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