POKA-YOKE

Mankind is an animal which makes mistake

JICA Expert Master Engineer Kenji TAKEMURA

8:30--

The frame of Practical Technologies for Productivity

by Selected few by Everyone
*Background ? *Organization ? *Management ? *Example ? *Start ?

JIT
KANBAN POKA-YOKE

QCC P Q

TQM C

TPM D

KAIZEN
Suggestion Scheme

Collecting data Analyzing data Finding problem Countermeasure Implementation Checking result

QC Tools I.E. Statistics

Morale & Discipline 5S

Technological Process
by K. Takemura
PRACTEC.PPT

-9:00

Method of KAIZEN

9:15

POKA-YOKE
Mankind is an animal which makes mistake
Which idea do you take ?
Admitting( affirm ) mistake and hating( deny ) those who made mistake.

Hating( deny ) mistake and admitting( affirm ) those who made mistake.

1. What does POKA-YOKE means?

*POKA: Careless mistake *YOKE: to avoid
In Japanese.

Fail Safe or Fool Proof

Tools

Exercise: Why we make POKA?

PO KA Mistake Dark Small Noisy Similar Broken Thin Many Discontinuation etc., Forget Tired No concentration Busy Low attention Poor memory Interruption Discontinuation Habitual etc.,
9:25

9:30

How does a mistake ( POKA ) take place ?

There are some kinds of mistake. The causes of these POKA mostly lead to people.

Type of POKA
1. POKA by Carelessness 2. POKA by misunderstanding 3. POKA by brief look 4. POKA by novice ( amateur ) 5. POKA by selfishness 6. POKA by dull-witted 7. POKA by irresponsibility 8. POKA by mal function 9. POKA on purpose

Examples while driving

Thoughtless mistake. Driving a car in a crossing with red signal. Braking an automobile instead of clutch while driving automatic car. Mistake red signal as yellow one by brief look while driving. A novice driver only concentrate on driving. and forget to stop. Crossing a road while red signal because everyone does so. Late for braking a car because one is slow in judgment and action. A novice is irresponsible because of no correct training for him Brake suddenly does not work while driving Violation. Crossing a road while red signal on purpose.

Countermeasures
Periodical confirmation and in advance. Confirmation by call. Confirmation in advance. Meeting. Operation standard Meeting. Caution. Confirmation by call. Training. Operation standard. Basic education on self-discipline and custom. Training. Standard work. Instructions on the job. Standard work T otal Productive M aintenance (TPM) Standard work Basic training on discipline

-9:40

What are the worst 10 of POKA ?

Types of Order POKA of causes 1. Missing process on work 2. Mistake of process on work 3. Work set mistake 4. Missing parts 5. Mixing with foreign parts 6. Wrong work 7. Mis-action of machines 8. Mis-adjustment 9. Defective machine 10. Defective tools and jigs Carelessness Misunderstanding Brief look Novice Selfishness Dull-witted Irresponsibility

: Strongly related : Related

Mal function On purpose

tytsys16.doc

9:40--

2. How to make POKA-YOKE ?

1) Wares cant be fixed to the jig in case of wrong work. 2) A machine doesnt start processing in case the wares is something wrong. 3) A machine doesnt start processing in case of miss-work. 4) A machine proceeds processing after correcting miss work or miss-operation automatically. 5) A following process checks the results of preceding process and stop processing in case of wrong wares. 6) A following process doesnt start in case there were missing works.

Sign and mark system

Make easy to detect by Indicating lamps or different Color.

Jig system
Give ideas to jigs so that wrong wares cant be fixed Or processing doesnt start in case of miss-fixing

Automatic system
A machine stops autoMatically in case of wrong processing

10:00

Type of POKA
Type of POKA Real Cause
1, 2,3 3,15 3,4,8,10,12,15,17 5,6,10 5,6,7,9,10,14 5,10,16 5.6,11 5,6,10 11,12,13 4,5,6,10,12,17 4, 10, 17,18,19 4,10,12,16,17,20

1 Mistake (1) 2 3 4 5 Forget 6 7 8 9 Mistake (2) 10 11 12

Wrong Assembly or Processing Wrong Work-set Wrong ( Foreign) Parts assembly Wrong amount in number Missing Assembly or Processing Missing Parts at assembly or processing Mistake of operation Missing parts Wrong setting of arrangement Mistake of parts Mistake of indication Mixing of foreign parts

Real Cause of POKA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 No system to stop the work to flow to the next process in case of wrong assembly or processing The assembly or processing method depends on the judgment by operator Mistake of reading because of similar name or number.

-10:00 Coffee Break

Inverse setting of up/ down, right/left and inside/outside due to the similar or symmetrical shape.

