The document defines poka-yoke as a Japanese term meaning "mistake-proofing" and discusses its use in manufacturing to eliminate defects. Poka-yoke aims to prevent human errors by making processes foolproof through simple mechanisms that detect and correct mistakes. The document outlines principles of mistake-proofing, types of poka-yoke devices, and how poka-yoke can be implemented at different stages of production to catch errors early.
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.
“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
PDCA Cycle
PDCA is an iterative four-step management method used in business for the control and continual improvement of processes and products. It is also known as the Deming circle/cycle/wheel, Shewhart cycle, control circle/cycle, or plan–do–study–act (PDSA). Another version of this PDCA cycle is OPDCA.
Cost of Quality is a widely spread and widely misunderstood concept.Here is a presentation that will evaporate all your doubts regarding this topic.A very well explained case study of H&S motors.It is a very well structured presentation.
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.
Activity-based costing (ABC) is a costing model that identifies activities in an organization and assigns the cost of each activity resource to all products and services according to the actual consumption by each: it assigns more indirect costs (overhead) into direct costs.
In this way an organization can precisely estimate the cost of its individual products and services for the purposes of identifying and eliminating those which are unprofitable and lowering the prices of those which are overpriced.
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.
“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
PDCA Cycle
PDCA is an iterative four-step management method used in business for the control and continual improvement of processes and products. It is also known as the Deming circle/cycle/wheel, Shewhart cycle, control circle/cycle, or plan–do–study–act (PDSA). Another version of this PDCA cycle is OPDCA.
Cost of Quality is a widely spread and widely misunderstood concept.Here is a presentation that will evaporate all your doubts regarding this topic.A very well explained case study of H&S motors.It is a very well structured presentation.
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.
Activity-based costing (ABC) is a costing model that identifies activities in an organization and assigns the cost of each activity resource to all products and services according to the actual consumption by each: it assigns more indirect costs (overhead) into direct costs.
In this way an organization can precisely estimate the cost of its individual products and services for the purposes of identifying and eliminating those which are unprofitable and lowering the prices of those which are overpriced.
Becoming lean john shook lean manufacturingJohn Gillis
John Shook was the first American hired into Japan's productivity network. His thinking is essential, basic and clean, on the Toyota Production System, Lean Thinking, and the American adaptation of the principles. Adapted from "Becoming Lean: Inside Stories of U. S. Manufacturers" Jeffrey K. Liker, editor, himself an acknowledge expert in this universe.
Just in time (JIT) is a production strategy that strives to improve a business' return on investment by reducing in-process inventory and associated carrying costs. Just in time is a type of operations management approach which originated in Japan in the 1950s. It was adopted by Toyota and other Japanese manufacturing firms, with excellent results: Toyota and other companies that adopted the approach ended up raising productivity (through the elimination of waste) significantly.
Poka Yoke - Fundamentals by Praneet SurtiPraneet Surti
A presentation on the Introduction, Purpose, History & Origin, Concept, Principles, Methods, Types & Implementation of Poka-Yoke [Mistake Proofing] in any manufacturing or service setting.
Poka-yoke is a quality assurance technique developed by Japanese manufacturing engineer Shigeo Shingo. The aim of Poka-Yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Poka- yoke has been used most frequently in production environments. Production defects or errors are always the key concerns of any production industry. The success of any organization depends on the quality of product especially right product produced.
It’s a quality assurance process introduced by Japanese engineer Shigeo Shingo. This term is used in Japanese language as “Poka” meaning mistake and “Yoke” meaning prevent i.e. mistake preventing or mistake proofing technique.
The purpose of Poka-Yoke is to develop processes to reduce defects by avoiding or correcting (design to show alerts or warning messages to the user) mistakes in early design and development phases.
[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.
Research Inventy : International Journal of Engineering and Scienceresearchinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
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
Business Valuation Principles for EntrepreneursBen Wann
This insightful presentation is designed to equip entrepreneurs with the essential knowledge and tools needed to accurately value their businesses. Understanding business valuation is crucial for making informed decisions, whether you're seeking investment, planning to sell, or simply want to gauge your company's worth.
