Diana Howard ASQ CA/RABQSA

1. Quality Tools Diana Howard ASQ CA/RABQSA

2. 1.Poka – Yoke a. Heat sink example2. Four Up Charts 3. Lean Sigma a. Value Stream Mapping 4. Resources Topics of Discussion

3. What is Poka-Yoke? • The phrase Poka-Yoke originates from the Japanese words: yokeru = to avoid poka = inadvertent errors • It is a methodology that is used to strive toward zero defects by either preventing or automatically detecting defects.

4. Guide/Reference/Interference Rod or Pin: Template: Limit Switch/Microswitch: Counter: Odd Part Out Method: Mistake Proofing Devices

5. Sequence Restriction: Standardize and Solve: Critical Condition Indicator: Detect Delivery Chute: Stopper/Gate: Sensor: Mistake Proofing Devices (p. 2)

6. Other Prevention Techniques • Eliminate the Condition • This method isolates the specific characteristic and removes it. For example: Certain non-functional holes cause confusion about where to insert parts during assembly. We simply plug the non-functional holes and eliminate any possibility that they might be used and cause errors. • Redesign for Symmetry • Redesign for symmetry means to revise or modify the appearance or function of a part, tool or fixture so that its opposite sides are identical or nearly identical. In this way they become interchangeable. • Redesign for Asymmetry • This involves revising or modifying the appearance or function of a part, tool or fixture so that its opposite sides are no longer identical. In this way they can no longer be confused and mistakenly interchanged. This is especially useful when a particular orientation is critical.

9. Four – Ups charts • Used for Reporting to management • Graph of measurement over time • Analysis of quarterly data • Issues/causes • Action Items

10. Pre-Ship Acceptance • Great improvement! • Customer intro during quarter( XXXXX volumes ramped during qtr) • Hardware Missing: XXXXXX 9131-0031-0004 Screws • PDC: Misc customers and locations. • Missing: No Common locations or assemblies. • Hardware Missing: Developed UV/black light marker check. Operator to use pen and “Touch for Quality” - QA to audit with black light. Due date: 2/3/06 • PDC: 10 different refdes locations across 8 different assemblies. No common trend. • Missing: Nozzle replacement program instituted and refresher on operator training.

11. Lean Sigma – The combination • Rationale for combined approach • History with concepts since 1996 • Independent successes • Amplified by using both together • Industry trends toward Operational Excellence • The Lean Sigma philosophy: • Utilizes the DMAIC approach • Incorporates Toolsets from both • Guide to faster solution • Maintains accuracy • Provides standardization and improves control 15

12. Lean Sigma

13. What is Value Stream Mapping? A tool used to create a material and information flow of a product or process The value stream includes the following: People Tools Technologies Physical facilities Material and Information flows Policies and procedures

14. Why Value Stream Maps? It helps visualize what may be otherwise un-seen Find the sources of waste and quantifies those wastes so that efforts for reduction can be prioritized

15. Target Waste with Value Stream Maps Lean Manufacturing / Enterprise Long Setup – Apply lean tools (SMED) to reduce set up time Excess Inventory – Apply line balancing (Lean) and Kanban to reduce or eliminate inventory Non-Value Add Value Add

16. Summary • Poka Yoke “Make it fool proof” • 4-Ups Picture representation for Management • Combine Lean and Six Sigma to reduce lead time, increase productivity,reduce WIP, better utilize space.

17. Resources http:isixsigma.com http://en.wikipedia.org Sasa Todorovic Quality Engineer, Black Belt Master “Learning to See” by Mike Rother and John Shook Available at www.lean.org