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Poka-Yoke: A Strategy For Performance Excellence

Poka-yoke is a method that uses sensors or devices to catch errors before defective parts are manufactured. It was formalized by Shigeo Shingo as part of the Toyota Production System to "foolproof" processes. Poka-yoke can be implemented anywhere in a manufacturing process that could result in errors. The goal is zero defects by establishing controls and processes to produce acceptable products 100% of the time. Poka-yoke systems govern processes with control and warning approaches to shut down or signal issues so operators can correct problems.

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180 views12 pages

Poka-Yoke: A Strategy For Performance Excellence

Poka-yoke is a method that uses sensors or devices to catch errors before defective parts are manufactured. It was formalized by Shigeo Shingo as part of the Toyota Production System to "foolproof" processes. Poka-yoke can be implemented anywhere in a manufacturing process that could result in errors. The goal is zero defects by establishing controls and processes to produce acceptable products 100% of the time. Poka-yoke systems govern processes with control and warning approaches to shut down or signal issues so operators can correct problems.

Uploaded by

Indranil
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd

POKA-YOKE

A Strategy for Performance


Excellence
WHAT IS POKA-YOKE?
 A method that uses sensor or other devices for
catching errors that may pass by operators or
assemblers.
 Poka-yoke will catch the errors before a
defective part is manufactured.
DEVELOPMENT OF POKA YOKE
 The concept was formalized, and the term adopted,
by SHIGEO SHINGO.
 As part of the Toyota Production System.
 It was originally described as BAKA-YOKE, which
means "fool-proofing”.
IMPLEMENTATION IN
MANUFACTURING
 Poka-yoke can be implemented at any step
of a manufacturing process where something
can go wrong or an error can be made
Why is “Zero Defects” an
Important Concept?
Maintain Customer Satisfaction &
Loyalty

Happy Customers mean more sales!

5
Costs of Defects ?

Does it cost more to make processes better ? NO


Making processes better leads to reduced
Rework
Scrap
Warranty costs
Inspection costs

6
What Causes Defects?
Human Mistakes

Simple errors-the most common cause of defects-occur unpredictably.

The goal of ZDQ is zero! Make


certain that the required conditions
are in place and controlled to make
acceptable product 100% of the
time.

7
NINE TYPES OF HUMAN MISTAKES
 Forgetfulness
 Misunderstanding
 Wrong identification
 Lack of experience
 Willful (ignoring rules or procedure)
 Inadvertent or sloppiness
 Lack of standardization
 Surprise (unexpected machine operation, etc.)
 Intentional (sabotage)

8
The 4 Components of ZDQ

ZDQ functions by combining four elementary


components:
1. Point of Origin Inspection
2. 100 % Audit Checks
3. Immediate Feedback
4. Poka-Yoke

9
Poka-yoke Systems Govern the
Process
Two Poka-Yoke System approaches are utilized in manufacturing
which lead to successful ZDQ:
1. Control Approach:
Shuts down the process when an error occurs.
Keeps the “suspect” part in place when an operation is
incomplete.
2. Warning Approach:
Signals the operator to stop the process and correct the
problem.

10
The Six Guidelines to Poka- Yoke Attainment

•Quality Processes – Design “rich” quality processes to achieve zero


defects.
•Utilize a Team Environment- leverage the teams knowledge, experience
to enhance the improvement efforts.
•Elimination of Errors -Utilize a robust problem solving methodology to
drive defects towards zero.
•Do It Right The First Time- Utilizing resources to perform functions
correctly the “first” time.
•Eliminate Non-Value Added Decisions- Don’t make excuses-just do it !
•Implement an Incremental Continual Improvement Approach-implement
improvement actions immediately and focus on incremental
improvements; efforts do not have to result in a 100% improvement
immediately.

11
THANK YOU

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