The Sixth Sigma

SME on poka yoke techniques.

Pokayoke, or mistake proofing, focuses the mind on the reduction of errors by designing them out of the product or process.  What could go wrong?  The most likely or prevalent mistakes should be engineered out.  This is especially helpful for your customers, who will appreciate a thoughtful design.  Not only will you lower defects.  Customer satisfaction will be higher and your reputation will rise in the marketplace.  …

…   “Good Poka Yokes include things like keyed plugs and sockets that prevent the wrong connectors being fitted together or fitted the wrong way round, or asymmetrical hole patterns in matching plates so they can only be screwed together the right way round … “   …

via Cambridge Network: Insight on Poka Yoke Techniques.

[youtube=http://www.youtube.com/watch?v=p7VFcC4sNY4&hl=en&fs=1&]

Simple tools are illustrated to prevent mistakes, using poka-yoke techniques.

Open position requires kaizen understanding …

… “Requires a BS in Engineering and a minimum 5-9 years of experience in a manufacturing environment with heavy emphasis cost savings through improved processing. An understanding of Cellular Manufacturing, KanBan, Kaizen, Take time, Single Part Flow, Visual management, Poka-Yoke and 5′s required. ” …

Via Spokesman Review: Link

Rebecca Morgan explores the concept of poka-yoke or mistake proofing to proactively drive to high quality and low defect levels. …

Mistake-Proofing: Six Sigma PokaYoke: Via Fresh Inc.: Getting the Laundry Out …

… “In the last century we even decided that quality should be treated as a science and created the profession of quality management. Since then we’ve developed tools like quality circles, total quality management, statistical process control, and Six Sigma, all designed to help us reach the nirvana of zero defects. ” …

A Brief Tutorial: “An example cited by Shingo early in the development of poka-yoke shows how finding mistakes at a glance helps to avoid defects. Suppose a worker must assemble a device that has two push-buttons. A spring must be put under each button. Sometimes a worker will forget to put the spring under the button and a defect occurs. A simple poka-yoke device to eliminate this problem was developed. ”

Via Automation World Article: Pokayoke Sensing For Color (Features): “Pokayoke is a lean manufacturing technique by which mistake-proofing devices are used to keep errors from turning into defects. Tom Rosenberg, industry manager at sensor manufacturer Balluff Inc., in Florence, Ky., defines the term further as a system that is always checking. It’s making sure the part is manufactured correctly before proceeding to the next stage of manufacture. ”

The 7 Wastes of Lean: “These kind of issue can be tackled using mistake proofing methods (Pokayoke) and by understanding the machine process capabilities of the production equipment. Statistical process control (SPC) will also help monitor production outputs and give warning of problems before they occur.”

ZeroDefect Manufacturing: Subaru Committment: In the latest brochure for the 2006 B9 Tribeca, Subaru highlights its benchmark development and manufacturing process. Subaru of Indiana Automotive, Inc. manufactures the B9 Tribeca for the global market and made a major investment in retooling the factory. A zero defect process is used to ensure quality and customer satisfaction. Quality checks are built into every step of the assembly process and pokayoke control boxes to track the process steps. Also, a significant investment in robotics was made to increase the flexibility in manufacturing. …

PokaYoke Human ErrorProof System: Via Autoworld: Proton Tanjung Malim Plant – Building The Next Generation of Cars …

… “A Human Error Proof (POKAYOKE) System in the assembly equipment is installed in critical and safety related torque devices (bolts, nut runners, wrenches, etc). Any operation missed by the operator will cause the line to stop automatically and the operator will need to manually reset the torque. ” …

Cell Design and Pull Systems 160 …

… “A Japanese term meaning mistake proofing. An example of pokayoke would be a machine designed so that parts can be fixtured only in the correct position. ” …

Via KEYENCE America: POKA-YOKE Methodology Using Bar Codes : Bar Code Reader …

Reference guide on pokayoke using barcode approach …

… “POKA-YOKE Methodology Using Bar Codes. ” …

Via Levinson Productivity Systems: Poka-Yoke (Error-proofing)

… “The idea is to prevent mistakes as opposed to relying on operator vigilence. (A work instruction that calls for operator vigilence is a sign that the job can be improved by error-proofing.) ” …

PokaYoke Before Defects Occur: Via QUICK Update – Entire Issue

… “Pokayoke refers to any device that can check critical part dimensions and provide feedback so that the process can be immediately improved before any defects are made. ” …

PokaYoke in Manufacturing Processes: Via Arvin Sango: Products: How can we make this better?

… “To assist with quality control, we employ Pokayoke — fail-safe technology that guards against defects. Pokayoke finds possible faults in the manufacturing process before they occur. Constant evolution and refinement of manufacturing processes eliminates waste and operator error. ” …

Pokayoke Japanese Principle: Via Vink: Cast Polyamide in colours: what’s the use?

… “The second reason coloured cast polyamide gains popularity is the Japanese principle of Pokayoke. Poka stands for accidental mistakes, yoke for avoiding and reducing these mistakes. Pokayoke prevents accidental mistakes through smart processes, product designing principles and technical precautions. Using different colours on products and throughout processes is a way of using pokayoke. ” …

Automotive Manufacturing Pokayoke: Via TACO Group: Tata Ficosa Automotive Systems Limited

… “Multi-stage fully automatic assembly and stage-wise testing lines like the Pokayoke system have been successfully installed and commissioned for outer rear-view mirrors and command and control systems. ” …

Pokayoke Quality Assurance Technique: Via Inside Outcomes July 2002

… “Pokayoke is a quality assurance technique developed by a Japanese manufacturing engineer to eliminate defects in a product by preventing or correcting them early. The Pokayoke system is an important step in Eaton’s efforts to significantly improve quality control by verifying each step of assembly. Eaton installed the system to increase production, reduce waste and maintain electronic records for heavy-duty truck transmissions produced by the facility. ” …

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