Kaizen Details

1. 1
KAIZEN – Pokayoke
July 2010
Welcome to the
presentation on
POKA YOKE
An Effective Kaizen Tool
• Introduction of Kaizen
• Introduction of Pokayoke
• Structure of Pokayoke
• Examples of Pokayoke

2. 2
KAIZEN – Pokayoke
July 2010
The Japanese word “KAIZEN” means Continuous Improvement
KAI - Change
- Number of
times
ZEN - Good or better
- Self Realisation
What is KAIZEN ?

3. 3
KAIZEN – Pokayoke
July 2010
•Kaizen is Kanji word. Kanji is Chinese language.
•Kai - Change , Zen -Good
Kaizen = Change for better
( Taiichi Ohno & Toyoda started
in Toyota - 1960 )
•It is proven philosophy used world over for
organisational growth and competitive environment
( Toyota, Cannon, Sony, Hyundai, Honda, Tourism in
Mauritius )
•Kaizen emphasises developing culture of continuos
improvement. Human being at center
•Kaizen is beneficial in every walk of life.
"To improve is to change. To be perfect is to
Change often."
Cummins India Limited January 2002
Kaizen
Kaizen
A Journey of thousand leagues
Begins with a single step

4. 4
KAIZEN – Pokayoke
July 2010
• Continuous Improvement is
the need for survival in
Global competitive environment
- Safety,
- Quality,
- Productivity
-- Cost saving
• Develop Culture - Everybody can participate in
Safety & Quality Improvement activity.
• Understand human behavior
eliminate waste & design Pokayoke
• Bakayoke – Fool proof
Pokayoke – Mistake proof
- Why Kaizen?

5. 5
KAIZEN – Pokayoke
July 2010
- How to Practice ?
• Understand the “Pokayoke Concept
• Involve everybody in implementation
• Maintain the improvements
• Support the “Team” Concept for developing
the “Pokayoke Culture”
• Recognize / Appreciate “others” also
• Be “Advocate” for Pokayoke
“Safety is need of every job, every moment”

6. 6
KAIZEN - POKAYOKE
Sep 2006
• Poka-yoke (pronounced "POH-kah YOH-kay“ )
• Japanese words "poka" (inadvertent mistake) and
"yoke" (prevent) was invented by Shigeo Shingo in the
1960s.
• The essential idea of poka-yoke is to design your
process so that mistakes are impossible or at least
easily detected and corrected.
About Shigeo Shingo………..
• A leading proponent of statistical process control.
• Became frustrated with the statistical approach.
• Statistical sampling implies that some products to go
untested, with the result that some rate of defects
would always reach the customer.
About POKA YOKE…………

7. 7
KAIZEN - POKAYOKE
Sep 2006
• Shingo was communicated of a problem in
“Yamada Electric plant” in 1961.
• A small switch with two push-buttons supported by two
springs, occasionally, the worker assembling the switch
would forget to insert a spring under each push-button.
• Sometimes the error would not be discovered until the
unit reached a customer.
• Factory would have to dispatch an engineer to the
customer site to disassemble the switch, insert the missing
spring, and re-assemble the switch.
• This problem of the missing spring was both costly and
embarrassing.
• Despite everyone's best intentions, the missing spring
problem would eventually re-appear.
Birth of POKA YOKE ………

8. 8
KAIZEN - POKAYOKE
Sep 2006
Pokayoke Action
Error Has
Occurred
Detection
Is Made
Defect
Is
Signaled
Control /
Feedback
Given
Process
Is
Stopped
POKA YOKE Action

9. 9
KAIZEN - POKAYOKE
Sep 2006
• A system for organising work that prevents the error.
• Excludes any risk of error even by the beginner.
• Allows everyone to operate without mistake.
• Prevents error that are about to occur.
• Inspection time will be minimised.
What is “Mistake Proofing “ ?
Why should we do it ?

