poka yoka
TRANSCRIPT
POKA-YOKEpresent
Goutam Kumar
Toyota 1st car
PIBM, Pune
History
The term poka-yoke was applied by Shigeo Shingo’s in the 1960s
1919 to 1991
Poka-yoke is a Japanese word that means "fail-safing" or "mistake-proofing".
A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes .
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
Poka-Yoke was developed by Shigeo Shingo from Toyota Motor as a tool to achieve Zero Defects.
• The process of Zero Defects is also known as “Mistake Proofing” or “Fail-Safe”.
Old type’s Lift Set by engineer in a
building&
Its maximum weight
capacity is 200 kg
Weight 50kg
Weight 60 kg
Weight 90 kg
Lift capacity=People weight
Total lift capacity =200
If more people enter the lift then
weight will increase, which
increases the possibility of
break down of lifts wire because
there is no warning
mechanism on excess weight .
Latest lifts are very advanced, because
when it is over weight the alarm will start & indicate light , until
weight is not reduced This is done through
poka yoke
Lift move without
any fault.
Here people want lift but he /she
can’t use , why ?Because lift can’t run on
overload. People want but they can’t use. This is good
for our safety, so here no any defect comes out .
This is also called zero defect.
Key principle
Error is inevitable but can be eliminated
Before Poka yoke After Poka yoke
Where I put my
keyboard cable ???
To achieve quality, it has to be designed into the product
If I want to build good quality product we should use good quality material.
Mistake provides an opportunity for improvement and errorAAA,
Next time I will not
do
Mishaps/error/problem/crisis are the results of inadvertent negligence of small little things(small things) by some one in the chain.
Cent percent inception deployed at the end-of-the line cannot solve the problem of defects
Cent percent inception cannot ensure 100 percent quality
1ST GENRATION COMPUTER 2ND GENRATION
COMPUTER
3RD GENRATION COMPUTER 4TH GENRATION
COMPUTER
The faster we discover the problem, the easier and less expensive it is to correct it.
Characteristics of poka yoke
Fail safe machine for quality control
Poka yoke proofing is
powerful because its every part is connected to a digital signal so
when any fault is found signal is
passed
simpleinexpensive
comprehensive
Advantage of poka- yoke
Element rejection and rework.
Reduce transport, handling, and rerouting of job.
Let’s take a tea break
where I am at fault?
Free a person’s mind from maintaining repetitive vigil.
Build up
moral on the floor
Creates extra capacity which is otherwise wasted due to rework
and rejection
Improve productivity of the process
Thanks