Error / Mistake Proofing Poka Yoke
Contents |
research should be removed. (April 2014) (Learn how and when to remove this template message) Poka-yoke example: Ethernet cable plug is designed to be plugged in only one orientation. Poka-yoke (ポカヨケ?) [poka yoke] is a Japanese term that means "mistake-proofing" or mistake proofing examples “inadvertent error prevention”. The key word in the second translation, often omitted, is "inadvertent". mistake proofing methods There is no Poka Yoke solution that protects against an operator’s sabotage, but sabotage is a rare behavior among people.[1] A poka-yoke mistake proofing ppt is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.[2] The mistake proofing definition concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota Production System.[3][4] It was originally described as baka-yoke, but as this means "fool-proofing" (or "idiot-proofing") the name was changed to the milder poka-yoke. Contents 1 Usage 2 History 3 Implementation in manufacturing 4 Benefits of Poka Yoke implementation 5 See also 6 References 7 Further reading 8 External links Usage[edit] More broadly, the term can refer to any
Mistake Proofing Six Sigma
behavior-shaping constraint designed into a process to prevent incorrect operation by the user. A simple poka-yoke example is demonstrated when a driver of the car equipped with a manual gearbox must press on the clutch pedal (a process step, therefore a poka-yoke) prior to starting an automobile. The interlock serves to prevent unintended movement of the car. Another example of poka-yoke would be the car equipped with an automatic transmission, which has a switch that requires the car to be in "Park" or "Neutral" before the car can be started (some automatic transmissions require the brake pedal to be depressed as well). These serve as behavior-shaping constraints as the action of "car in Park (or Neutral)" or "foot depressing the clutch/brake pedal" must be performed before the car is allowed to start. The requirement of a depressed brake pedal to shift most of the cars with an automatic transmission from "Park" to any other gear is yet another example of a poka-yoke application. Over time, the driver's behavior is conformed with the requirements by repetition and habit. History[edit] The term poka-yoke was applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent human errors.[5] Shingo redesigned a process in which factory workers, while assembling a small switch, would often forget to insert the r
Events Submit an Event News Read News Submit News Jobs Visit the Jobs Board Search Jobs Post a Job Marketplace Visit the Marketplace Assessments Case
Mistake Proofing Levels
Studies Certification E-books Project Examples Reference Guides Research Templates Training Materials & error proofing vs mistake proofing Aids Videos Newsletters Join71,844 other iSixSigma newsletter subscribers: MONDAY, OCTOBER 10, 2016 Font Size Login Register Six Sigma mistake proofing lean Tools & Templates Poka Yoke How Mistake Proof Are Your Processes? Tweet How Mistake Proof Are Your Processes? Kerri Simon 24 It was a Japanese manufacturing engineer named Shigeo https://en.wikipedia.org/wiki/Poka-yoke Shingo who developed the concept that revolutionized the quality profession in Japan. Originally called "fool proofing" and later changed to "mistake proofing" and "fail safing" so employees weren't offended, poka yoke (pronounced "poh-kah yoh-kay") translates into English as to avoid (yokeru) inadvertent errors (poka). The result is a business that wastes less energy, time and resources doing things wrong https://www.isixsigma.com/tools-templates/poka-yoke/how-mistake-proof-are-your-processes/ in the future. What Is Poka Yoke? Poka yoke is one of the main components of Shingo's Zero Quality Control (ZQC) system – the idea being to produce zero defective products. One way this was achieved is through the use of poka yoke; a bunch of small devices that are used to either detect or prevent defects from occurring in the first place. These poka yoke methods are simple ways to help achieve zero defects. Who Develops Poka Yokes? Here's the beauty of the methods…anyone, from manager to line supervisor to line employee can develop a poka yoke. (Alright for you transaction people out there…anyone, from regional sales manager to sales associate to document specialist). All it takes is the empowerment of employees, as well as a little instruction around what makes a good poka yoke. What Does a Poka Yoke Look Like? Poka yoke looks different in each situation. I'll try to present a few different scenarios for poka yoke use. Let's take a transactional situation and analyze a few parts of it. Say, for
