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poka yoke presentation detailed presentation .pptx
- 1. Poka Yoke: Mistake-Proofingfor Quality Improvement • An Overview of Concepts and Applications • Your Name / Organization
- 2. What is PokaYoke? • • Poka Yoke = Japanese for “mistake-proofing” or “error prevention” • • Developed by Shigeo Shingo at Toyota • • Purpose: Prevent human errors in manufacturing and service processes • • Simple, low-cost devices or methods to avoid mistakes
- 3. Why is PokaYoke Important? • • Reduces defects and rework • • Improves product and service quality • • Increases safety and reliability • • Lowers cost of poor quality • • Enhances customer satisfaction
- 4. Types of PokaYoke • 1. Warning Poka Yoke → Alerts when an error is about to happen • 2. Control Poka Yoke → Prevents the error from happening
- 5. Methods of PokaYoke • • Contact method: Detects deviations in shape, size, color • • Fixed-value method: Ensures correct number of actions/items • • Motion-step method: Ensures correct sequence of steps
- 6. Examples of PokaYoke • • Power plug design to fit only one way • • Car with automatic warning if headlights left on • • Washing machines that stop when the door is open • • USB connectors designed for one-way insertion
- 7. Steps to ImplementPoka Yoke • 1. Identify the problem or error-prone area • 2. Analyze root causes • 3. Design a simple mistake-proofing device or method • 4. Test and refine the solution • 5. Train operators and monitor performance
- 8. Benefits of PokaYoke • • Eliminates human error at the source • • Builds a culture of quality • • Simplifies training and supervision • • Supports continuous improvement (Kaizen)
- 9. Challenges and Considerations •• Initial cost and effort to design solutions • • Risk of overengineering • • Importance of involving frontline workers • • Need for regular review and improvement
- 10. Summary • • PokaYoke is a practical, effective tool to prevent errors • • Focuses on simplicity and prevention • • Widely applicable across industries • • Integral part of Lean Manufacturing and Quality Management
- 11. Thank You • Questions& Discussion • Your contact details