No system for breaking away from the position at the time of rest, interruption and other job. Imperfect system of transfer of the job at the time of shift change. Operator does his job as he like and forgets

Only the person in charge knows parts and jigs storage yard. Then, helpers make mistake. No system to stop the work to flow to the next process in case of missing assembly or processing The letters of indication or drawing are small or thin, therefore miss-reading takes place. Operating conditions such as temperature, humidity, and pressure etc., differ. Then, mistake happens. Mistake of parts and material because of similar shape, size and color.

It is difficult to ascertain wrong or correct on size, amount and condition setting.

Difficult to detect missing parts and process because of so many parts and works. Operator does his job and takes parts at his convenience because no rule for stock yard. No system to stop the works in inner process when defective products happen. No fixed storage yard of parts and products. The amount is not constant and missing. Recording and counting of lot No. of indication is done by just memory. Indications, such as Labels and cases, are similar in size and color.
10:30 Break

Assembly of corrugated cartons and labeling are done by lot because of shipping information in mass.

Mechanism of POKA-YOKE
Stop on abnormality

10:20-

Prediction for occurrence

( may happen ? )

Control for misoperation

Stop
Prediction alarm

A defective product

Control
Stop on failure

POKAYOKE

Detection on occurrence
( Happened ! )

Alarm
Flow control

Devices Situation
Alarm on occurrence

Some hints on POKA-YOKE

Hint- 1: Method by Distinctive feature
1) by Weight Method
Set standard weight for an accepted article and then detect defective one by comparison with the standard weight. The balance weight of left and right can also be applied for detection.

When a product is heavier than standard weight, it stops.

2) by Dimension Method
Set standard by dimension such as length, height, thickness and diameter, and then detect defective one by comparison with the standard.

Good product
Nut

Stop!

Defective product

3) by Shape Method
Set standard of correct article by making use of distinctive shape such as, hole, edge, projection, bend or quality of material, then detect defective one by comparison with the standard.

Defective product

Good product Selection arm Defective product Next process Correct product

Hint- 2: Method by Sequence

1) by Process Sequence Method
Make it impossible to continue successive operation, when combined motion of workers or machines does not follow standard.
Stop !

Blanking

Corner cutting

Bending

Welding

Buzzer

Touching Sensor
Parts Box

2) by In- process Sequence Method

In a certain process, when a worker did not follow a standard and missing work would happen, the following work could not be continued.
Each time a operator picks up part, each lamp turns off. When all parts from A to H are picked up, the air cylinder of I is opened. Until a part from I is picked up, the air cylinder of A is closed.

Prepare one set of parts in a box, and pick up one by one , assemble in numerical order.

A B C D E F G H I

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Hint- 3: Method by Counting and Measuring

1) by Counter
In case the numbers, such as number of jobs or that of parts, is decided in advance, make the number as the standard then alarm of the difference.

Correct

Failure !

2) by Number of parts remained

In case several sets, which consist of some parts, are being prepared, arrange corresponding number of parts by group in advance first. Then, confirm wrong arrangement by the parts remained.
N pieces

N sets

PK-YK4.PPT

-10:40

3) by Detecting Fix Number

Numbers, such as pressure, electric current, temperature or time and so on, are fixed to control. When detected numbers are over the value, work or operation can not be continued.

Air pressure, Temperature, Oil level, Thickness Electric current, Voltage -----etc.

Some examples of POKA-YOKE

Preventing wrong jig fixing at the time of jig change
Before KAIZEN
upper jig A Correct Jig long Correct product body lower jig A Preventing Pin and hole

After KAIZEN

upper jig B Wrong Jig short Wrong product lower jig B

Preventing a missing nut in welding

Before KAIZEN
Nut

After KAIZEN

work Nut

Shield plate

Work

work

The work can be welded without a nut

Photo electric relay

Preventing to miss cooling water for high induction heating

Before KAIZEN After KAIZEN

Cooling water cock

Heating coil
Foot switch

Foot switch for heating

Limit switch

Preventing missing and wrong calking

Before KAIZEN After KAIZEN

Correct calk in previous process Missing calk in previous process

Wrong side calk in previous process

Micro switch

Examples of POKA-YOKE by the Type of Mistake

1. Missing Process on Work
Theme Problem Mis-work for number of hole in drilling In case of drilling work, fixed number of holes is not kept then lack of holes takes place sometimes.
After KAIZEN A limit switch was attached to detect drilling and count hole. Further more, another L/S was attached to the fixing jig in order to detect setting of the work. When a worker takes out work with lack of number, a buzzer alarms.
Buzzer L/S for hole count Jig Work L/S for setting work

Before KAIZEN A operator makes hole by counting number. Then, mistake of number of hole happens.

