
 6.“When you buy bananas all you want is the fruit not the skin, but you have to pay for the skin also. It is a waste. And you the customer
should not have to pay for the waste.”
 7.“A relentless barrage of ‘why’s’ is the best way to prepare your mind to pierce the clouded veil of thinking caused by the status quo.
Use it often.”
 8.“Are you too busy for improvement? Frequently, I am rebuffed by people who say they are too busy and have no time for such
activities. I make it a point to respond by telling people, look, you’ll stop being busy either when you die or when the company
goes bankrupt.”
 9.“Even the greatest idea can become meaningless in the rush to judgment. To gauge an idea as feasible we must cut our ties to the status
quo and find the balance between constructive criticism and judgment. Within that balance we will uncover crucial input for making our
ideas a reality.”
 10.“The best approach is to dig out and eliminate problems where they are assumed not to exist.”
Zero Quality Control – Four fundamental
principles
 Use source inspection – the application of control functions at the stages where defects
originate.
 Always use 100 percent source inspections rather than sampling inspections.
 Minimize the time to carry out corrective action when abnormalities appear.
 Set up Poka-Yoke (mistake- proofing) devices, such as sensors and monitors, according to
product and process requirements.
Shigeo Philosophy

 A true “zero defects” level of quality is the ultimate level of conformance to specification.
 Zero defects (ZD) implies that each and every item built conforms to specification.
 Shingo maintains that statistical-based quality control is not conductive to zero defects.
 He states that statistical quality control can lower, but not eliminate, defects. Shingo
proposes the Poka-Yoke (mistake-proofing) system to totally eliminate defects.
Shigeo Philosophy

 The mistake-proofing concept is a human or machine sensor based series of 100 percent
1. Source inspections,
2. Self-checks, or
3. Successive checks
 To detect abnormalities when or they occur and to correct them on the current unit of
production as well as system wide.
 OSV with objective eye

OSV with Poka-Yoke

Make it impossible by
Poka-Yoke