Sunday, July 29, 2018

Poka yoke | know about its history | QSQTECH.COM

POKA-YOKE

Hello friends,
Today, we'll discuss on Poka-Yoke concept. Hopefully, you'll understand this topic.
First of all, 
Thanks for visiting.

 Now, below topics that are covering today.
  • INTRODUCTION 
  • AWARENESS / DETECTION / PREVENTION 
  • OLD WAYS TO PREVENT MISTAKES 
  • BETTER WAYS TO PREVENT MISTAKES 
  • HISTORY. 

Training on Poka-Yoke.pdf  click here yo download.

INTRODUCTION: 

In companies, Poka yoke devices are implement in such places where the chances of mistakes are more. This device is make mistake proof process. It prevents mistakes in any process. This makes work easy and safe. 

Definition: 

Poka-yoke is also called a mistake proofing element.

Poka yoke is a system which prevents the mistakes from happening or if mistakes are happen and immediately catches and after that we correct it.

Mistake proofing (Poka-Yoke) is the activity of awareness, detection, and prevention of mistake which adversely affect :-
  • Our customers & consumers (Defects) 
  • Our employees (injuries) 
And result is zero.

AWARENESS: 

Awareness means knowing about allow the mistakes to our process owner and associates of shop floor. We will make our process or product design such be prepare so that we can prevent or detect the defects easily.

DETECTION: 

Detection means we allowing the mistakes. We are not preventing it, but we install a system that if mistakes are allowing then we catch & detect them and stop them before reaching customer.

PREVENTION: 

Prevention means that we will such changes in design so that any mistake cannot be done by mistakenly. Not allowing the chances for the error to occur within the first place.
Prevention is the best other than.

Example image of Poka yoke.


OLD WAYS TO PREVENT MISTAKES: 

  • Reprimand workers 
  • Give motivational talks to worker              (Tell them to pay attention and be more careful) 
  • Retrain workers 

BETTER WAYS TO PREVENT MISTAKES: 

  1. You should remove the opportunity for error 
  • Improve the process 
  • Make wrong action more difficult 

2. You can't remove the opportunity for error, then,
  • Make it easier to discover the error that does occur. 

HISTORY:

Poka yoke invented by Shigeo Shingo. 
Shigeo shingo (1909-1990) was a Japanese industrial engineer who was considered as the world's leading expert on manufacturing practices and the Toyota Production System. In 1945, at the end of second World war, he started to works at the Japan Management association (JMA) in Tokyo and becoming a consultant focused on the improvement of factory management.

Poka yoke means to mistake proof the process.
The essential idea of Poka yoke is to design your process so that mistakes are impossible or at least easily detect or correct. 

First Poka yoke device: 

Shigeo shingo suggested a solution during visiting in a switch manufacturing plant that became the first Poke yoke device. 
When, Shigeo shingo was visiting in a switch manufacturing plant. Then he saw there the workers during the time of a switch assembly, they pickup a spring from spring box, and after that assembled it in switch assembly. But mostly switches such made in which only one spring assembled instead of two springs. It means that one spring was missing by mistakenly. Then Shigeo shingo provide the best solution for this.

He suggested that :-
A small plate is placed in front of the parts box, and the worker's first task is to take two springs out of the box and place them on the plate.
Then the worker assemble the switch, if any spring remains on the plate, then the worker knows that he has forgotten to insert it.
Then  new procedure completely eliminated the problem of the missing spring.
Poka yoke devices are divided into two major categories:
  1. Prevention 
  2. Detection 

Thank you.

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