Poka-yoke is a Japanese strategy developed by Shigeo Shingo in 1961 to prevent defects by making mistakes impossible. It aims for zero defects through techniques that stop production processes from errors like missing parts or incorrect operations. Poka-yoke includes prevention methods that avoid defects and detection methods that find defects before they spread, using controls, warnings, or direct contact with parts. Examples are sensors that count steps or colors that ensure the right parts are used. Poka-yoke benefits include faster quality improvement at lower worker attention cost while improving safety and reliability.
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.
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
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.
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
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.
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.
Download the presentation together with train-the-trainer guide and workshop templates at http://wcm.nu
This presentation is made by Oskar Olofsson, WCM Consulting AB
Make changes in the background template if you want to change the appearance
The purpose of this session is to provide you with a high level overview and sense of importance of what Lean is and how it can be applied to your organization. We will also help you identify waste in your processes and give you a flavor of some tools that will help to eliminate that waste, making your processes more efficient and effective.
In this presentation you will learn about Error Proofing and their types which refers to the IATF:16949 clauses and some practical examples from the industry.
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.
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.
Download the presentation together with train-the-trainer guide and workshop templates at http://wcm.nu
This presentation is made by Oskar Olofsson, WCM Consulting AB
Make changes in the background template if you want to change the appearance
The purpose of this session is to provide you with a high level overview and sense of importance of what Lean is and how it can be applied to your organization. We will also help you identify waste in your processes and give you a flavor of some tools that will help to eliminate that waste, making your processes more efficient and effective.
In this presentation you will learn about Error Proofing and their types which refers to the IATF:16949 clauses and some practical examples from the industry.
Poka yoke: The Science of Mistake Proofing in SoftwareGurpreet Luthra
Presentation on Poka Yoke in Software which was delivered by Dhaval Doshi and Gurpreet Luthra at ThoughtWorks xConf in July 2012.
For details refer to Blog Post:
http://techie-notebook.blogspot.in/2012/07/poka-yoke-applying-mistake-proofing-to.html
TALAT Lecture 2402: Design Recommendations for fatigue loaded structuresCORE-Materials
This lecture presents calculation of design stresses for variable stress ratios in practice, explanation on the background of design recommendations; it demonstrates the concept of partial safety factors and supply appropriate background information for aluminium; it enables the designer to evaluate service behavior of structural details on a more sophisticated level applying the same principles as in current design recommendations; it provides understanding of the fatigue design procedure according to current recommendations. Background knowledge in engineering, materials and fatigue as well as some knowledge in statistics is required.
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.
Poka-Yoke is concept which stops you from doing mistakes.It is reintroduced by the top consultant of Toyota Production System,he developed it for his workers,so that they can work easily without forgetting any steps to prepare the product.
[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 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.
Metis Automation specialise in designing and implementing advanced connected manufacturing systems. Our proven software products allow your project to be delivered efficiently, with assurance that your investment is a success.https://www.metisautomation.co.uk
The semiconductor industry is highly advanced and constantly evolving, with manufacturers always seeking new ways to improve their processes and reduce defects. There are several tools and techniques that are commonly used in the industry to achieve, zero defects or near-zero defect rates.
2. Poka -yoke is a Japanese improvement
strategy for mistake proofing to prevent
defects from arising during production
processes.
It’s aim is to achieve ‘zero defect’
3. Developed by Shigeo Shingo in 1961
Poka means mistakes yokeru means avoid
Poka-yoke refers to techniques that make it
impossible to make mistakes.
Poka-yoke techniques can drive defects out
of products and processes and substantially
improve quality and reliability.
4. Errors can be of any type-
i. Processing Error: Process operation missed or not
performed per the SOP.
ii. Setup Error: Using the wrong tooling or setting
machine adjustments incorrectly.
iii. Missing Part: Not all parts included in the assembly,
welding, or other processes.
iv. Improper part/item: Wrong part used in the process.
v. Operations Error: Carrying out an operation
incorrectly; having the incorrect version of the
specification.
vi. Measurement Error: Errors in machine adjustment,
test measurement or dimensions of a part coming in
from a supplier.
5. PREVENTION BASED
Prevents the defects from occurring
DETECTION BASED
Detects the defects and prevent its progress
6. CONTROL METHOD
This method senses a problem and stops a
line or process, so that corrective action can
take place immediately
EXAMPLE: Assembly operation in which one
component is missing before actual assembly
whole operation is stopped
7. This method signals the occurrence of a
deviation or trend of deviations through an
escalating series of buzzers, lights or other
warning devices
This method does not shut down the process
on every occurrence
8. CONTACT METHOD
This method detects any deviation in shape,
dimensional characteristics or other specific
defects, through mechanisms that are kept in
direct contact with the part
Fixed Value Method: This method is used in
operations, where a set of steps is
sequentially performed.
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.
9. Motion Step Method:
This method ensures that a process or
operator does not mistakenly perform a step
that is not part of the normal process.
An example of this is colour coding of
electronic components on drawings and totes
to prevent using mixed or incorrect parts.
10. Remove defect from root cause or source
Faster detection and correction
Lesser attention from workers/operators
Improve safety of workers
Improves equipment effectiveness and
assures higher reliability
11. Requires special expertise on instrumentation
knoweledge
Implementation cost is high
Training of workers is a must which adds the
cost
