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 source
- It provides instant feedback and prevention of quality problems
Definition of a Defect
Poka Yoke Simulation Game
- 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
Poka Yoke Presentation
- 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
