Pokayoke training objectives gain a basic understanding of pokayoke procedures and how they fit into the lean process improvement culture learn skills to identify causes for mistakes by applying problem solving tools and nominal group techniques understand the six pokayoke techniques to eliminate mistakes or to make them immediately. In this technique the system eliminates errors or make it impossible for errors to happen. In 1961, shingo visited a plant where a very simple assembly procedure was resulting in defective parts being sent to the parent. I would suggest you read those articles first so that you better connect yourself with poka yoke examples in this article. Likewise, this paper includes a selection from nearly hundred aec examples i have collected to date, to show the broad applicability of. Poka yoke is a system to prevent mistakes from happening. While a poka yoke is often a physical device, such as a fixture that only accepts parts one way, processes and parts can also be designed to have a builtin poka yoke. Pokayoke is a quality assurance technique developed by japanese manufacturing engineer shigeo shingo. Poka yoke was invented by shigeo shingo in 1960 as a part of the toyota production system. Poka yoke is a quality assurance technique developed by japanese manufacturing engineer shigeo shingo. The below link has a detailed guide of poka yoke definition, types of poka yoke, and how to implement poka yoke.
We can see many examples of poka yoke in our daily life like specific design of sim card, they are explained in the later part of this article. These are simple, yet effective design features that make it almost impossible for errors to occur. It was a japanese manufacturing engineer named shigeo shingo who developed the concept that revolutionized the standard career in japan. The amount of waste generated declines 60 % after using cutcrop. The design of mistakeproofing and reduce of waste reduction. Gain a basic understanding of pokayoke procedures and how. Poka yokes final free download as powerpoint presentation. A good poka yoke must be early in the process, so that it can provide quick feedback and help in detecting mistakes the moment they occur. Poka yoke or quality by mistake proofing design and construction systems. Using pokayoke techniques for early defect detection abstract. Poka yoke definition poka yoke is a japanese term that means mistakeproofing to correct mistakes before they happen mistake proofing is everywhere from our home, to our car, to our work t r a n s f o r m i n g t h e p u b l i c s e c t o r lean. This prevents defective products from making it to the end of the process.
Poka yoke is not just used in manufacturing processes. You can find examples of mistakeproofing everywhere, from your car to your. Shingo noticed that in one process at the toyota plant the workers often forgot to place a required spring under a switch button. Jan 07, 2015 a visual guarantee is a mechanism that builds information so deeply into the process of work that it becomes the work itself. Poka yoke is a quality assurance technique,the aim of poka yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Mar 01, 2017 poka yoke 2u1a0479 page 23 geethanjaliinstitute of science and technology gangavarmv, kovurm, nellore 6. The ideas that became pokayoke were introduced by shigeo shingo, an industrial engineer who went on to develop several of the tools and techniques still vital to lean and six sigma today. A free powerpoint ppt presentation displayed as a flash slide show on id.
Poka yoke is a japanese word which means mistake proofing and it is explained in this article with examples. Such devices are already a part of process and quality control solutions in continue reading doorway 6. Poka yoke has been used most frequently in manufacturing environments. A poka yoke device must make it physically impossible to make a mistake.
As a result, a higher quality of output naturally follows. Six sigma tools poka yoke process exam process exam. Cutcrop, a tool created to facilitate photo frame building in the outlining and cutting processes, was. Ppt mistakeproofing pokayoke powerpoint presentation. Yokeru avoid poka inadvertent errors the term was introduced by shigeo shingo, who was one of the industrial engineers at toyota. The term originated in lean manufacturing, where it refers to any mechanism that helps a machine operator avoid. Poka yoke history poka yoke pronounced pohkah yohkay 1 was invented by shigeo shingo in the 1960s. More broadly, the term can refer to any behaviorshaping constraint designed into a. Shingo ejemplo solucion niveles del pokayoke nivel 2. The term poka yoke was coined by shigeo shingo, a key contributor to the the toyota production system tps, in the 1960s.
Sumit thakur ece seminars poka yoke seminar and ppt with pdf report. The aim of poka yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Poka yoke in parts design primarily in manufacturing. Pokayoke has been used most frequently in manufacturing environments. Initially referred to as foolproofing and later modified to mistake proofing and fail to save so workers werent offended, poka yoke pronounced pohkoh youkay interprets into english as to keep away from yoke ru inadvertent. Poka yoke definition plus page lean guide w mistake.
When that happens, it becomes impossible to do the wrong thing. Wednesday, june 1, 2005 poka yoke slide 5 poka yoke defined shigeo shingo defines poka yoke as. Gain a basic understanding of poka yoke procedures and how. Hydraulic hoses and wiring harnesses can have different size connectors. Pdf using pokayoke techniques for early defect detection. By introducing pokayoke mistakeproofing into our software process, we have been able to prevent literally hundreds of software localization defects from. By integrating poka yoke inline, mistakes are either prevented or caught shortly after they happen. The essential idea of poka yoke is to design your process so that mistakes are impossible or at least easily detected and corrected. Apr 25, 2020 poka yoke is a japanese term that refers to an idea of quality assurance that utilizes good design or uses engineering devices to prevent or detect failure modes and causes of the failure modes. Pokayoke definition, examples, how to create your own. While a poka yoke is often a physical device, such as a fixture that only accepts parts one way, processes and parts can also be designed to have a builtin poka yoke some poka yoke examples poka yoke in parts design primarily in manufacturing. This page contains poka yoke seminar and ppt with pdf report. Pokayoke was originally baka yoke, but as this means foolproofing or idiotproofing the name was changed to the milder pokayoke. Jun 28, 2017 poka yoke is a japanese term which roughly translates to mistakeproofing.
The aim of pokayoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. P oka yoke provides many benefits to manufacturing processes, the foremost being an improvement in overall quality control. Hewlett packard currently develops its common desktop environment software to run in twelve locales or. Pokayoke is a system to prevent mistakes from happening. Adaptive branding is an important mechanism in cruise control that helps a car to. The term poka yoke comes from the japanese words poka inadvertent mistake and yoke prevent 2. Shigeo shinyo, was employed in this study in order to promote wastefree production as part of zqc zero defect quality control system.
1736 187 1411 351 890 129 1604 1586 582 918 919 1026 569 736 964 769 503 1289 1442 115