This document describes two different poka-yoke systems for line feeding/side kanbans: a color-coded system and a number-based system. The color-coded system uses a 4-digit color code to identify the exact point-of-use for materials and tools in both space and time. The number-based system uses a card-to-card approach where kanban cards move between bins and the material operator to trigger replenishment of empty bins. Pictograms and work instructions illustrate the material replenishment process under the number-based system.

1. Color-coded and number based Poka-Yoke for Line Feed/Side Kanbans
Istvan Fekete
(fekete.istvan.pic@gmail.com)
Capro/Teleflex, 2006-2008
Nokia, 2012-2013

2. Color-coded Poka-Yoke for Line Feed/Side Kanbans2006-2008

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After market
business model
as per 5S, ie
rarely used line is
built to order
Production mgmt,
Customer service,
TPS, Logistics in
one block
Maintenance
in open
area, with
closed
warehouse
FG kanbans
with cards to
be used in
production
management
One main
road for
primaries and
FG
warehouse
RM Warehouse:
large space
components feed
pre-assembly and
replenishment
kanbans
Machines, Tools,
CP-s, DOX
dedicated to the
line with constant
availability
Two bins Line-feed-
kanbans
(LFK)
90% of
components all
time available.
Supermarkets FIFO
racks with Dock-to-Stock
and 4-Bin Replenishment
kanbans.
80% of the material flow.
High volume
primaries in
kanbans
70% of the
total use
Ready primaries
on FIFO racks
80% of the use
controlled by
kanbans
The environment of color-coded Poka Yoke

4. ANYAGGAZDÁLKODÁSI POKA-YOKE
KÉK ÚTON
ZÖLD CELLA
LILA MŰVELET Művelet, amely szerszámot és/vagy komponenst igényel
KÉK SZERSZÁM/KOMPONENS
3
3
2
2
1
1
1st digit = Path (street side)
4-digit color code identified exact point-of-use
both in space and time for materials and tools
2nd digit = Cross
– perpendicular to
street
3rd digit in U-shape cell
differentiates materials/tools
by Point-of-Use
4th digit in U-shape cell
differentiates materials/tools
by time/products
1 2 3 4 5 6 7 8 9 10 0
41 4 6 1 3 15 45 7 34 53 2
10-digit Color Code from
MS Excel with clear visual
distinction
Example on color
coding of Tools:
1st digit = Blue Path
2nd Digit = Light Blue
Cross
The first 2 digits are the
same, i.e.
same production cell
Example on PoU with time separation:
3rd digit = Black (PoU)
4th Digit = Different as per the need of
different Products/Clusters

5. Streetsbetween self- bearing power supply ‚bus-bars’ under which the U-shape cells could be flexibly arranged, re-arranged
Flow-racksin supermarket with 4- digit color coding
Modular, adjustable ‚Pigeon-holes’with tripodeboth for Materials and Tools
2-Bin Line Feed Kanban Module for 3 different Materials, with FIFO ‚flow’
Tool Module with box color other than of materials
Path & Cross color codes (1st & 2nd digits) seen from both directions

6. Extract from work instruction (pictogramms)
1.Operátoruses the material from box (BB2.1.1, BB4.3.2).
2.Emptybox to put on top of material holder, work from next box
3.SRO(Stock Replenishment Owner) collects emptyboxes
4.SROputs the full boxesto their location
5.SROtakes the emptyboxes to Supermarket
1.SRO brings theempty boxes (BB2.1.1, BB4.3.2) to Supermarket and refillsthem from SM boxes (BB4.3.2, YB6.4.3, DTS)
2.SRO putsthe empty Supermarket boxes on top of Flow-rack upside-down
3.Supermarket Ownerrefillsthe empty SM-boxes with exact quantities. 4 empty boxes upside-down warns to material shortage

7. Number based Poka-Yoke for Line Feed/Side Kanbans2012-2013

8. Full Bin with Kanban Card = Nothing todo
Empty Bin with Kanban Card = MO takes the demand fromCell
Missing KanbanCard or Material Operator Card = Find Material Controler forhelp
Empty Bin with MO Card = MO delivers the demand toCell
OK
OK
OK
NOK
NOK
Kanban driven material replenishment to cell – card-to-card approach

9. Role:Material Operator
Puts the Free Kanban Card to Trolley Cardholder
In: 16
Task Step: 17
Out:18
Role:Material Operator
Takes the Kanban Card from Cardholder of the Empty Bin and puts his MO Card to Cardholder
In: 15
Task Step: 16
Out: 17
Role:Material Operator
Checks if there is Empty Bin in Cell to be replenished
In: 14
Task Step: 15
Out:16
2
1
3
2
pick up the kanbancard only on your return to supermarket
Material Operator takes the demand fromhis/herCell(card-to-cardapproach)

10. Material Operatorpicks Material with Kanban CardfromFlow Rack(card-to-cardapproach)
Role:Material Operator
Picks the required Bin from Supermarket Location with Kanban Card
In: 20
Task Step: 21a
Out:22
Role:Material Operator
puts the Full Bin to Trolley with Kanban Card on Bin
In: 20
Task Step: 21b
Out:22
1
2
1
2

11. Material Operator delivers the demand to Cell(card-to-cardapproach)
Role:Material Operator
Takes the Bin with its Kanban Card Puts the brought Full Bin to Cell
In: 23
Task Step: 23d
Out:23e
Role:Material Operator
Takes his MO Card from Cardholder and puts back the Kanban Card to Cardholder
In: 23d
Task Step: 23e
Out:23f
3
1
2
1
Role:Material Operator
ComparesKanban Card with Cell Location label
In: 23e
Task Step: 23f
Out:
2
3