Quality Tools

Diana Howard ASQ CA/RABQSA

Topics of Discussion 1.Poka Yoke a. Heat sink example 2. Four Up Charts 3. Lean Sigma a. Value Stream Mapping 4. Resources

What is Poka-Yoke?
The phrase Poka-Yoke originates from the Japanese words: yokeru poka = = to avoid 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 or Pin: 2. Template: 3. Limit Switch/Microswitch: 4. Counter: 5. Odd Part Out Method: Rod

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

Pre-Ship Acceptance
Graph
35000 30000 25000 20000 15000 10000 5000 0 Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec05 05 05 05 05 05 05 05 05 05 05 05 DPM Goal # Shipped 20000 18000 16000 14000 12000 10000 8000 6000 4000 2000 0
14 12 10 8 6 4 2 0 HRDM PDC MSS LVS HRDL VRD

Analysis
50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0%

Nov-Dec # of defects % of sum

Issues/Causes

Action Items

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. PDC: 10 different refdes locations across 8 different assemblies. No common trend. Missing: Nozzle replacement program instituted and refresher on operator training. 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

Lean Sigma The combination

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

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

Excess Inventory Apply line balancing (Lean) and Kanban to reduce or eliminate inventory

Non-Value Add

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.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