Poka-Yoke Systems = Mistake Proofing

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Company Confidential

Poka-Yoke Systems POKA-YOKE

POKA
Inadvertent Mistakes

YOKE
To Avoid ( Yokeru )

The Poka-Yoke Concept was developed by Shigeo Shingo, who also developed the SMED System.

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Poka-Yoke Systems POKA-YOKE

Human Errors are usually inadvertent. Poka-Yoke devices help us to avoid defects before they occur, even when human errors are made. Poka-Yoke is a tool that builds Quality into the process and shifts the attention from detection and inspection to building it right the first time.

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Poka-Yoke Systems ERRORS AND DEFECTS

Two Arguments : Errors are Inevitable: Humans always will make mistakes. Errors can be Avoided: Any kind of mistake people make can be avoided one way or another !!

Where Do You Stand?

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Poka-Yoke Systems INSPECTION

Sampling Inspection vs. 100 Percent Inspection: Sampling Inspection: Is an Average Quality Level (AQL) of 0.10% good enough? One Customer in a thousand will get a defective part !! 100 Percent Inspection: Can it efficiently become part of your standard operation?? How??

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Poka-Yoke Systems ZERO DEFECTS

Strategies for Zero Defects: Dont Make Products You Do Not Need!! The more parts you produce, the greater the opportunity for defects to happen. Therefore, make only what you need, when you need it, one piece at a time. Continuous Flow Make sure that continuously value is added to the product until it is a finished product. Build Quality into the Process Put safeguards into the production process to ensure quality. Moreover, standardize the process and always think of mistake proofing. This is where Poka-Yoke comes in!

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Poka-Yoke Systems TYPES OF ERRORS

1. Forgetfulness: Forgetting a step or a part. Safeguard: Checklist, Visual Standard Operating Procedure 2. Errors due to Misunderstanding: Not very familiar with the required operation. Safeguards: Continuous Training, Visual SOP 3. Errors in Identification: Problems in identification or clearness of required steps or parts. Safeguards: Training, Visual Training, Standardization

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Poka-Yoke Systems TYPES OF ERRORS

4. Errors due to Lack of Experience: New Employees. Safeguard: Skill Building & Training, Work Standardization 5. Errors due to Lack of Standards: No clear way to perform the task or job. Safeguards: Standard Operations, Visual Instructions 6. Errors due to Machine Readability: Machine out of spec. Safeguards: TPM , Critical Parts List, Maintain Equipment History List.

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Poka-Yoke Systems TYPES OF ERRORS

Keep in Mind :
Mistakes do happen for many reasons, but almost all can be prevented if we take the time to identify WHEN & WHY they happen and take steps to prevent the recurrence of these errors and mistakes by using a systematic approach to Mistake Proofing aimed at eliminating foreseeable errors.

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Poka-Yoke Systems TYPES OF DEFECTS

Defective Product

Processing Defects

Material Defects

Processing Omissions

Processing Errors

Missing Parts

Wrong Items

Adjustment Errors

Operation Errors

Wrong Piece

Wrong Set-Up

Other Errors

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Poka-Yoke Systems ELEMENTS OF PRODUCTION

Information Material People Methodology / Procedure
The four elements of production determine whether a product is correctly manufactured or not. Defect Free Products are a result of Controlled Standards of Operation in each of these principle areas.

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Poka-Yoke Systems SOURCES OF DEFECTS

There are many sources of defects, the following are a few to look for:

Omitted Processing Processing Errors Set-Up Errors Missing Parts Wrong Parts Processing Wrong Work-Piece Adjustment Errors Tools and Jigs improperly prepared

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Poka-Yoke Systems FIVE BASIC CONCEPTS OF POKA-YOKE

Standardized Guiding Pins Alarms Limit Switches Counters Checklists

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Poka-Yoke Systems POKA-YOKE STRATEGY

Errors
About to Happen Have Happened

Actions

Prevention Prediction Warning

Detection

Focus on this first .

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. and then on this!

Poka-Yoke Systems POKA-YOKE HINTS

Identify Items by their Characteristics:

By Weight: Establish weight standards to determine defective parts by pre-defining the weight for a good part. By Dimension: Length, Width, and Diameteretc. Use jigs, fixtures, stoppers, and limit switches to eliminate errors associated with positioning.

By Shape: Angles, Projections, Position of Holes, Curvature..etc and Identify standards, limit switches, and fixtures.

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Poka-Yoke Systems METHODS FOR USING POKA-YOKE SYSTEMS

There are three main methods for using Poka-Yoke Systems: 1. Contact Methods 2. Fixed-Value Methods 3. Motion-Step Methods Each of these methods can be used with either Control Systems or Warning System. Focus on your end objective and select the proper system accordingly.

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Poka-Yoke Systems CONTACT METHODS

Contact Methods work by detecting whether a product makes physical or energy contact with a single detection device.

Contact Devices :

Micro Switches Limit Switches Displacement Sensors Metal-Passage Sensors A Variety of other Mechanical & Electro-Mechanical devices

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Poka-Yoke Systems CONTACT METHODS

Contact Methods may also be energy sensing devices that do not physically touch the product but sense when something is not in the desired position.

Energy Sensing Devices:

Proximity Switches: Respond to changes in distance from objects and

to changes in magnetic force. Positioning Sensors: Control cylinder strokes or determine screw heights. Transmission Photoelectric Switch: Light beam between two objects detects any obstruction of beam. Reflecting Photoelectric Switch: Responds to light reflected from an object to detect its presence.

