Poke Yoke

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Poke Yoke

  1. 1. What is Poke Yoke ? For Internal Use Only Presentation by Senthilkumar RM
  2. 2. 1-10-100 Rule The 1-10-100 rule states that as a product or service moves through the production system, the cost of correcting An error multiplies by 10. Activity Cost Order entered correctly $1 Error detected in billing $ 10 Error detected by customer $ 100 Dissatisfied customer shares the experience with others the costs is 1000 $ For Internal Use Only Presentation by Senthilkumar RM
  3. 3. Who Makes Defects ? TO ERR IS HUMAN NATURE… For Internal Use Only Presentation by Senthilkumar RM
  4. 4. 10 Common Human Mistakes Forgetfulness Misunderstanding Wrong identification Lack of experience Willful (ignoring rules or procedure) Inadvertent or sloppiness Slow liness Lack of standardization Surprise (unexpected machine operation, etc.) Intentional (sabotage) For Internal Use Only Presentation by Senthilkumar RM
  5. 5. Relationship of Defects & Human Errors Relationship of Defects and Human Errors Misunderstanding Non-supervision Misidentification Human errors Inadvertant Intentional Slowness Amateurs Forgetful Surprise Willful Causes of defects Missed operations Processing errors Errors in part set-up Missing parts Wrong parts Processing wrong workpiece Misoperation Adjustment error Improper equipment set-up Improper tools and jigs highly correlated correlated For Internal Use Only Presentation by Senthilkumar RM
  6. 6. Levels of Poke Yoke For Internal Use Only Presentation by Senthilkumar RM
  7. 7. Two Types of Approaches ? 1. Control Approach - Shuts down the process when an error occurs. - Keeps the “suspect” part in place when an operation is incomplete. 2. Warning Approach - Signals the operator to stop the process and correct the problem. For Internal Use Only Presentation by Senthilkumar RM
  8. 8. 3 Primary Methods • Contact • Counting • Motion-Sequence Each method can be used in a control system or a warning system For Internal Use Only Presentation by Senthilkumar RM
  9. 9. Contact Method A contact method functions by detecting whether a sensing device makes contact with a part or object within the process. Cylinder present Missing cylinder;piston fully extended alarm sounds Cannot proceed to next step. Contact Method using limit switches identifies missing cylinder. For Internal Use Only Presentation by Senthilkumar RM
  10. 10. Examples : Contact methods Toggle Switches Limit Switches For Internal Use Only Presentation by Senthilkumar RM
  11. 11. Counting Method Used when a fixed number of operations are required within a process, or when a product has a fixed number of parts that are attached to it. A sensor counts the number of times a part is used or a process is completed and releases the part only when the right count is reached. For Internal Use Only Presentation by Senthilkumar RM
  12. 12. Counting Method : Examples Another approach is to count the number of parts or components required to complete an operation in advance. If operators finds parts leftover using this method, they will know that something has been omitted from the process. “I have an extra part. I must have omitted a step!” For Internal Use Only Presentation by Senthilkumar RM
  13. 13. Motion – Sequence Methods In order to help operators select the right parts for the right step in a process the “sequencing” aspect of the motion-step method is used. This is especially helpful when using multiple parts that are similar in size and shape. In this example, each step of the machine cycle is wired to an indicator board and a timer. If each cycle of the machine is not performed within the required “time” and “sequence”, the indicator light for that step will be turned on and the machine will stop. For Internal Use Only Presentation by Senthilkumar RM
  14. 14. Quick Ponder !! 1. What is Poke Yoke ? 2. Who Invented Poke Yoke ? 3. Levels of Poke Yoke? What r they ? 4. Approaches of Poke Yoke ? What r they? 5. Methods of Poke yoke ? What r they ? Answer coming slides with Levels, Approaches & Method used in these Poke Yoke’s? For Internal Use Only Presentation by Senthilkumar RM
  15. 15. Examples For Internal Use Only Presentation by Senthilkumar RM
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  43. 43. Stroop Test .. Read the color not the word For Internal Use Only Presentation by Senthilkumar RM

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