Learn What is Poka Yoke, Elements of Error Proofing, General Inspection, Error Proofing Devices, Ways to Mistake Proofing, Common Sources of Errors, Poka Yoke Principle and much more.
POKA-YOKE - A Lean Strategy to Mistake ProofingTimothy Wooi
A Lean Strategy in Human Error Prevention aims to detect and correct possible error immediately, eliminating defects at the source.
Poka-Yoke overcome the inefficiencies of inspection through the use of automatic devices that seek,
1.Not to accept a defect for the process
2.Not to Create a Defect
3.Not to Allow a Defect to be passed to the next process
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System.
It was originally described as baka-yoke, meaning "fool-proofing“ or “idiot proofing” but the name was later changed to the milder poka-yoke.
Learn What is Poka Yoke, Elements of Error Proofing, General Inspection, Error Proofing Devices, Ways to Mistake Proofing, Common Sources of Errors, Poka Yoke Principle and much more.
POKA-YOKE - A Lean Strategy to Mistake ProofingTimothy Wooi
A Lean Strategy in Human Error Prevention aims to detect and correct possible error immediately, eliminating defects at the source.
Poka-Yoke overcome the inefficiencies of inspection through the use of automatic devices that seek,
1.Not to accept a defect for the process
2.Not to Create a Defect
3.Not to Allow a Defect to be passed to the next process
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System.
It was originally described as baka-yoke, meaning "fool-proofing“ or “idiot proofing” but the name was later changed to the milder poka-yoke.
This Presentation gives a brief idea on what is Poka yoke and the various types of Poka yoke with examples. It also talks about the short comings of Poka yoke
What is poka yoke?, Classification of poke yoke Poka, What Causes Defects?, Why is it important?, When to use it?, Step by step process in applying poka-yoke, Characteristics of Poka Yoke devices, ADVANTAGES and LIMITATIONS.
This presentation will help you identify waste in your environment. Reducing these wastes from your life will give you more time and freedom for more important things which matter to you in your life.
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
The term KAIZEN has been derived from two Japanese words KAI & ZEN which means Change for better, precisely which means Continuous Improvement with no cost/ negligible cost by thinking differently using creativity.
This presentation includes
1. Concept of KAIZEN
2. KAIZEN Vs innovation/ modernization
3. KAIZEN and different level of Management
4. Targets of KAIZEN
5. Sample of KAIZEN checklist
6. Poka-Yoke
7, Examples of KAIZEN & Poka-Yoke
et.
its a general term used in cnhi india to allocate public interest and used as a tern in tractor company to see what things are working properly and what things are not working properly
This Presentation gives a brief idea on what is Poka yoke and the various types of Poka yoke with examples. It also talks about the short comings of Poka yoke
What is poka yoke?, Classification of poke yoke Poka, What Causes Defects?, Why is it important?, When to use it?, Step by step process in applying poka-yoke, Characteristics of Poka Yoke devices, ADVANTAGES and LIMITATIONS.
This presentation will help you identify waste in your environment. Reducing these wastes from your life will give you more time and freedom for more important things which matter to you in your life.
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
The term KAIZEN has been derived from two Japanese words KAI & ZEN which means Change for better, precisely which means Continuous Improvement with no cost/ negligible cost by thinking differently using creativity.
This presentation includes
1. Concept of KAIZEN
2. KAIZEN Vs innovation/ modernization
3. KAIZEN and different level of Management
4. Targets of KAIZEN
5. Sample of KAIZEN checklist
6. Poka-Yoke
7, Examples of KAIZEN & Poka-Yoke
et.
its a general term used in cnhi india to allocate public interest and used as a tern in tractor company to see what things are working properly and what things are not working properly
[To download this poster, visit:
https://www.oeconsulting.com.sg/training-presentations]
Jidoka, a fundamental pillar of Lean manufacturing and the Toyota Production System (TPS), is a concept that revolutionizes how we approach quality control in manufacturing. Derived from Japanese, "Jidoka" translates to "automation with a human touch." It represents a powerful strategy for building quality into the production process, thereby enhancing product quality, reducing waste, and fostering more efficient and reliable manufacturing practices.
