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Seminar ppt


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poka yoke seminar report

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Seminar ppt

  2. 2. Introduction (to avoid) (errors) POKA-YOKE 2  Japanese phrase: Yokeru poke Poke Yoke Geethanjali institute of science and technology
  3. 3. Also known as MISTAKE PROOFING Poka Mistakes YOKE Prevent Coined in japan during 1960’s by Shigeo shingo POKA-YOKE 3 Geethanjali institute of science & technology
  4. 4. Initially ‘BAKA-YOKE’ ‘fool proofing’ Dishonorable and offensive POKE-YOKE ‘Mistake proofing’ (or) ‘Error avoidance’POKA-YOKE 4 Geethanjali Instute Of Science & Technology
  5. 5. Why is it important? Helps people and processes. Refers to techniques that make it impossible to make mistakes. Helps drive defects out of products and processes and substantially improve quality and reliability. Used to fine tune improvements and process designs from six-sigma. can eliminate both human and mechanical errors. POKA-YOKE 5 Geethanjal Institute of Science & Technology
  6. 6. When to use it? It is a technique, a tool that can be applied to any type of process be it in manufacturing or the service industry.  Poka-yoke can be used wherever something can go wrong or an error can be made. POKA-YOKE 6 Geethanjali Instittute of Science & Technology
  7. 7. Contd.. Errors can be of any types: Processing error Setup error Missing part Improper item/part Operations error Measurement error POKA-YOKE 7 Geethanjali Instittue of Science & Technology
  8. 8. What Does Poke yoke Do? Eliminates the cause of an error at the source; Detects an error as it is being made; Detects an error soon after it has been made but before it reaches the next operation. POKA-YOKE 8 Geethanjali Institute of Science & Technology
  9. 9. Qualities of a good poka-yoke: Early Precise Simple Light POKA-YOKE 9 Geethanjali Institute of Science & Technology
  10. 10. Methodology of Poka-yoke Identify problem Observe at work stations Brain storming for idea Select best ideas Implementation plan and implementation Monitoring and signoff Geethanjali Institute of Science & Technology POKA-YOKE 10
  11. 11. Are Errors Unavoidable? There are two approaches to dealing with errors:  1. ERRORS ARE INEVITABLE!  2. ERRORS CAN BE ELIMINATED! POKA-YOKE 11 Geethanjali Institute of Science & Technology
  12. 12. 1.Errors Are Inevitable  People always make mistakes.  While we accept the mistakes as natural, we blame the people who make them.  With this attitude, we are likely to overlook defects as they occur in production.  They may be detected at final inspection, or worse still, by the customer. POKA-YOKE 12 Geethanjali Institute of Science & Technology
  13. 13. 2.Errors Can Be Eliminated Any kind of mistake people make can be reduced or even eliminated. People make fewer mistakes if they are supported by proper training and by a production system based on the principle that errors can be avoided. POKA-YOKE 13 Geethanjali Institute of Science & Technology
  14. 14. Two types of error proofing devices POKA-YOKE  Control - eliminates the possibility of a mistake to occur (automatic machine shutdown)  Warning - signals that a mistake can occur (blinking light, alarm, etc.) POKA-YOKE 14 Geethanjali Institute of science Technology
  15. 15. POKA-YOKE Examples POKA-YOKE 15 Geethanjali Institute of science & Technology
  16. 16. Alarm Systems POKA-YOKE 16 They are activated with alarms for security purposes. If an unauthorized person enters the bank, or the electric circuit of the door bell catches fire, a warning alarm rings, which ensures that you can take care of the problem before it gets out of hand. Geethanjali Institute of science & Technology
  17. 17. Connector and charger POKA-YOKE 17 figure shows a charger and connector. All the three pins need to fit perfectly within the three slots provided. This has to be monitored during production. And for that, the design phase of the product needs to be executed perfectly as well. A slight error in the calculation of the slot-size or the pin- size can make the device redundant or faulty Geethanjali Institute of science & Technology
  18. 18. Fingerprint Identification POKA-YOKE 18 This is used extensively in biometrics, forensics, detective agencies, etc. Every fingerprint in the world is unique, no two are ever the same. The device is such that only the fingerprint of that particular person will be required as input. Trying to replicate or use some one's fingerprint forcibly will not work either. Geethanjali Institute of science & Technology
  19. 19. Dialysis machine POKA-YOKE 19 These machines perform the function of the kidneys and are used for patients suffering from CKD (Chronic Kidney Disorder). An example of a safety device in this machine is the efficient design of the air bubble detector. This detector must be fully functional and should ensure that no air bubble passes to the patient's body. If this occurs, the patient may have seizures and this can prove fatal. Hence, the detector must be equipped with a proper mechanism to find out the problem, and give out beeps so that proper action can be taken immediately. Geethanjai Institute Of Science & Technology
  20. 20. POKA-YOKE 20 Many Elevators are equipped with an electric eye to prevent doors from shutting on people. They also are equipped with sensors and alarms to prevent operation when overloaded. Geethanjali Institute of Science & Technology
  21. 21. Advantages: Simple and chip Remove defect from root cause/source Faster defect detection and correction Improve safety of workers Improve equipment effectiveness and assures high realbility POKA-YOKE 21 Geethanjali Institute Of Science & Technology
  22. 22.  Making mistakes is OK; Just don’t make them again and again. And to avoid making same mistakes again there should be some checks or process in a place. Poka-yoke technique is used to solve the problem POKA-YOKE 22
  23. 23. THANK YOU POKA-YOKE 23