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Poka-Yoke Systems CONTACT METHODS

Contact Methods do not have to be high-tech in order to be effective. Some of the best contact devices are passive devices SUCH AS : Guide Pins Blocks Jigs Fixtures

Color Coded Devices

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Poka-Yoke Systems CONTACT METHODS

Rule of Thumb:
Contact Devices often take advantage of parts that are designed with uneven shape, such as a work-piece with a bump or a hole on only one end. Use a Jig that matches the shape or a limit switch positioned to detect an abnormal shape. We can also make design recommendations based upon adaptability to manufacturing.

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Poka-Yoke Systems FIXED VALUE METHODS

Fixed Value Methods are used when a fixed number of parts must be attached to the product or when a fixed number of repeated operations needs to be done at a process station. In this method, a device counts the number of times something is done and signals or releases the product only when the required number is fulfilled.

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Poka-Yoke Systems FIXED VALUE METHODS

The Fixed-Value Method may use Limit Switches that are tripped with each movement. The switch sends a signal to a counter that detects when the correct number of movements has taken place.

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Poka-Yoke Systems MOTION-STEP METHODS

The Motion-Step Methods are used to sense whether a motion or step in the process has been carried out within a certain expected time, such as a machines Cycle Time. Devices normally used in the Motion-Step Method:

Sensors Photo-electric Switches Timers Counters

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Department / Machine : POKA-YOKE SHEET Assembly

Product : Bearing Date : 14 Dec. 2004

Problem : Ball missing.

Poka-Yoke Sheet Sheet Poka-Yoke

Prevent Error

Shutdown Control

Solution : Sensing the difference of weight against standard weight. Key Improvement : Weighing scale installed on line.

X
Detect Error Alarm

Before
No device was present to detect Ball missing from the bearing in the assembly cell.

After
Weighing machine installed on line after Etching station which detects any Ball missing bearing and the transfer plate automatically stops if any bearing comes even with one Ball missing.

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Department / Machine : POKA-YOKE SHEET

Product :

Problem : Solution :

Poka-Yoke Sheet (blank)

Prevent Error

Date :
Shutdown Control

Key Improvement :

Detect Error

Alarm

Before

After

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Poka-Yoke Systems POKA-YOKE 8 MAIN PRINCIPLES

Build Quality into the process. All inadvertent errors and defects can be eliminated. Stop doing it wrong and start doing it right - now !!! Do not think up excuses, think about doing it right. An 80% chance of success is good enough - focus on implementation. Attack defects and errors as a team. Ten heads are better than one - Brainstorm ideas, Discuss, Think. Seek out the root cause, use the 5 Whys.

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Poka-Yoke Systems

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Poka-Yoke Systems TYPES OF SENSING DEVICES

The Sensing Devices used in the Poka-Yoke System can be divided into three broad categories: Physical Contact Sensing Devices Energy Sensing Devices Sensors that detect change in Physical Condition - Pressure: Pressure Gauges - Temperature: Thermometers - Electrical Current: Meter Relays

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Types of Sensors Physical Contact Sensing Devices

limit switches microswitches touch switches trimetrons

line plane

Break

Energy Sensing Devices

photoelectric switches beam sensors transmission types reflection types transmission types reflection types

proximity switches fiber sensors area sensors position sensors dimension sensors vibration sensors displacement sensors tap sensors metal passage sensors color-mark sensors double-feed sensors weld position sensors

Shape

Passage

Color Mismatch

What They Detect

Presence

Measurement

Confirmation of Position

Overlap

Foreign Matter

Damage

Poka-Yoke Systems
PHYSICAL CONTACT SENSING DEVICES
Physical Contact Sensing Devices work by physically touching the product or machine part. In many cases, particularly in automated processes, physical contact sensing devices send an electrical signal when they are touched. This signal can be a command to start or stop a machine or a warning. Here are some common examples: Limit Switches and Microswitches are the most common devices. They are used to confirm the presence and position of objects that touch the small lever on the switch. Touch Switches have the same basic function as a limit switch, but they are activated by a light touch on a thin antenna. Touch switches are more sensitive than limit switches and can detect whether an object is present, properly positioned, broken, or of proper dimensions. Trimetrons are needle-type gauges that send out signals to sound alarms or stop machinery when the conditions they measure are not within acceptable limits.

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Poka-Yoke Systems
ENERGY SENSING DEVICES
Energy Sensing Devices use energy rather than physical contact to determine whether an error is occurring. Here are some examples: Photoelectric switches use beams of light to inspect transparent objects, judge welds, or verify conditions such as proper size and color. Beam sensors use electron beams to verify conditions such as the proper level of liquid in a container or the passage of an object on a conveyor. Proximity switches respond to changes in distance from objects and to changes in magnetic force. Fiber sensors detect motor revolutions, color coding marks, or marks on translucent objects or printed matter. Area sensors detect random breaks in a fixed area, such as hands placed in hazard areas or parts dropping from a conveyor. Position sensors control cylinder strokes or determine screw heights.

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Poka-Yoke Systems
ENERGY SENSING DEVICES
Dimension sensors ensure correct product dimensions. Vibration sensors detect product ejection areas, width distortion, seam position, or start of processing. Displacement sensors detect and measure warping, thickness, and fluid level heights. Tap sensors detect incomplete tap screw machining. Metal passage sensors detect metal in motion. Color-mark sensors detect colored marks or differences in color. Double-feed sensors detect two products fed at the same time. Weld position sensors detect joints such as weld lines in coil stock, seams in pipes and cans, or splices in wires.

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