RMD24 | Debunking the non-endemic revenue myth Marvin Vacquier Droop | First ...BBPMedia1
Marvin neemt je in deze presentatie mee in de voordelen van non-endemic advertising op retail media netwerken. Hij brengt ook de uitdagingen in beeld die de markt op dit moment heeft op het gebied van retail media voor niet-leveranciers.
Retail media wordt gezien als het nieuwe advertising-medium en ook mediabureaus richten massaal retail media-afdelingen op. Merken die niet in de betreffende winkel liggen staan ook nog niet in de rij om op de retail media netwerken te adverteren. Marvin belicht de uitdagingen die er zijn om echt aansluiting te vinden op die markt van non-endemic advertising.
Buy Verified PayPal Account | Buy Google 5 Star Reviewsusawebmarket
Buy Verified PayPal Account
Looking to buy verified PayPal accounts? Discover 7 expert tips for safely purchasing a verified PayPal account in 2024. Ensure security and reliability for your transactions.
PayPal Services Features-
🟢 Email Access
🟢 Bank Added
🟢 Card Verified
🟢 Full SSN Provided
🟢 Phone Number Access
🟢 Driving License Copy
🟢 Fasted Delivery
Client Satisfaction is Our First priority. Our services is very appropriate to buy. We assume that the first-rate way to purchase our offerings is to order on the website. If you have any worry in our cooperation usually You can order us on Skype or Telegram.
24/7 Hours Reply/Please Contact
usawebmarketEmail: support@usawebmarket.com
Skype: usawebmarket
Telegram: @usawebmarket
WhatsApp: +1(218) 203-5951
USA WEB MARKET is the Best Verified PayPal, Payoneer, Cash App, Skrill, Neteller, Stripe Account and SEO, SMM Service provider.100%Satisfection granted.100% replacement Granted.
Premium MEAN Stack Development Solutions for Modern BusinessesSynapseIndia
Stay ahead of the curve with our premium MEAN Stack Development Solutions. Our expert developers utilize MongoDB, Express.js, AngularJS, and Node.js to create modern and responsive web applications. Trust us for cutting-edge solutions that drive your business growth and success.
Know more: https://www.synapseindia.com/technology/mean-stack-development-company.html
Improving profitability for small businessBen Wann
In this comprehensive presentation, we will explore strategies and practical tips for enhancing profitability in small businesses. Tailored to meet the unique challenges faced by small enterprises, this session covers various aspects that directly impact the bottom line. Attendees will learn how to optimize operational efficiency, manage expenses, and increase revenue through innovative marketing and customer engagement techniques.
Putting the SPARK into Virtual Training.pptxCynthia Clay
This 60-minute webinar, sponsored by Adobe, was delivered for the Training Mag Network. It explored the five elements of SPARK: Storytelling, Purpose, Action, Relationships, and Kudos. Knowing how to tell a well-structured story is key to building long-term memory. Stating a clear purpose that doesn't take away from the discovery learning process is critical. Ensuring that people move from theory to practical application is imperative. Creating strong social learning is the key to commitment and engagement. Validating and affirming participants' comments is the way to create a positive learning environment.
RMD24 | Retail media: hoe zet je dit in als je geen AH of Unilever bent? Heid...BBPMedia1
Grote partijen zijn al een tijdje onderweg met retail media. Ondertussen worden in dit domein ook de kansen zichtbaar voor andere spelers in de markt. Maar met die kansen ontstaan ook vragen: Zelf retail media worden of erop adverteren? In welke fase van de funnel past het en hoe integreer je het in een mediaplan? Wat is nu precies het verschil met marketplaces en Programmatic ads? In dit half uur beslechten we de dilemma's en krijg je antwoorden op wanneer het voor jou tijd is om de volgende stap te zetten.
Unveiling the Secrets How Does Generative AI Work.pdfSam H
At its core, generative artificial intelligence relies on the concept of generative models, which serve as engines that churn out entirely new data resembling their training data. It is like a sculptor who has studied so many forms found in nature and then uses this knowledge to create sculptures from his imagination that have never been seen before anywhere else. If taken to cyberspace, gans work almost the same way.
