From the exciting world of learning by playing we bring to you another Lean Simulation, geared towards error proofing alias Poka-Yoke. We refer to the principle of QUALITY AT THE SOURCE.

The purpose of the game is to prove the benefits of using Poka-Yoke or error proof devices in your operations.

By playing two rounds (assembling gadgets from blocks, before and after implementing Poka Yoke and in-station quality checks) we will demonstrate how we can increase the quality levels while using a smaller number of workers. The results show also a decrease of the lead time while increasing the throughput.

The game comes as a 51-slide presentation with an introduction of the Poka Yoke concepts and theory, footnote instructions for the lean trainer, pictures with the visual aids for assembly and gauging, spreadsheet that you can print and use during the game, current and future conditions, all in a presentation format, ready to be delivered.

There are two rounds, each round is played for 15 min (1 min equates 30 min real time), as we simulate one shift of 480-30 = 450 minutes.

The game is for 6-8 people. If you have more players, just buy another Mega Bloks or Lego game and use the same instructions. It can be seen as a competition between teams.

Agenda:

1. Poka Yoke Basics

• Definition
• Error Proofing vs. Mistake Proofing
• Causes for Errors
• Implementation

2. Introduction of the Poka Yoke Simulation

• Operations Description
• Play Rules
• Data Collection
• Widget Assembly Picture, BOM

3. Play Round 1 – Mass Production

• Work cell layout, Assembly Visual Aids for every station, - Various options for errors
• Final Inspection Gauge Assembly Instructions
• Collect Data

4. Play Round 2 – Lean Production (In-Station Quality Gauge)

• New Work Layout, Assembly Visual Aids
• In-Station Gauge Specs for every operation
• Collect Data

5. Discussions based on Results

The Story of Astro Electronics Company

Let's look at the operations of Astro Electronics Company:

• Traditional manufacturing set-up
• Produces a poor quality product
• Quality is checked at final inspection
• Operations - no error/mistake proofing
• Has rework loop
• Has negotiated a new contract and it must improve their operations, to be able to produce only good parts with no rework loop

How do you think they implemented build-in checks in their operations at each work station? Seems unrealistic or unneeded?

Let us prove the difference they made by implementing QUALITY AT THE SOURCE.

All products are now available from ELSE Inc.`s website please click the logo to go to our new site's store.

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