What is Jidoka?
Jidoka is a manufacturing philosophy that seamlessly blends automation and human intervention. It encompasses the automatic detection of problems (automation) and empowers humans to intervene when necessary (autonomy).
Benefits to Practitioners of Lean Manufacturing:
1. Improved Product Quality: Jidoka's focus on early defect detection ensures that faulty products are identified and addressed promptly, preventing the production of defective goods.
2. Reduced Waste: By catching defects early in the production process, Jidoka minimizes rework, scrap, and the consumption of additional resources, contributing to waste reduction.
3. Enhanced Efficiency: Jidoka optimizes processes by prioritizing quality over quantity, leading to more streamlined and reliable manufacturing operations.
4. Empowerment of Workers: Jidoka empowers frontline workers by enabling them to take immediate action when issues arise, promoting a culture of continuous improvement.
The Four Steps of Jidoka:
Jidoka consists of four essential steps, each contributing to its overarching goal of enhancing quality and efficiency:
1. Detect the Abnormality:
- Goal: Identify deviations from the standard process.
- Key Activities: Implement Poka-yoke devices, use time as a detection mechanism, and employ visual controls like andon and Kanban for immediate problem signaling.
2. Stop Production:
- Goal: Halt production immediately upon detecting an abnormality.
- Key Activities: Initiate manual or automatic stoppage of the process to prevent the production of defective goods.
3. Fix the Problem at the Source:
- Goal: Address the root cause of the issue and ensure production can resume smoothly.
- Key Activities: Fix or correct the abnormal condition, implement temporary countermeasures, and make decisions at the lowest possible organizational level.
4. Implement Countermeasures:
- Goal: Prevent the recurrence of the abnormality and foster continuous improvement.
- Key Activities: Investigate the root cause of the problem, install permanent countermeasures, and prioritize efforts for ongoing process enhancement.
"Poka Yoke" is a Japanese lean manufacturing technique. It means to avoid mistakes and to form a defect free product or with 100% accuracy. In this presentation POKA YOKE system is explained which include three steps: awareness, root cause (5 why?) analysis, and six poka yoke techniques. Poka Yoke worksheet and its classification is illustrated with its approach, seven guidelines and advantages.
Repeatable, effective maintenance procedures are seen as “not required” however this couldn’t from the truth. Over my career I have seen thousands of examples of human variation creating equipment failure at the wrong time. We as humans are built to produce variation in almost everything we do. Most people deny this human variation exist however when I ask a manager if they ever could not find their car keys they look at me sheepishly and say “yes, great point”.
Many companies honestly believe there maintenance staff are paid to “know how to do it” without a procedure with specifications, step by step instructions, etc. What if a maintenance employee does “know how to do it” every-time? One must take into consideration their skill level, current state mind, and current working condition, in order to mitigate human error. In addition, what would happen if new information presents itself based on failure data? The only way to insure this new information is used effectively would be to write or change a procedure.
Well-designed maintenance procedures will mitigate human induced failures and allow for continuous improvement to occur naturally.
Temptation in English and Quiet Time in TeluguJaya Teja
Temptation and Quite time
Temptation in English, a desire to obtain some thing in wrong way.
Quite time in Telugu
meditating, studying word of God in a inductive method.
Applications
characteristics
classification
Processing of ceramics
Powder preparations
hot compaction-drying
sintering-finishing of ceramics
Areas of application
How to Excel in studies
Smart Goals
Why to Excel in studies
When to study
Where to study
10 study Habits of Successful students
How do we Remember more
Inter-Metallics,
Materials for cryogenic application,
Materials for space environment,
Evaluation of materials for extreme environment,
Introduction to metallic foams
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
2. Mistake/error-proofing
Avoiding simple human errors that occur in
manufacturing process by taking preventive action
early in the product design process.
The process of Zero Defects is also known as
“Mistake Proofing”.
