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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02000400060008000100001200014000160001800020000
DPM Goal # Shipped
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HRDM PDC MSS LVS HRDL VRD
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# of defects % of sum
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
