diana howard asq ca/rabqsa quality tools. 1.poka – yoke a. heat sink example 2. four up charts 3....

Diana Howard ASQ CA/RABQSA

Quality Tools

1.Poka – Yokea. Heat sink example

2. Four Up Charts 3. Lean Sigma

a. Value Stream Mapping

4. Resources

Topics of Discussion

What is Poka-Yoke?

• The phrase Poka-Yoke originates from the Japanese words:

yokeru = to avoidpoka = inadvertent errors

• It is a methodology that is used to strive toward zero defects by either preventing or automatically detecting defects.

Mistake Proofing Devices

1. Guide/Reference/Interference Rod or Pin:

2. Template:3. Limit Switch/Microswitch: 4. Counter:5. Odd Part Out Method:

Mistake Proofing Devices (p. 2)

6. Sequence Restriction:7. Standardize and Solve:8. Critical Condition Indicator: 9. Detect Delivery Chute:10.Stopper/Gate:11.Sensor:

Other Prevention Techniques

• Eliminate the Condition– This method isolates the specific characteristic and removes it. For

example: Certain non-functional holes cause confusion about where to insert parts during assembly. We simply plug the non-functional holes and eliminate any possibility that they might be used and cause errors.

• Redesign for Symmetry– Redesign for symmetry means to revise or modify the appearance or

function of a part, tool or fixture so that its opposite sides are identical or nearly identical. In this way they become interchangeable.

• Redesign for Asymmetry– This involves revising or modifying the appearance or function of a part,

tool or fixture so that its opposite sides are no longer identical. In this way they can no longer be confused and mistakenly interchanged. This is especially useful when a particular orientation is critical.

Four – Ups charts

• Used for Reporting to management

• Graph of measurement over time

• Analysis of quarterly data

• Issues/causes

• Action Items

Graph Analysis

Issues/Causes Action Items

Pre-Ship Acceptance

• Hardware Missing: Developed UV/black light marker check. Operator to use pen and “Touch for Quality” - QA to audit with black light. Due date: 2/3/06

• PDC: 10 different refdes locations across 8 different assemblies. No common trend.

• Missing: Nozzle replacement program instituted and refresher on operator training.

• Great improvement!

• Customer intro during quarter( XXXXX volumes ramped during qtr)

• Hardware Missing: XXXXXX 9131-0031-0004 Screws

• PDC: Misc customers and locations.

• Missing: No Common locations or assemblies.

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Lean Sigma – The combination

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Rationale for combined approach• History with concepts since 1996• Independent successes• Amplified by using both together• Industry trends toward Operational Excellence

The Lean Sigma philosophy:• Utilizes the DMAIC approach• Incorporates Toolsets from both• Guide to faster solution • Maintains accuracy• Provides standardization and improves control

Lean Sigma

What is Value Stream Mapping?A tool used to create a material and information

flow of a product or process

The value stream includes the following:• People• Tools • Technologies• Physical facilities • Material and Information flows• Policies and procedures

Why Value Stream Maps?

It helps visualize what may be otherwise un-seen

Find the sources of waste and quantifies those wastes so that efforts for reduction can be prioritized

Target Waste with Value Stream Maps

Lean Manufacturing / Enterprise

Excess Inventory – Apply line balancing (Lean) and Kanban to reduce or eliminate inventory

Long Setup – Apply lean tools (SMED) to reduce set up time

Value Add

Non-Value Add

Summary

• Poka Yoke “Make it fool proof”

• 4-Ups Picture representation for Management

• Combine Lean and Six Sigma to reduce lead time, increase productivity,reduce WIP, better utilize space.

Resources

http:isixsigma.comhttp://en.wikipedia.orgSasa Todorovic Quality Engineer, Black Belt Master

“Learning to See” by Mike Rother and John Shook

Available at www.lean.org