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Mistake Proofing or Poka-Yoke

2. Understand why mistake proofing is important to reducing defects and variationUnderstand the use of mistake proofing (poka-yoke) strategiesKnow how to design and implement a poka-yoke strategy. In This Module We Will... Objective. 3. Poka-yoke: to avoid (yokeru) inadvertent errors (poka). Wh

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Mistake Proofing or Poka-Yoke

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    2. 2 Understand why mistake proofing is important to reducing defects and variation Understand the use of mistake proofing (poka-yoke) strategies Know how to design and implement a poka-yoke strategy

    3. 3 What is Poka-Yoke? Shigeo Shingo developed it to achieve zero defects Translated into “ mistake-proofing”(“fool-proofing”) Used to avoid inadvertent errors Worker originated components: Source inspection 100%inspection Immediate action

    4. 4 Poka-Yoke Zero Defects Zero defects can only be a reality when 2 basic concepts are in place, namely: A focus on controlling the factors which cause errors rather than on correcting the resulting defective output Inspection which is effective and tireless

    5. 5 Everyday Mistake- Proofing

    6. 6 Everyday Mistake- Proofing

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    8. 8 A Good Poka-Yoke A good poka-yoke satisfies the following requirements: Simple, with long life and low maintenance High reliability Low cost Designed for the process conditions Designed to detect the mistake before it happens

    9. 9 Common Examples of Poka-Yoke

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    11. 11 Errors Versus Defects Errors are the cause of defects…an error occurs when the conditions for successful processing are either incorrect or absent Error: a nonconformity before it escapes to another area Defect: an error which has passed to another area Error Defect Processing Error Missing information Incorrect job set up Late delivery

    12. 12 Errors Versus Defects

    13. 13 Errors Versus Defects

    14. 14 Common Types of Human Errors Forgetfulness (not concentrating) Errors due to misunderstanding (jump to conclusions) Errors in identification (view incorrectly … too far away) Errors made by untrained workers Willful errors (ignore rules) Inadvertent errors (distraction, fatigue) Errors due to delay in decision-making Errors due to lack of standards(written & visual) Surprise errors (machine not capable, malfunctions) Intentional errors (sabotage – least common)

    15. 15 Guidelines For Mistake-Proofing Describe the defect or potential defect including the rate Identify where (operations) the defect is likely to occur Analyze current tasks associated with the operation (relative to the standard) Identify error conditions contributing to the defect Apply 5-why analysis to the error conditions to determine root causes Identify ( using a team approach) mistake-proofing strategies Verify the efficiency of the mistake-proofing actions(simulate the error)

    16. 16 Mistake Proofing Strategies

    17. 17 Advantages of Mistake-Proofing No formal training programs required Eliminates many separate inspection operations Relieves operators from repetitive tasks Promotes creativity and value adding operations Contributes to defect free work Effectively provides 100% internal inspection without the associated problems of human fatigue and error Often very cost effective to implement

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    19. 19 Workshop

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