Process Error Proofing
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Mistake Proofing Examples
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Error Proofing Vs Mistake Proofing
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Mistake Proofing Levels
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 front of the garage. When you close a
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Mistake Proofing Examples In Manufacturing
& Aids Videos Newsletters Join71,734 other iSixSigma newsletter subscribers: MONDAY, OCTOBER 24, 2016 Font Size Login Register Six mistake proofing principles Sigma 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 https://www.moresteam.com/toolbox/error-proofing.cfm Shigeo 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 https://www.isixsigma.com/tools-templates/poka-yoke/how-mistake-proof-are-your-processes/ wrong 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.
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 Studies Certification E-books Project Examples Reference Guides Research Templates https://www.isixsigma.com/tools-templates/poka-yoke/work-instructions-mistake-proofing/ Training Materials & Aids Videos Newsletters Join71,734 other iSixSigma newsletter subscribers: MONDAY, OCTOBER 24, http://www.six-sigma-material.com/Mistake-Proofing.html 2016 Font Size Login Register Six Sigma Tools & Templates Poka Yoke Work Instructions for Mistake Proofing Tweet Work Instructions for Mistake Proofing Kiran Walimbe 3 1. Use cross-functional teams (CFT) approach to mistake proofing. 2. Selection of process for mistake proofing. During the third phase of advanced product quality planning (APQP), the CFT shall identify the mistake proofing processes, where, due to avoidable human errors, the rating of "occurrence" and/or "detection" have increased thereby increasing the risk priority number (RPN) for the process. Poka-yoke techniques of mistake proofing are applied to these processes in order to lower the ratings of occurrence and/or detection. Analysis of customer complaints also reveals activities which are in need of mistake proofing, in order to achieve a zero defect level of working. mistake proofing examples CFT will undertake application of poka-yoke techniques to these processes. 3. The selected mistake proofing technique should qualify the following criteria: Inexpensive Based upon common sense, preferably of the operator or the first line employee It MUST eliminate occurrence/detection of the problem at the source itself 4. Occurrence oriented poka-yoke should follow the procedure as below: First classify the source of occurrence as follows: Required action is NOT performed or is performed incorrectly. Undesired action is exercised. Information essential for performing the action is mis-interpreted. Mistake occurs due to complexity. After having classified the source, apply one of the following techniques, as appropriate, to prevent the occurrence: Use of 100 percent prevention devices such as fouling pins; contoured locators or templates; proximity or photo-electric sensors; limit- or micro-switches; warning lights or buzzers; or pressure transducers. Design to modify to ensure that in assembly the parts shall not join if aligned wrongly. The machine will not run if operators' hands or feet are not outside, or if the job and tooling are not in right position. These techniques should be integral part of the process. The devices are placed sufficiently close to where the mistakes occur, providing fast feedback to the operator, of mistakes
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 stabilit