Lean Error Proofing
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Mistake Proofing Examples Ppt
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Mistake Proofing Examples In Manufacturing
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 requires this type of focus on prevention rather than detection. You may not realize it, but you probably encounter many examples of error-proofing in your every-day life, as outlined below: Examples From Every-Day: The brake-shift interlock device on your automatic transmission vehicle prevents you from starting the engine unless the brake is depressed and the shift selector is in park or neutral. A tennis ball hung from a screen in your garage can make parking easier, and avoid crashing into items stored at the fr
occur or makes the error immediately obvious once it has occurred. When to Use Mistake Proofing When a process step has been identified where human error can mistake proofing levels cause mistakes or defects to occur, especially in processes that rely on "poke yoke" the worker’s attention, skill or experience. In a service process, where the customer can make an error which
Mistake Proofing Principles
affects the output. At a hand-off step in a process, when output or (for service processes) the customer is transferred to another worker. When a minor error early in the https://www.moresteam.com/toolbox/error-proofing.cfm process causes major problems later in the process. When the consequences of an error are expensive or dangerous. Mistake–Proofing Procedure Obtain or create a flowchart of the process. Review each step, thinking about where and when human errors are likely to occur. For each potential error, work back through the process to find its source. For each error, think of http://asq.org/learn-about-quality/process-analysis-tools/overview/mistake-proofing.html potential ways to make it impossible for the error to occur. Consider: Elimination—eliminating the step that causes the error. Replacement—replacing the step with an error-proof one. Facilitation—making the correct action far easier than the error. If you cannot make it impossible for the error to occur, think of ways to detect the error and minimize its effects. Consider inspection method, setting function and regulatory function. Choose the best mistake-proofing method or device for each error. Test it, then implement it. Three kinds of inspection methods provide rapid feedback: Successive inspection is done at the next step of the process by the next worker. Self-inspection means workers check their own work immediately after doing it. Source inspection checks, before the process step takes place, that conditions are correct. Often it’s automatic and keeps the process from proceeding until conditions are right. Setting functions are the methods by which a process parameter or product attribute is inspected for errors: The contact or physical method checks a physical characteristic such as diameter or temperature, often using a sensor. The motion-step or seque
Heating Dies/Die Materials Simulation/IT Handling QC Advertisement Home > Feature > Lean Error-Proofing for Productivity http://forgingmagazine.com/feature/lean-error-proofing-productivity-improvement Improvement Lean Error-Proofing for Productivity Improvement Error-proofing is an outgrowth of the quality movement, specifically the "zero defects" initiative. It is a team-based, plant-floor improvement http://leanqcd.com/2010/08/factsheet-poka-yoke-error-proofing/ strategy that focuses on production processes and operations. Apr 27, 2007 Subramaniam (Mani) Manivannan | Forging EMAIL Tweet Comments 0 Error-proofing is an outgrowth of mistake proofing the quality movement, specifically the "zero defects" initiative. It is a team-based, plant-floor improvement strategy that focuses on production processes and operations. By Subramaniam Manivannan The Zero Defects Initiative is a team-based plant floor improvement strategy, focusing on production processes and operations. Shigeo Shingo, then an industrial engineer at Toyota mistake proofing examples Motor Corp., introduced the concept of poka-yoke (pronounced POH-kah YOH-kay) in 1961. Shingo's initial term was bakayoke, which means "fool-proofing." In 1963, a worker at Arakawa Body Co. refused to use baka-yoke mechanisms in her work area, because of the term's dishonorable and offensive connotation, and subsequently the term was changed to poka-yoke, which means "error-proofing" or "mistake-proofing." What is Poka-Yoke? A mistake is the execution of a prohibited action, the failure to correctly perform a required action, or the misinterpretation of information essential to the correct execution of an action. Poka-Yoke involves using process or design features to prevent the manufacture of a "non-conforming" product. It may also be a processimprovement system that prevents personal injury, promotes job safety, prevents faulty products, and prevents machine damage. In other words, Poka-Yokes are mechanisms used to mistake-proof an entire process. Ideally, Poka-Yokes ensure that proper conditions exist before ac
Chris Turley Process excellence through Poka Yoke In order to achieve Operational Excellence it is vital to have processes capable of delivering Zero defects. Poka Yoke is the concept of eliminating process errors, ensuring the output is defect free. Eliminating errors and preventing defects not only improves quality but enables improvements in productivity and delivery and increases process capacity. Why do we need Poka Yoke? (Errors Vs Defects) An ERROR is any deviation from the intended process, they can be made by machines or people and can be caused by errors that occurred previously (knock on effect) A DEFECT is a product that deviates from specification or fails to meet the customers expectation. All DEFECTS are caused by ERRORS so ERRORS = DEFECTS If ERRORS can be prevented / eliminated, DEFECTS will not be created The concept of Poka Yoke was developed by the Japanese industrial engineer Shigeo Shingo, who is closely linked to the development of TPS (Toyota Production System) with Taiichi Ohno during the 1950's onwards. Derived from the Japanese words Yokeru, meaning avoiding and Poka, meaning inadvertent errors, Poka Yoke is commonly translated as error or mistake proofing, and has become an integral part of problem solving. Poka Yoke is based on the concepts of Prediction and Detection and clearly targets Zero Defects, Right First Time (RFT) and the reduction of waste. There are 3 methods of Poka Yoke: Contact The contact method is based on detecting the shape, colour or other physical properties or features. Fixed Value The fixed value method is based on the completion of a preset number of actions or movements. Motion Step The motion step method is based on the completion of prescribed steps performed in a sequence by a single person Requirements: • Prevent errors from occurring or immediately detect abnormalities in real time as they occur. • Stop the process from producing further errors. • Address the root cause of the process problem before resuming. What makes a good Poka Yoke: • Robust & Reliable (CRITICAL) • Inexpensive • Easy to implement • Doesn't require continuous attention from the user • Specific to the need • Developed with the user • Simple basic engineer