10. 10
KAIZEN - POKAYOKE
Sep 2006
Mistake -Proof Approach
List of Problems – Select
Form a Team
Brain-writing at Gemba
Why-Why Analysis leads to root cause
Kaizens on root cause
Establish Activities to maintain standard
Work Towards Low Cost Automation
Plan
Do
Check
Act

11. 11
KAIZEN - POKAYOKE
Sep 2006
• Elimination (to remove or take away) : Redesign
the system to eliminate the chance of the error.
• Facilitation (The act of making easy or easier):
Provide methods of guidance to minimize the
chance of an error.
• Mitigation (to make something less harmful) : Lessen the
effect of the error if the resulting defect gets to the
customer.
• Flagging (to put a mark on something) : Proven methods
for insuring 100% chance of capturing and
removing all defective units prior to shipment.
Shigeo Shingo’s Four primary types of mistake
proofing…..

12. 12
KAIZEN - POKAYOKE
Sep 2006
The essential idea of poka-yoke is to design your process so
that mistakes are impossible or at least easily detected and
corrected.
Is it always an Intrinsic Technology ????
Not At All…………………
It is classified in three categories,
Minor Characteristics Level 1 POKA YOKE
Major Characteristics Level 2 POKA YOKE
Critical & Key Characteristics Level 3 POKA YOKE
POKA YOKE –More information……….
POKA YOKE

13. 13
KAIZEN - POKAYOKE
Sep 2006
Selection of POKA YOKE Projects
• Safety & Quality issues to be resolved
permanently- These are candidates
• Find out permanent solutions and
complete CAPA
• Go to the root cause and observe
Brain writing / Brainstorming.
• Use 80-20 concept for deciding corrective action.
( Use CEdac chips and why, why analysis )
(CEdac-Cause &effect diagram with addition of cards)
• Team finalises the root cause on which we have to act.

14. 14
KAIZEN - POKAYOKE
Sep 2006
Pokayoke 10 steps
1. Form a Team – Central and Each Station
2. Before study–Accident history and Quality problems
3. Prepare Data Bank – Section wise
4. Decide priority-Monthly / Quarter / Year
5. Team Training – Include operators
6. Study – Brain storming / Brain writing
7. Kaizens to eliminate problems
8. Change process sheet – Data Bank one page - savings
9. Audit every month – PDCA
10. Recognition- Magazine /Noticeboard/Quarterly Function

15. 15
KAIZEN - POKAYOKE
Sep 2006
Step 1 -- Form a Team(Central / Each BU)
• Normal team will be 5 to 6 members
• Involve all shift Operators in the Team
• Involve Finance man & Process Engr.
• Involve one OR two members to learn
• Facilitator to attend – Gen. Manager
• Dy. Leader – Admin. Work- MOM etc.
• Give equal responsibility to all
• Use CEdac chips in Brain Writing

16. 16
KAIZEN - POKAYOKE
Sep 2006
Step 2 -- Before Study -
• List of projects to put on Poka yoke Board
• Give priority for each Quarter / month
• Check the estimated savings in RS.
• Check increase in Production
• Decide the time & day of meetings
• Training of Team may be required
• Check camera etc. availability

17. 17
KAIZEN - POKAYOKE
Sep 2006
Step 3 -- Prepare Data Bank-- Before study
• Check accident History & Collect Data
• Check Quality History & Prepare Data
• No. Of Problems in a day/month/year
• List the actions in chart
• Note actions difficult- Ergonomics
• Note safety requirements
• Check Lighting / Ventilation also
• Check Tools used & modification if any
• Check footsteps & movements of operator
• Check Tool post / Platform available
• Put recording charts on Board
• Bring visibility for all observations

18. 18
KAIZEN - POKAYOKE
Sep 2006
Step 4 – Decide Priority -- Analyze all activities –
• Check every small activity
• Consult the Leader & prepare quarterly program
• Make proactive preparation for tools
• Prepare SOP for initial preparation
• Colour code if possible the trays etc.
• Check with Operators all activities included
• Keep tools / equipments etc. one set always ready
• Think of Kaizens in every step

19. 19
KAIZEN - POKAYOKE
Sep 2006
Step 5 -- Team training- Operator – New activities
• Take operator into confidence in every step
• Ask him to practice in minimum movements
• Put the chart of sequence
• Check Tool post position
• Modify standing platforms
• Have PEEP for each thing you use
• Operators in shift to Practice same thing
• Put Alarm at Gemba for Safety norms

