Introduction_to_Poka_YokeContinuous improvement to Zero Quality Control.ppt

Poka-yoke and Jidoka:  Continuous improvement to Zero Quality Control
Introduction to Poka Yoke
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Quality and Human Error
“To err is human…”…Alexander Pope
Human beings make mistakes, human beings sometimes forget.
If you rely on a human being to produce quality product and not make a mistake or not forget sometimes…..
Then you really do not care to make a quality product.
ADDRESS QUALITY ISSUES THROUGH THE PROCESS.
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Evolution of Key “Lean” Concepts
1945: Just In Time
1948: Pull: Withrawal by subsequent processes
1953: “Supermarket” systems
1947: Dual machine handling, “L” shaped layout
1953: Work cells in “U” shaped layouts
1950: Multi (3-4) machine handling, rectangular or “U” shaped layout
1955: Water spider concept
1962: Kanban, company wide, internal
1965: Kanban, external suppliers
1950: Andon, visual control
Set-up reduction: internal & external, 1st stages of SMED: 1950
Shigeo Shingo begins consulting relationship with Toyota: 1954
Inspired by Toyota “Foolproofing” measures, develops methodology to apply techniques to source inspection: 1965
SMED methodology formalized: 1969
1950: Fool proofing techniques and the concept of “autonomation”(Poka-yoke)
“Zero Defects” concept: 1975
Zero Quality Control concept: 1977
Shigeo Shingo
Toyota &
Taichii Ohno
= Concepts related to Poka-yoke
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Contents
Introduction to Poka-yoke and types of inspection systems
Poka-yoke Systems
Poka-yoke mon Mistake Proofing Devices
Poka-yoke exercises
Shingo Quiz
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Poka-yoke and Jidoka: Simple & Clear
Poka-yoke: Poka-yoke prevents defects from being made
Jidoka: Prevents defects from being passed on to the next step in the process
Human Inspection Human Intervention Mistake Proofing
with machine assist
Toll-gate
Inspection
at Finished Goods
or the end of main processes
In-Process
Inspection
Final Inspection may decrease, operators may do required process inspections
Visual Inspection
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Jidoka
The beginning of autonomation - significan