Wrong work

Correct work

2. Mistake of Process on Work

Theme Problem Defect of hole in drilling In case of drilling work, an operator draws back the drill before enough penetration. This causes wrong holes and trouble in assembly process.
After KAIZEN A limit switch was attached to detect drilling and count hole. Further more, another L/S was attached to the fixing jig in order to detect setting of the work. When a worker takes out work with lack of number, a buzzer alarms.
Confirmation switch for starting drill

Before KAIZEN It was decided in standard to let the drill go through, however, sometimes an operator draws the drill back before enough penetration. The operator judged the timing of drill draw-back by intuition. Therefore wrong holes were found sometimes in assembly.

L/S1

Buzzer

Confirmation switch L/S2 for penetration

3. Work Set Mistake

Theme Problem Prevention of hole position mistake in drilling job In case of drilling work, an operator mistakes the setting and makes wrong drilling. This causes wrong holes and trouble in assembly process.
Before KAIZEN It takes place often to set a work inverted in drilling job. As a result, the position of holes are also inverted then it causes trouble in assembly process. Wrong work Correct work After KAIZEN Groove in two sides of the work was utilized to detect correct setting. A limit switch was attached on the jig and then in case of wrong setting the machine did not start operation. Jig

L/S

4. Missing parts
Theme Problem Prevention of missing insert parts in assembly process After die casting an insert part has to be attached, however, missing of the part takes place often. In spite of total inspection by full-time inspector, the company still gets claims by customers for missing the parts.
Before KAIZEN Insert part was often missing, and the work was sent to following process. After KAIZEN A sensor was attached in bar removal pressing process after die casting to detect insert parts. In case insert was missing, the machine did not work and at the same time buzzer made alarming. Press Cross section of the work Sensor Missing !! Insert parts Die

5. Mixing with foreign parts

Theme Problem Prevention of attaching wrong parts in assembling process There are several change of products in type daily and workers sometimes attached wrong foreign parts.
Before KAIZEN Parts Shelf
A E I B F J C G K D H L

After KAIZEN
A B C D Panel E F G H I J K L

Request
L

B A

C D E F G H

K J I

Rotating Rack

11:15--

POKA-YOKE for Safety: How do you make POKA-YOKE?

Picture from: JISHA

These are POKA-YOKE for Safety:

Any more?

Picture from: JISHA

Exercise Sheet No. 1

How do you foresee accidents? Make POKA-YOKE.

Removing line connected

Your situation: You are a maintenance worker. You are removing electric line of electro- magnetic valve. Remember that there is a Control room of the line.

Picture from: JISHA

Exercise Sheet No.1

How do you foresee accidents? Make POKA-YOKE.

Tightening terminals

Picture from: JISHA

Lets be creative!!
Takemuras advice

1. Lets have flexible mind. 2. Curiosity is the driving power of creativity. 3. Make your own tools/methods for developing idea. 4. Concentrate to make idea (by hands) then ideas will visit you. 5. Be prepared to record ideas. 6. Lets be positive all ways.

Lets have positive mind!

Now lets apply POKA-YOKE!!

Hoping prosperity of your company, VJCC is always ready to work with you.

Xin cam on !

Osborne Check List

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Methods for Productivity Improvement(Example)

Process Analysis Transportation Anal Operation Analysis Motion Analysis Time Analysis 6 big Loss of Machine Autonomous Mainte. Productive Mainte. Quality Maintenance POKA-YOKE 4M in Production IE PM 5S Activity P-Q Analysis VRP Method QC 7 Tools New QC 7 Tools FMEA Quality Audit System Statistical Method Experimental Design VE/VA Idea Method Flow Frequency Chart
Production Aproval Sys

Useful Method Requirement ( What do you want?)

IE

TPM

JIT

Layout Impvmt Unit Consu. Yield Ratio VE/ VA Daily Control Product Control

P,C P,C C P P Q P,C P,C,D C,D P,C,D P,C,D C C C C C C C C P,C,D C,D D D,C

Improvement of Job Method Efficient Man Power Elimination of Muda in Material Improvement of Operational Ratio Improvement of Machine Efficiency Good Quality with machine Capable Operator for machine Production System for Small Lot Reduction of WIP Layout Change Steps for layout improvement What is Unit Consumption Production Cost by Process Elimination of Muda in Material Material Change New Idea for Product Development Summary of Product Performance Design with Cost Consciousness Plan for Cost Reduction Variation of WIP Term in Process Clear Process Progress Standard Process Schedule Note: Note: P: P: Production Production C: C: Cost Cost D: D: Delivery Delivery

Productivity Improvement

Inventory Cost Reduction

Muda Elimination Method Performance Evaluation Break Even Point Anal.

Category of Result and Effect

Lead Time Reduction Leveling of Production

JIT

JOB Control System

3 Elements in Standard

Big Category

KANBAN System

Middle Category