Team Partners Careers Contact Us E-LEARNING & CERTIFICATION e-Learning Home Course Catalog New to e-Learning? Training for Deployments Training https://www.moresteam.com/toolbox/error-proofing.cfm for Individuals Blended Black Belt Black Belt Green Belt Transactional Green http://www.six-sigma-material.com/Mistake-Proofing.html Belt Yellow Belt Master Black Belt Compare Belt Courses Lean Methods Kaizen Leader Design for Six Sigma (DFSS) Short Courses Language Options Certification Home Black Belt Certification Green Belt Certification Master Black Belt Certification SOFTWARE & TECHNOLOGY Software Web-based Data Analysis- EngineRoom Desktop Data Analysis- mistake proofing EngineRoom for Excel Simulation- Process Playground Training Simulations New to Simulations? SigmaBrew DMAIC SigmaBrew InBox Learning Lab - St. Sigma Sherlock Holmes Zombie Hunter Enterprise Technology Project Tracking - TRACtion Online Testing - Crucible Admin Tools - Wave Machine BLENDED LEARNING Blended Learning Home Blended Learning Basics The Playbook Research Examples KNOWLEDGE CENTER All Free Resources error / mistake New to Lean Six Sigma? Webcasts Toolbox (Tutorials) Papers & Articles The Playbook SigmaPedia Metrics Lean Resource Center Blog Newsletter MORESTEAM UNIVERSITY Student Login Support Center Alumni Network SUPPORT > Knowledge Center > Toolbox > Error-Proofing Error-Proofing Definition: Error-proofing refers to the implementation of fail-safe mechanisms to prevent a process from producing defects. This activity is also know by the Japanese term poka-yoke, from poka (inadvertent errors) and yokeru (to avoid) - pronounced POH-kuh YOH-kay. Although this common-sense concept has been around for a long time, it was more fully developed and popularized by Shigeo Shingo in Japan. The philosophy behind error proofing is that it is not acceptable to make even a very small number of defects, and the only way to achieve this goal is to prevent them from happening in the first place. In essence, error-proofing becomes a method 100% inspection at the source rather than down the line, after additional value has been added (wasted). Achieving extremely high levels of process capability requ
The concept was first put to widespread use by Shigeo Shingo within the Toyota Production System (TPS).Objective:PREVENT a defect from occurring and when this is not possible, DETECT the defect every time one occurs. There are various levels, effort, and costs of error proofing. The team needs to identify the optimal states and examine feasibility of implementation in the new product or process KPIV's. He recognized three types of poka-yokes: Contact method - identifies defects by testing product characteristics.Fixed-value - a specific number of movements every time.Sequence method - determines if procedure were followed. Defects found in later operations or steps of a process have more costs associated with them. There are more materials, labor, overhead, previously reworked product that are at risk. Ultimately if the product gets to the customer as a defect, the intangibles, such as reputation, can exceed the tangible cost.For example, a carbon monoxide detector will not be as effective if the inputs of dangerous and tolerable PPM levels are not known, or if the proper location for installation is not clear.GOOD: Detect defect before proceeding to next step.BETTER: Detects defects while in process at an operation.BEST: Prevent defects from occurring at all.Each process should have error-proofing to ensure defects are not passed on to the next step and that each operation has mistake proofing in place to ensure only defect free parts are accepted in. Connection to the FMEA The FMEA has three categories of:1) Severity2) Detection3) OccurrenceMistake Proofing is applied to reduce the scores in Detection and Occurrence.Once a mistake proofing device or method is proven it is important that the GB/BB follow up with the Quality Department to update the company FMEA if applicable. Risk reduction is another soft savings benefit from a Six Sigma team (reducing the RPN number of a failure mode).The Six Sigma team also updates their own project FMEA and this becomes the Revised FMEA in the CONTROL phase. Examining the Cost of Defects Their is an initial cost to implementing poka-yokes just like their is a significant cost to implementing SPC. However, this cost will be more than offset in the long term stability and perf