+ All Categories
Home > Documents > Sps0650en Poka Yoke

Sps0650en Poka Yoke

Date post: 14-Apr-2015
Category:
Upload: patimasv4875
View: 212 times
Download: 12 times
Share this document with a friend
8
Faurecia Excellence System Check that this is the latest version of this document. Group Quality Department Quality System Efficiency The 6 Quality Basics -> Poka Yoke Purpose: Poka Yoke methodology Scope: all production sites FAU-S-PS-0650 / EN issue 01
Transcript
Page 1: Sps0650en Poka Yoke

Faurecia Excellence System

Check that this is the latest version of this document.

Group Quality Department

Quality System Efficiency

The 6 Quality Basics -> Poka Yoke

Purpose: Poka Yoke methodology

Scope: all production sites

FAU-S-PS-0650 / EN issue 01

Page 2: Sps0650en Poka Yoke

- 2/ 8FAU-S-PS-0650 / EN issue 01

1 – Definition

A poka-yoke is a simple and reliable device that physically prevents:either the error leading to the defect or the transmission of the defect to the next workstation

Of course, not producing the defect in the first place is always preferable to detecting the defect afterwards. (An once of prevention is worth a pound of cure, as they say.)

There are two types of poka -yoke: Product: based on inherent product characteristics such as shape or symmetryProcess: based on certain product characteristics in order to avoid errors in the manufacturing process.

The poka-yoke must be permanent .

The poka-yoke must be “foolproof” (i.e. it must be impossible to bypass).

Only an authorized person (e.g. Gap Leader, Supervisor) may intervene.Situations to avoid: - reset button

- master key- simple disconnection (e.g.from electrical outlet)

The poka-yoke must be foreseen upstream, right from the product/process design phase.

Examples of poka-yokes in everyday life:3.5” diskettes can not be inserted upside down because one corner is cut. If the cut corner is on the wrong side, it hits something and the diskette will not go all the way in.In an ATM (cash dispenser), you have to remove your credit card before you can get your money. This prevents you from forgetting your card in the machine.

Page 3: Sps0650en Poka Yoke

- 3/ 8FAU-S-PS-0650 / EN issue 01

2 - Examples

PRODUCT poka-yoke:

Example: guide pins of different shapes and/or sizes

PROCESS poka-yoke :

Example: poka-yokes are built into the process to check that an operation has been properly performed:

Without poka-yokes: defect possible (reversed assembly)

With poka-yokes: defect cannot be created

Screw-counter. If a screw is missing or there is insufficient torque, the part is prevented from moving on to the next workstation.

The conveyer stops automatically if the seat is in the wrong position for delivery (headrest too high).

Page 4: Sps0650en Poka Yoke

- 4/ 8FAU-S-PS-0650 / EN issue 01

3 – Identification of Process Poka-Yoke

To improve identification and tracking of process poka-yokes, each one is given a reference number and represented on the plant layout diagram as shown:

FINAL INSPECTION

PKY 001

PKY 002

PKY ___

Page 5: Sps0650en Poka Yoke

- 5/ 8FAU-S-PS-0650 / EN issue 01

4- Visual Management

This red symbol is PERMANENTLY fixed to the machine

Red means the poka-yoke is out of order.

The label shows the poka-yoke number and the parameter that must be inspected 100%.

The system must be repaired within 8 hours of the breakdown. If necessary, a spare parts stock is created.PARAMETER:

OUT OF ORDER100 % INSPECTION REQUIRED

PKY002

Green means the poka-yoke works properly.

Validation must take place before applying this symbol.

The label shows the poka-yoke number and the parameter that is under control.

PARAMETER:

WORKING

PKY002

This symbol must be visible and accessible to the operator, who is responsible for visual management

=ON PARAMETER :

IN ORDER

PKY002

No inspection of this characteristic

The poka-yoke works

The poka-yoke doesn’t work

= ON PARAMETER :

OUT OF ORDER100 % INSPECTION REQUIRED

PKY002

100 % Inspection

Page 6: Sps0650en Poka Yoke

- 6/ 8FAU-S-PS-0650 / EN issue 01

5- Validation and capitalisation

Validation:

Each poka-yoke has a dedicated validation sheet :(FAU-F-PS-0222) specifying:parameter or critical characteristic validation method: master part (correctly identified), description of incorrect operation

It is the operator who validates poka-yokes:at each start-up: start of shift or after breakdown (see guide “OK 1st part")using validation sheet FAU-F-PS-0222

As soon as the operator sees a poka-yoke malfunction, s/he must immediately notify the Supervisor. The operator logs the time of the malfunction in order to organize an inspection of all the parts produced up to this point.

The operator must be trained to conduct 100% inspection of the parameter when the poka yoke fails.

Capitalisation:

Each poka-yoke has a definition sheet (FAU-F-PS-0221). This document is managed and updated by the UAP Quality correspondent and contains the following information:

Detection methodLocationExplanation of improvementsEffects and costs

Page 7: Sps0650en Poka Yoke

- 7/ 8FAU-S-PS-0650 / EN issue 01

Appendix: suggestions for designing Poka-Yokes

Identify objects by characteristics such as:weightdimensionsshape

To detect operator deviation or errors, use devices:with physical contact (e.g. contactor, lever) without physical contact: photo-electric cells (transmission, reflection)

To detect deviation from set values, use measurement systems:pressure,temperatureelectricity (voltage,amperage)vibrationrpmdata transmission

Page 8: Sps0650en Poka Yoke

- 8/ 8FAU-S-PS-0650 / EN issue 01

General Information

Author :Group QSE

Date : 12 January 2004

Aim of the modification:Complete revision of the previous version

Cancels and replaces:• FAU S PS 0220

Associated documents:• FAU S PS 0610• FAU S PS 0620• FAU S PS 0630• FAU S PS 0640• FAU S PS 0660• FAU F PS 0221• FAU F PS 0222


Recommended