+ All Categories
Home > Documents > Poko Yoke TQM

Poko Yoke TQM

Date post: 14-Oct-2014
Category:
Upload: prasanna-ganesh
View: 93 times
Download: 2 times
Share this document with a friend
9
POKE YOKE
Transcript
Page 1: Poko Yoke TQM

POKE YOKE

Page 2: Poko Yoke TQM

POKA YOKE is a japanese term which means “Fail safing” and “Mistake Proofing”.

The concept was originated by Shigeo Shingo as part of Toyato production system.

“Poka Yoke means mechanism used to mistake proofing.Ideally Poka Yoke ensures that proper conditions exist before actually executing a process step , preventing defects from occuring in first place”

Page 3: Poko Yoke TQM

Importance: (i) It can be a thought of as an extension of

FMEA

(ii) The use of simple methods in product and process design can eliminate both human and mechanical errors

(iii) The Techniques can drive out defects of products and improve quality and realibility

Page 4: Poko Yoke TQM

When to Use it: It can be used wherever something can

go wrong or an error can be made.

It is a techinique or toolthat can be applied to any type of industry

Page 5: Poko Yoke TQM

Types of Errors:

Processing Error

Set up Error

Missing part

Improper part

Operations Error

Measurement Error

Page 6: Poko Yoke TQM

Poka Yoke Framework:

Prevention Based Poka Yokes:

There are two approaches. They are;

(i) Contral methods – Senses problems or stops a line or process.

(ii) Warning methods – Signals the occurrence of a deviation or trend of deviation through an escalating series of buzzers, lights ect

Page 7: Poko Yoke TQM

Detection Based Poka yokes:

(i) Contact method: This method detects any deviation in shape,dimentional characteristics or other specific defects through mechanism that are kept in direct contact .

(ii) Fixed value method: This method is used in operation ,in which set of steps is sequentially performed .

Page 8: Poko Yoke TQM

Motion step method: This method ensures that a process or operator does not mistakenly perform a step that is no part of normal process.

How to use it:

Identify the operation or process, based on pareto Analyze the 5 whys and understand the ways process fails Decide the right Poka Yoke approach shut out type or attention typeDetermine whether the contact , constant, sequence method is appropriate or not

Page 9: Poko Yoke TQM

Trial the method and see if it works Train the operator , review the performance and measure the success

Benefits of Poko Yoke:

Improved productivityReduced inspection timeIt is the fastest way to zero defectsEliminates scrap, rework,and repairIncreased customer satisfaction and customer loyalty


Recommended