What are the main advantages of using HR recruiter services.pdfHumanResourceDimensi1
HR recruiter services offer top talents to companies according to their specific needs. They handle all recruitment tasks from job posting to onboarding and help companies concentrate on their business growth. With their expertise and years of experience, they streamline the hiring process and save time and resources for the company.
Cracking the Workplace Discipline Code Main.pptxWorkforce Group
Cultivating and maintaining discipline within teams is a critical differentiator for successful organisations.
Forward-thinking leaders and business managers understand the impact that discipline has on organisational success. A disciplined workforce operates with clarity, focus, and a shared understanding of expectations, ultimately driving better results, optimising productivity, and facilitating seamless collaboration.
Although discipline is not a one-size-fits-all approach, it can help create a work environment that encourages personal growth and accountability rather than solely relying on punitive measures.
In this deck, you will learn the significance of workplace discipline for organisational success. You’ll also learn
• Four (4) workplace discipline methods you should consider
• The best and most practical approach to implementing workplace discipline.
• Three (3) key tips to maintain a disciplined workplace.
Affordable Stationery Printing Services in Jaipur | Navpack n PrintNavpack & Print
Looking for professional printing services in Jaipur? Navpack n Print offers high-quality and affordable stationery printing for all your business needs. Stand out with custom stationery designs and fast turnaround times. Contact us today for a quote!
2. INTRODUCTION
What is a Poka- yoke?
Shigeo shingo defined poka-yoke as POKA- ‘Inadvertent
mistake that anyone can make’ and YOKE- ‘To prevent or
proof’
Poka-yoke is a tool to have “zero defects” and even reduce or
eliminate quality control.
Poka-yoke is a Japanese name for “fool-proofing”.
Poke-yoke represents the intelligence of the operator by
excluding repetitive actions that require a thinking process.
May 26, 2012 2
3. MISTAKE PROOFING
Mistake-Proofing a product's design and its manufacturing
process is a key element of design for manufacturability /
assembly (DFM/A)
Mistake proofing is also a key element of improving product
quality and reliability
FACTORS CONTRIBUTING TO MISTAKE PROOFING:
Attention
Perception
Memory
Logical reasoning
May 26, 2012 3
4. PRINCIPLES OF MISTAKE-PROOFING
There are six mistake-proofing principles or methods.
Elimination seeks to eliminate the possibility of error by
redesigning the product or process so that the task or part is
no longer necessary.
Replacement substitutes a more reliable process to improve
consistency.
Prevention engineers the product or process so that it is
impossible to make a mistake at all.
Facilitation employs techniques and combining steps to
make work easier to perform.
Detection involves identifying an error before further
processing occurs so that the user can quickly correct the
problem.
Mitigation seeks to minimize the effects of errors.
May 26, 2012 4
5. 2-STATUS & 3-FUNCTIONS OF POKA-YOKE
POKA-YOKE HAS 2 STATUS AND 3 FUNCTIONS:
Status:
1.The fault will happen or
2.The fault has happened
Functions:
1.Stop
2.Check or
3.Alarm
May 26, 2012 5
6. THREE STRATEGIES FOR ZERO DEFECT
Only make the product when required!
Make the product so it can not be used for anything else.
If the product is ready use it immediately.
May 26, 2012 6
7. POKA-YOKE CLASSIFICATION
Poka-yoke is classified into the following types:
Server Poka-Yokes Customer Poka-Yokes
Task Preparation
Encounter
Treatment Tangibles Resolution
May 26, 2012 7
8. PROVIDER(SERVER) ERRORS
Task Errors
• Doing the work incorrectly
• Doing work not requested
• Doing work in the wrong order
• Doing work too slowly
Treatment Errors
• Not acknowledging the customer
• Not listening to the customer
• Not reacting appropriately to the customer
Tangible Errors
• Failure to clean facilities
• Failure to control noise
May 26, 2012 8
9. CUSTOMER ERRORS
Preparation Errors
• Failure to bring necessary materials to the encounter
• Failure to engage the correct service
Encounter Errors
• Failure to remember steps in the service process
• Failure to follow system flow
• Failure to follow instructions
Resolution Errors
• Failure to learn from experience
• Failure to adjust expectations appropriately
May 26, 2012 9
10. SEVEN STEPS TO POKA-YOKE ATTAINMENT
Quality Processes
Utilize a team environment
Elimination of Errors
Eliminate the “Root Cause” of The Errors
Do It Right The First Time
Eliminate Non-Value Added Decisions
Implement a Continual Improvement Approach
May 26, 2012 10
11. POKA-YOKE APPROACH
Proactive Approach :
A fully implemented ZERO DEFECT QUALITY system requires
Poka-Yoke usage at or before the inspection points during the
process.
