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What is pokeyoke
The document discusses the concept of Poka-yoke, a technique aimed at preventing human errors in work processes by identifying causes and implementing safeguards. It outlines various types of errors, their origins, and ways to eliminate them through standardization, training, and process improvement. Ultimately, it emphasizes that most mistakes can be prevented with proper identification of their causes and using effective Poka-yoke methods.
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What is pokeyoke
- 1. EK KADAM FOUNDATION "Accelerating Youth-Accelerating Nation"
- 2. Concept Behind PokeYoke Poke-Yoke ( Check out for all our Problems - Why, Why analysis ) - Albert Ainstein
- 3. Approaches to dealwith errors Poke-Yoke • We blame people who make mistakes • With this problem is not solved but lowers morale of people. Errors are inevitable • People make fewer mistakes if they are supported by proper training and production system. Errors can be eliminated
- 4. Concept Behind PokeYoke Poke-Yoke The term “ Error ” means a sporadic deviation from standard procedures resulting from loss of memory, perception or motion of human being. Defect Vs Errors Error Defect Cause Result
- 5. Concept Behind PokeYoke Poke-Yoke Causes of Errors : • Inadequate written standards • Too many parts • Mix up • Too many steps • Too many adjustments • Tooling change • Frequent repetition • Environmental factors • Specifications / critical conditions
- 6. Errors and safeguardsPoke-Yoke 1. Forgetfulness - Alerting operator in advance or checking at regular intervals. 2. Errors due to - Training, standardizing work procedure. misunderstanding 3. Errors in identification - Training, attentiveness and vigilance. 4. Errors by amateurs - Skill building & standardization. 5. Willful errors - Basic education & experience. 6. Inadvertent errors - Attentiveness, discipline, work standardization. 7. Errors due to slowness - Skill building, work standardization. 8. Errors due to lack of - Work standardization & work instructions. Standards 9. Surprise errors - Work standardization, TPM. 10. Intentional errors - Fundamental education, discipline. Different kinds of errors Safeguards Almost all mistakes can be prevented if we take time to identify and why they happen and then take steps to prevent them by using Poka-yoke methods and the safeguards listed above.
- 7. Concept Behind PokeYoke Poke-Yoke Poka - yoke is a technique for avoiding simple human errors at work. Part of “Zero Quality Control” developed by Dr. Shigeo Shingo. Yokeru to avoid poka Inadvertent mistakes People make fewer mistakes if they are supported by proper training and by introducing good system. Errors can be eliminated
- 8. Concept Behind PokeYoke Poke-Yoke Normal functions stopped when defect predicted Even intentional errors are impossible Signals Abnormality / Error about to occur Normal functions stopped when defect detected Defective Items cannot pass on process Signals that defects have occurred STATE FUNCTION DEFECTS About to occur (Prediction) SHUT DOWN CONTROL WARNING POKA FLOW CONTROL WARNING Occurred (Detection) SHUT DOWN CONTROL WARNING SHUT DOWN ∩ ∩ ∩ STOP ! Flash lights Hooter
- 9. Avoiding defects atthe source Poke-Yoke
- 10. Eight principles ofbasic improvement Poke-Yoke 3. Stop doing it wrong and start doing it right-now! 1. Build quality into processes 2. All inadvertent errors and defects can be eliminated 6. Mistakes and defects can be reduced to zero when everyone works together to eliminate them 4. Don’t think up excuses, think about how to do it right 5. A 60% chance of success is good enough - implement your idea now! 8. Seek out the true cause, using 6 W’s and 2 H 7. Ten heads are better than one
- 11. Two target directionsPoke-Yoke • Exclude the possibility for mistakes at Development stage. Target group : Product designers, process planners. • Stop the blunders (mistakes) committed at once. Target group : Learn start groups, foreman, setters.
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- 15. Poka-yoke hints Poke-Yoke 1.Identify items by their characteristics • By weight: Establish weight standards. • By dimension: Establish standards for length, width, diameter, etc. • By shape Establish standards for shape characteristics such as angles, depressions, projections, curvature, or position of holes.
- 16. Poka-yoke hints Poke-Yoke 2.Detect deviation from procedures or omitted process • Process sequence method: The subsequent work cannot be performed if the prescribed sequence is not followed. Cannot be drilled after bending Incorrect procedure • Process to process sequence method: Operations cannot be performed if one of a series of processes has been omitted.
- 17. Poka-yoke hints Poke-Yoke 3.Detect deviations from fixed values • Using a counter A fixed number, such as the number of operations or parts, is used as a reference. • Odd-part-out method When a number of parts are assembled as a lot. The exact number of parts needed is prepared. • Critical condition detection: A critical manufacturing condition such as pressure, current, temperature, or time is measured. Leftover parts
- 18. Poka-yoke hints Poke-Yoke 1. Guidepin of different sizes 2. Error detection and alarms 3. Limit switches 4. Counters 5. Checklists Five best examples of avoiding human errors
- 19. Examples Poke-Yoke IMATION 3MENHANCED PERFORMANCE Floppy can be inserted only in the correct direction
- 20. Examples Poke-Yoke Cannot beopened if the arrow is downwards
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- 22. Examples Poke-Yoke Wrong position Correctposition Befor e Check station prevents incorrectly positioned parts going into the machine After
- 23. Examples Poke-Yoke Before Products withshort cables were being accepted After Products with short cables cannot be tested
- 24. Examples Poke-Yoke Right Wrong Before Possibleto reverse the polarities After Asymmetric shape ensures correct orientation
- 25. Conclusion Poke-Yoke Almost allmistakes can be prevented : - if we take time to identify why they happen - if we take steps to prevent them by using Poka-yoke - if we introduce the safeguards and maintain