20. 20
KAIZEN - POKAYOKE
Sep 2006
Step 6 – Study – Brain storming / Brain writing
• Use Ergonomics to avoid difficult movements
• Use color codes for similar nuts & its spanners
• Mark the point where operator to stand
• Checking instrument to provide at right place
• Check good lighting & cool air at point of work
• Mark the Nut tightening positions on both sides
• Coolant etc. to change by Maint. In SMED time
• Make Use of Andon Lamp during set up
• Complete first job machining and check
• Remove setting tools to PEEP

21. 21
KAIZEN - POKAYOKE
Sep 2006
Step 7 -- Kaizens – Implementation
• Try to to eliminate problem 100 %
• Kaizen are must in each step
• Check operators concerns in new steps
• Modify the activities to reduce the
movements
• Practice new activities & prepare the chart

22. 22
KAIZEN - POKAYOKE
Sep 2006
To prevent mistakes - Use
• Sensors ( Photo sensors )
• Temperature Controllers
• Humidity Sensors
• In circuit & M/c Ladder modifications
• Limit switches
• Mechanical Stoppers
• Pressure switches
• Proximity switches
• Float switches
• Flow switches
• Cold air gun for temperature rise problem
• Modify Jigs and fixtures
Step 7 --POKA-YOKE TOOLS / Techniques

23. 23
KAIZEN - POKAYOKE
Sep 2006
Step 8 – Change Process sheet/One page data/Savings
• Train the Operator – New activities
• Take operator into confidence in every step
• Ask him to practice in minimum movements
• Put the chart of sequence
• Check Tool post position
• Modify standing platforms
• Have PEEP for each thing you use
• Operators in shift to Practice same thing
• Put Alarm at Gemba for safety

24. 24
KAIZEN - POKAYOKE
Sep 2006
Step 9 - Measure new time & Modify the Process
• Measure new time after sufficient practice
• Note all the tools etc. required for new process
• Put the Process sheet on Board for changes
• Get suggestions & then finalize timings
• Safety norms may be revised after sometime
• Permanently put final process sheets and one page
Pokayoke at Gemba

25. 25
KAIZEN - POKAYOKE
Sep 2006
Step 10 -- Audit every Quarter – Recognition-PDCA
• Every Pokayoke project should be audited by
permanent audit Team
• Team takes suggestions from operators & makes
modifications
• Quarterly Recognition function to arrange by
Central Team
• All Top authorities & Union Leaders to attend the
function & greet the team
• House Magazine to publish Pokayoke Or put
Team Photograph on Notice Board
• Put BEST Team member in next Pokayoke
Project

26. 26
KAIZEN - POKAYOKE
Sep 2006
Step 10 -- Pokayoke Audit –
• Audit team is formed to check
sustenance of Pokayoke
• Audit team reviews sample Pokayoke
5 out of every 100 Pokayoke
• Important Pokayokes copied
in all the BUs
• After every layout change all Pokayokes
on machine shifted are checked.
• Pokayoke Bank is created through
“O” tag campaigns.

27. 27
KAIZEN - POKAYOKE
Sep 2006
Benefits
Zero field complaints. ( Improved Quality )
Zero rework / rejection
Building teamwork - Managers and associates
Zero accidents

28. 28
KAIZEN - POKAYOKE
Sep 2006
Safety Posters
all over shop.
More than
100 posters
displayed
on shop.

29. 29
KAIZEN - POKAYOKE
Sep 2006
In US, a special POKA YOKE system is made for blind
people to cross the road.
People cross the road only when “WALK” signal is green.
This signal can be seen by a normal person but blind
can not see this signal and cross the road. Hence when
“WALK” signal becomes green, a music also starts so
that blind person can hear that and cross
the road.

30. 30
KAIZEN - POKAYOKE
Sep 2006
How to build Pokayoke culture –
• After every minor or major accident
Pokayoke Team takes Preventive
actions
• Pokayoke Campaigns are taken on
Safety Day and number of
Opportunity tags are collected.
- Installation bolts removed
- Floor unevenness repaired
-- Canteen & Shop cooling
- Sand on street cleaned
• Communication meeting/Sunrise meeting
Sunrise Leaders camp/Yearly MD meeting

31. 31
KAIZEN - POKAYOKE
Sep 2006
Thanks