Poka-yoke will catch the errors before a defective part is
manufactured 100% of the time.
Reactive Approach :
Check occurs immediately after the process.
Can be an operator check at the process or successive check at the
next process.
Not 100% effective, will not eliminate all defects.
Effective in preventing defects from being passed to next process.
May 26, 2012 11
12. Two Poka-Yoke System approaches are utilized in
manufacturing which lead to successful ZERO DEFECT
QUALITY:
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.
May 26, 2012 12
13. CONTROL SYSTEM
Takes human element out of the equation ; does not depend
on an operator or assembler.
Has a high capability of achieving zero defects.
Machine stops when an irregularity is detected.
May 26, 2012 13
14. WARNING SYSTEMS
Sometimes an automatic shut off system is not an option.
A warning or alarm system can be used to get an operators
attention.
Color coding is also an effective non-automatic option
May 26, 2012 14
15. TEN TYPES OF HUMAN MISTAKES
Forgetfulness
Mis-understanding
Wrong identification
Lack of experience
Willful (ignoring rules or procedure)
Inadvertent or sloppiness
Slowliness
Lack of standardization
Surprise (unexpected machine operation, etc.)
Intentional (sabotage)
May 26, 2012 15
16. POKA-YOKE DEVICES
Poka yoke is implemented by using simple objects like
fixtures, jigs, warning devices and the like to prevent people
from committing mistakes, even if they try to!.
The main feature of poka-yoke devices is their exceptional
suitability for reducing or eliminating defects through
effective feedback and instantaneous corrective action.
These devices are capable of being used all the time by all
workers; simple and usually installed with low
implementation cost.
Poka-yoke devices help eliminate errors and defects by giving
machines the “intelligence” to stop and signal when a error
occurs.
Poka-yoke devices stop machines and alert workers when a
problem exists.
May 26, 2012 16
17. THE THREE LEVELS OF POKA-YOKE:
There are three levels at which your company can effect poka-
yoke:
Eliminating errors defects and losses at the source or
prevention of a mistake from being committed..
Detection of a loss or mistakes it occurs,allowing correction
before it becomes a problem.
Detection of a loss or mistakes after it has occurred,just in
time before it blows up into a major issue(least effective).
May 26, 2012 17
20. IMPLEMENTATION IN MANUFACTURING
Poka-yoke can be implemented at any step of a
manufacturing process where something can go wrong or an
error can be made.
Shigeo Shingo recognized three types of poka-yoke for
detecting and preventing errors in a mass production system:
The contact method identifies product defects by testing the
product's shape, size, color, or other physical attributes.
The fixed-value (or constant number) method alerts the
operator if a certain number of movements are not made.
The motion-step (or sequence) method determines whether
the prescribed steps of the process have been followed.
May 26, 2012 20
21. ADVANTAGES
They are simple and cheap.
They are part of the process, implementing what Shingo calls
"100%" inspection.
They are placed close to where the mistakes occur, providing
quick feedback to the workers so that the mistakes can be
corrected.
Once put in place, they require minimal supervision.
May 26, 2012 21
22. CONCLUSION
Poka-yokes deals with understanding why
people make errors and how to analyze the process to
know where errors are likely to occur and what root
causes contribute to them.
Since the poka-yoke devices detect errors at their
roots n prevent them from blowing up to become
bigger problems, there is consistency in the quality of
the products, saving the cost and time spent in
subsequent quality inspection processes.
May 26, 2012 22