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Poka Yoke or Error Proofing Techniques
Poka Yoke Definition - Techniques that help operators avoid mistakes in their work caused by choosing the wrong part, leaving out a part, installing a part backwards, etc. - It involves the implementation of fail-safe ways methods that detect or prevent human and machine error at or near the sourceIt provides instant feedback and prevention of quality problems Definition of a Defect - The result of any deviations from product specifications that lead to customer dissatisfaction Definition of an Error - Any deviation from a specified manufacturing process - The result of an error is shown in a defect. Prevention Device - Is a device or process that prevents errors from occurring or prevents these errors from creating defects - Examples: part locators, part present sensors Detection Device - Is a device that will detect a defect or concern and initiate a corrective action - Examples: vision system, limit sensors Causes of Errors - Processing omissions - Processing errors - Error in setting up the work piece - Missing parts - Improper item - Processing wrong work piece - Operations errors - Adjustment, measurement, dimension errors - Errors in equipment maintenance/repair - Errors in preparation of tools/jigs - Adjustments - Tooling and tooling changes - Dimensions/specifications - Many mixed parts - Multiple steps - Infrequent production - Lack of an effective standard - Symmetry - Asymmetry - Rapid repetition - High volume - Environmental conditions Implementation - Develop team - Create Error Proofing Implementation Sheet - Identify and describe defect - Determine location the defect was found & made - Identify root cause - Current process and deviations from standards - Propose and implement improved process - Measure - Standardize Guidelines for error proof devices - Low cost, easy to implement - Prevent the ability to make a defect / prevent the defect from being passed on - Provide immediate feedback
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