3. Importance of poka-yoke
‘Poka’ means ‘Mistakes’ & ‘Yoke’ means ‘Avoid’. It’s objective is to
achieve Zero Defects.
Poka-Yoke was developed by Shigeo Shingo from Toyota Motor in
1961 as a tool to achieve Zero Defects.
Discipline should be concerned with anticipating human error.
By taking over repetitive tasks or actions that depend on vigilance or
memory, Poka-Yoke can free workers time and mind to pursue more
value added activities.
Lean practice does not allow extra inventory to compensate for
scrap.
Lean ideology focuses on speed ...
... speed cannot exist when defects and rework prevail.
Cost pressures don’t tolerate continued mistakes: scrap, rework,
lateness.
4. Common mistakes in manufacturing are:
o Mistakes in work pieces and tools in machines or in fixtures
o Incorrect or missing parts in assemblies
o Processing the wrong work piece
o Improper operations or adjustment of machines
5. Inspection to find mistake
• Judgment Inspection: Separating good from bad after
processing.
• Informative Inspection: Inspect then take action to eliminate
future occurrence.
• 100% or Sampling inspection based on SPC (Statistical
process Control) methodologies.
• Inspection:
• assumes defects are inevitable.
• believes the process of inspection will reduce defects.
• can reinforce ‘quality’ is responsibility of the quality
department.
• is not 100% effective.
6. • “Self-Check” Inspection
A self-check occurs when the person performing the work
checks the work before the work moves to the next process
step.
• Successive-Check” Inspection
A successive-check occurs when the previous work is
completed and that work is checked by the next person in
the process.
7. Attributes of Zero Defect quality system
• source inspection - Checks conditions at the source
• 100% Inspection - Simple Poka-Yoke devices in place to
check every time the process occurs
• immediate Action - Operations stop and corrective action
is taken when a defect occurs
• teams brainstorm and implement new devices wherever
there is an opportunity for error
8. oThree basic poka-yoke functions to use
against defects:
1. shut down a machine or operation
2. control a process or operation
3. warn that a defect has occurred
oA defect exists in one of two states:
1. it is about to occur
2. it has already occurred
9. NEGATIVE APPROACH
Mistakes are Inevitable
• people make mistakes
• place blame
• detect at final inspection
• sampling inspection
• errors are inevitable
• no time, no money
• no support
POSITIVE APPROACH
Mistakes Can Be Eliminated
• create the ‘right’ environment
• focus on the process
deficiency
• ask “why?”, then “how?”
• learn from the opportunity
• apply mistake-proofing
methods
• train everyone to challenge
errors. show them it’s
possible; share
examples
10. Design mistakes
• Failure to properly use dimensions and tolerances.
• Incorrect information
Defective material
• Poor choosing of material
• Not up to quality standards
• Poorly designed dies or molds
11. Manufacturing mistakes
• Omitted operations, parts
• Wrong orientation of part
• Misaligned part
• Wrong location of part
• Selection of wrong parts
• Misadjustments
• Commit a prohibited action
• added material or parts
• Misread, mismeasure, or misinterpret
12. Human Mistakes Safeguard
• Inattentiveness Discipline; work standardization; work
instructions
• Forgetfulness Checking at regular intervals
Inexperience Skill enhancement; work
standardization
• Misunderstanding Training; checking in advance;
standard work practices
• Poor identification Training; attentiveness; vigilance
13. Mistake Proofing-process & solutions
• process
• Identify the problem
• Prioritize
• Use cause finding methods
• Identify and implement solutions
• Evaluate
• Solutions
• Control of variability
• Control of complexity
• Control of mistakes
17. Energy Contact Devices
Photoelectric switches
can be used with
objects that are
translucent or
transparent depending
upon the need
An example of a contact device using a limit
switch. In this case the switch makes contact
with a metal barb sensing it’s presence. If no
contact is made the process will shut down
18. Warning Sensors
• Warning sensors
signal the operator
that there is a
problem. These
sensors use colors,
alarms, lights to get
the workers attention
!
• These sensors may
be used in
conjunction with a
contact or energy
sensor to get the
operators attention