poka yoke asq621-presentation

8/2/2019 Poka Yoke ASQ621-Presentation

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Diana Howard ASQ CA/RABQSA

Quality Tools


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1.Poka Yokea. Heat sink example

2. Four Up Charts3. Lean Sigma

a. Value Stream Mapping

4. Resources

Topics of Discussion


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What is Poka-Yoke?

The phrase Poka-Yoke originates from theJapanese words:

yokeru = to avoid

poka = inadvertent errors

It is a methodology that is used to strive

toward zero defects by either preventing orautomatically detecting defects.


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Mistake Proofing Devices

1. Guide/Reference/Interference Rodor Pin:

2. Template:3. Limit Switch/Microswitch:4. Counter:

5. Odd Part Out Method:


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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:


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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 toinsert 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 ornearly 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 waythey can no longer be confused and mistakenly interchanged. This isespecially useful when a particular orientation is critical.


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Four Ups charts

Used for Reporting to management

Graph of measurement over time

Analysis of quarterly data Issues/causes

Action Items


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Graph Ana lys is

Issues /Causes Action Items

Pre-Ship Acceptance

Hardware Missing: Developed UV/black light markercheck. Operator to use pen and Touch for Quality - QAto audit with black light. Due date: 2/3/06

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

Missing: Nozzle replacement program instituted andrefresher on operator training.

Great improvement!

Customer intro during quarter( XXXXX volumes rampedduring 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


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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


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Why Value Stream Maps?

It helps visualize what may beotherwise un-seen

Find the sources of waste andquantifies those wastes so thatefforts for reduction can be

prioritized


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Target Waste with Value Stream Maps

LeanManufacturing/Enterprise

Excess Inventory

Apply linebalancing (Lean) and Kanban toreduce or eliminate inventory

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

Value Add

Non-Value Add


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Summary

Poka Yoke Make it fool proof

4-Ups Picture representation forManagement

Combine Lean and Six Sigma to reducelead time, increase productivity,reduceWIP, better utilize space.


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Resources

http:isixsigma.com

http://en.wikipedia.org

Sasa Todorovic Quality Engineer, Black Belt Master

Learning to See by Mike Rother and John Shook

Available at www.lean.org

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