Poka-yoke (Mistake proofing)

By -

Poka-Yoke:

Poka-yoke is a Japanese term developed by Shegio Shingo.

Poka-yoke means mistake proofing (error-proofing).

Poka-yoke is to identify and eliminate potential errors before they occur.

Poka-yoke is making mistakes impossible.

Poka-yoke is use of devices or method or designing systems or processes to make mistakes impossible.

Types of poka-yoke:

  1. Contact methods
  2. Fixed-value methods
  3. Motion-step methods

1.Contact methods:

These devices prevent errors by detecting abnormalities or deviations in the process.

Example 1-

A machine may have sensors that signals when a part is not at proper position. 

Machine stops before it can cause a problem.

These Poka-yoke prevents further actions untill part position is corrected.


2.Fixed-value methods: 

These types of poka-yoke are designed with fixed values or constraints that prevent errors to happen. 

Example 1-

A machine may have logics in programming that signals when a tool is wear out after specific number of machining. 

Auto cycle stops for checking the tool condition or tool change confirmation after specific frequency which is derived from past data.

These Poka-yoke prevents further process untill tool wear is confirmed and corrected.

3.Motion-step methods: 

Poka-yoke tools use the operator's body or other interfernce in the way of machine.

It detects and prevents errors by cycle interuption or by no cycle start message.

Example 1- 

A machine starts with two hand control start buttons at a time.As it requires to use two hands to activate a control button, accident will not occur  while one of the hand is in a dangerous position.

Example 2- 

On automated line production, some light sensor curtains are used to avoid door opening, or part declamping by operator while cutting cycle is running.


Benefits of poka-yoke:

  • Poka-yoke prevents mistakes from occurring.
  • Poka-yoke reduces costs.
  • Poka-yoke prevents accidents.
  • Poka-yoke improves quality.
  • Poka-yoke increases customer satisfaction.
  • Poka-yoke reduces breakdowns.

#
Location: India

Comments

Post a Comment

MOST POPULAR

Basic Work Content And Productivity Improvement.

By -
Factors Affecting Basic Work Content -   Basic work content is the minimum time required for production as per standard rate of working with the help of qualified worker and with perfect design and specifications. The heart of the productivity improvement in any manufacturing organisation is depend on its basic work content. Process of manufacturing is affected by some factors associated with basic work content. Following are the factors affecting basic work content and thus on the productivity. 1.Workmen Efficiency: Workmen enfluencing basic work content in following ways-  Careless workemenship  Accidents by workmen. Absentism of workmen. Idleness of workmen. Lateness of workmen. Indisciplined workmen.   2.Management Shortcomings: Management is also responsible for enfluence on basic work content . Some management shortcomings are as - Design changes. Excess product variety Bad planning. Lack of standardization. Plant Breakdowns.   Bad working conditions...
Read more

SMED

By -
SMED: SMED (Single Minute Exchange of Die): SMED  stands for  Single Minute Exchange of Die. SMED (Single-Minute Exchange of Die)  is a Lean tool used in manufacturing to reduce equipment changeover time.  The goal of  SMED  is to complete as many steps as possible while the equipment is running , to save time and quickly change over to processing the next product. The core principles of the  SMED  procedure involve separating changeover elements into two categories. Internal activities and External activities. For  SMED : Internal activities  -  can only be performed when the production process is stopped. External activities-  can be completed while the machine running or upto the actual changeover begins.  SMED  helps in achievement of  rapid setups and minimized downtime by  converting internal activities into external activities. Advantages of the SMED: Reduced changeover times / Reduced Downtime by min...
Read more

5S What is 5S ?

By -
5S : 5 S's meant for: 1st  S - Seiri means Sort. 2nd S - Seiton means Set in Order. 3rd S - Seiso means Shine. 4th S - Seiketsu means Standardize. 5th S - Shitsuke means Sustain. THE GOAL OF 5S - To create a clean and well-organized work environment for ease of operation. To reduce waste, to improve quality. To promote safety. To Encourage people for addressing problems  resulting in a positive change to the organizational culture.  For the quick set-ups in clean and well organized workplace. To improve equipment reliability. THE ELEMENTS OF 5S  - 1. SEIRI (SORT) -  Elimination of things that are not really needed at the work place. 2. SEITON (SET IN ORDER) -  Systematic Organization of the items remained after sorting. 3. SEISO (SHINE) -  Sanitizing ,Cleaning and Inspection of the work area. 4. SEIKETSU (STANDERDIZE) -  Standardization that means to create Standards. 5. SHITSUKE (SUSTAIN) - Self descipline that is ensure the regular application ...
Read more

JIT and Advantages Of JIT (Just In Time) Manufacturing.

By -
JIT and Advantages Of JIT (Just In Time) Manufacturing: JIT (Just In Time) manufacturing is very benificial for lean manufacturing. The benifits of JIT for manufacturing industries are a lot. Some of the advantages of JIT in manufacturing are as follows- Lesser Cost Of Production. Less working capital is required to finance for procurement.  Minimum re-order level. Works on a demand-pull basis, in the volatile and unpredictable market demand. Inspection costs and Rework costs are minimized. High customer satisfaction due to constant communication with the customer. Reduction in Manufacturing Lead Time and Increased Conformance to Delivery Lead Time. Reduction in Inventory Investment and Increased Investment Savings. Increased Revenue and High ROI (Return On Investments). Increased Response Speed to Market Needs. Close relationships and Improved Workforce Morales. Uncovering of Problems. Keeps stock holding costs minimum and better space utilization with Low or No warehousing cost. ...
Read more

Total Quality Management (TQM)

By -
WHAT IS TQM ? (Total Quality Management) 1. TQM is the management approach for the organization which aims for the continuous improvement in the products and services for the customer satisfaction with all employee involvement as the whole and taking into consideration the quality at center as the way for long term success of organization and improvement of the employees. 2. TQM is the Quality improvement with continuous efforts ,systematic analysis and improved work processes. THREE THEMES OF TQM - 1.The Customer 2.The Process 3.The Employees. PRIMARY ELEMENTS OF TQM- 1.Customer Focused. 2.Total Employee Involvement. 3.Process Centered. 4.Integrated System. 5.Strategic & Systematic Approach. 6.Fact Based Decision making. 7.Continual Improvement. 8.Communication LEADERS OF TQM- I MPORTANCE OF TQM - #Customer satisfaction #Team building #Reduction in customer complaint #Reduction in rejection rate #Helps to face competition #Better motivation to employees #Better facilities to emplo...
Read more

Lean management in COVID-19 vaccine production.

By -
L ean management in the pharmaceutical industry and COVID 19. The pharma companies manufacturing the vaccine for  Covid-19 has to follow strictly the lean manufacturing principles to eliminate non value added work so as to achieve the demand raised in this panademics of COVID-19 . For the organizations like Serum Institute of India, Lean Manucturing tools will help to do value added acts every time so as to meet the demand of vaccine in India and other countries. On time and quality production of vaccine with reduced associated costs will help the organizations like SERUM & PFIZER to meet the expectations of people of the whole world's  and high demand. Also Lean tools will results in reduced prices of the vaccine. The pharma industries must achieve Zero Losses due to downtime & minor stoppages so as to meet the demand of vaccine. Reduced manufacturing cost is going to help to provide the vaccine to the Governments with reduced cost and so the distribution amongst the ...
Read more

PPE (Personal protective equipment)

By -
PPE : PPE full form : Personal Protective Equipment. PPE means Personal Protective Equipment. Personal protective equipment (PPE) refers to protective clothings, helmets, gloves, face shields, goggles, facemasks, earplugs, muffs, coveralls, vests, full body suits,  high visibility suits, safety harnesses, respirators or other equipments designed for protection from injury ,infection, illnes or exposure to a variety of hazards. Why PPE: To promote good Hygiene To prevent Hazards To reduce spread of infection To enhance workplace safety To protect Lives   To comply businesses with regulatory requirements(e.g., The Personal Protective Equipment at Work Regulations 1992) To improve employee efficiency. Types of Protection: 1) Respiratory Protection: Protection against the adverse health effects caused by breathing contaminated air. Examples:Respirators. 2) Eye & Face Protection: Eye and face protection from the hazards of  hot sparks, and chemical splashes  flyi...
Read more

Industrial safety

By -
Industrial safety - Industrial safety  leads to ZERO ACCIDENT GOAL   of every organisation. Everyone working in the industries must follow Industrial safety rules. Creating and maintaining protective, safe and efficient workplace environment is the major role played by Industrial safety Management team. Workplace safety is very important for each and every employee to work in a safe and protected atmosphere. What is meant for term  safety  in  Industrial safety? Safety means a state of being safe from the risk of loss or danger. Safety plays a vital role in industry by protecting employees and assets by minimizing hazards, risks, accidents, and near misses. Safety is a condition that gives you freedom from hazards, risks, and accidents that may cause injury, damage, loss of material or property damage, and even death. Elimination of hazard is also known as safety.  Safe and healthy workplace protects workers from injury and illness which reduces absen...
Read more

Bottleneck in production process.

By -
BOTTLENECK IN PRODUCTION PROCESS- Bottleneck in production process , is a process whose limited capacity reduces, delays or stops the flow of operation and affects the capacity of overall manufacturing processes.   Almost every system has a bottleneck . The machine with the longest queue of accumulated input for processing is usually a bottleneck in production process. It is important to identify the bottleneck machine or process and to remove or reduce the waiting time for next operation so as to achieve the desired targets in manufacturing processes. Here discussed the various types of   bottleneck in production process. Types of Bottleneck in production process: 1.Short-term Bottleneck:  These are caused by temporary problems.  Short-term bottlenecks  do not need regular attention. 2.Long-term Bottleneck:   Long-term bottlenecks occur all the time. These have substantial impacts on the overall manufacturing processes.  Long-term bottl...
Read more

How to eliminate bottleneck.

By -
How to eliminate bottleneck. In previous artcle we discussed about bottleneck in production process. Now we will see How to eliminate bottleneck ? How to eliminate bottleneck is very important in manufacturing. Bottleneck removal in lean manufacturing is a very crucial task for management. How to eliminate bottleneck in manufacturing is important not only for productivity but also for smooth operations flow on line. For reducing WIP on production line, it is the important question that... How to eliminate bottleneck? Bottleneck analysis is important for the bottleneck elimination in manufacturing. How to eliminate bottleneck  in production line without having much inventory in process line is target for management.  Following are some goals of the bottleneck analysis. GOALS OF THE BOTTLENECK ANALYSIS : Identification of the key bottlenecks in manufacturing process. Relevant quantitative data collection for bottlneck analysis. Exploring possible solutions for bottleneck root c...
Read more