TOTAL

QUALITY
MANAGEMENT
Preventive Techniques
Chapter - 8

NAZMUN NAHAR
0
 Failure Mode and Effect
Analysis (FMEA)
Failure Mode and Effect Analysis is an
engineering technique used to define, identify
and eliminate known and/or potential failures,
problems, errors and so on from the system,
design, process and/or service before they reach
to the customer
The FMEA will identify actions required to
prevent failures from reaching the customers,
thereby assuring the highest durability, quality
and reliability possible is a product or service
1
 FMEA (contd.)
FMEA involves
Identifying known and potential failure
mode
Identifying cause and effect of each failure
mode
Prioritizing the failure mode according to
Risk Priority Number (RPN)
Finding out preventive action for failure
mode 2
 Steps of FMEA
Select the team and brainstorm
Team members who are all willing to
contribute are selected from various
departments and put together to work on
FMEA
After team selection the opportunities of
improving are identified and the right
direction to proceed is identified 3
 Steps of FMEA
Functional block diagram and/or
process flow chart
Functional block diagram gives the details
and helps to understand the system
Process flow chart focuses mainly on
process and service
Helps the team to understand the system,
design, process and service and the related
problems 4
 Steps of FMEA (CONTD.)
Prioritize
After understanding the problem, the team
tries to find out the important segment and
decide where to begin.
The top management assists this process
after analyzing customer complaints

5
 Steps of FMEA (CONTD.)
Data collection
Failure modes of FMEA are identified by
collecting data about failures occurred so
far in the company
Analysis
The severity, detection, and occurrence of
failure are identified by analyzing the
information which is derived from the 6
 Steps of FMEA (CONTD.)
Results
RPN is evaluated
Take preventive actions for each failure
modes
Confirm / Evaluate / Measure
This is used to evaluate the results of
actions, which are suggested to improve the
present condition. It is done by measuring
the present condition with the past 7
 Steps of FMEA (CONTD.)
Do it all over again
Since the continuous improvement is the
best method of eliminating errors, the
above stated seven steps have to be
repeated again and again

OCCURRENCE SEVERITY

DETECTION 8
!! Example from book !!
Page 195

9
 Poka Yoke

Developed By-
SHINGEO SHINGO

POKA-YOKE
to avoid (yokeru
yokeru) inadvertent errors (poka
poka)
10
 Poka Yoke
Poka-yoke is a Japanese term that means "fail-
safing" or "mistake-proofing".
A poka-yoke is any mechanism in process that
helps an equipment operator avoid (yokeru)
mistakes (poka).
Its purpose is to eliminate product defects by
preventing, correcting, or drawing attention to
human errors as they occur.
11
 Poka Yoke
The concept was formalised, and the term
adopted, by Shigeo Shingo as part of the Toyota
Production System .
It was originally described as baka-yoke, but as
this means "fool-proofing" (or "idiot-proofing")
the name was changed to the poka-yoke.
More broadly, the term can refer to any
behavior-shaping constraint designed into a
process to prevent incorrect operation by the
user. 12
 What Causes Defects?
1. Poor procedures or standards.
2. Machines.
3. Non-conforming material.
4. Worn tooling.
5. Human Mistakes.
Except for human mistakes these conditions
can be predicted and action can be
implemented to eliminate the cause of defects
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 Human Error
Humans make mistakes (errors) because of.
- Forgetfulness
- Misunderstanding
- Lack of experience/skills
- Lack of concentration
- Laziness
- Lack of standards
- Rushing
- Taking short cuts
- Malicious intent (deliberate action) 14
 Approaches
Two Poka Yoke System approaches are utilized
in manufacturing which lead to successful zero
defect systems:
1. Control Approach
Shuts down the process when an error
occurs.
Incomplete.
2. Warning Approach
Signals the operator to stop the process
and correct the problem. 15
16
 Examples of Poka Yoke

This pen prevents ruining shirts by retracting

the tip automatically when the pen is clipped
into your shirt pocket. The catch that keeps
the tip out is actually in the pocket clip. When
you pullout on the clip to put it on your shirt,
the pin that engages the catch is released
causing the tip to retract 17
 Benefits
The goal of manufacturing is to produce
value-added products in a timely manner,
which is free of defects. Poke Yoke is applied
in fundamental areas. The main objective of
Poka Yoke is to achieve zero defects.
It is used to create a system that prevents
defects from occurring, and it used as a
system to catch defects, which have just
occurred and prevent them from continuing
through the system 18
 Benefits
Poka-yoke helps people and processes work
right the first time. Poka-yoke refers to
techniques that make it impossible to make
mistakes. These techniques can drive defects
out of products and processes and
substantially improve quality and reliability.

19
 Poka Yoke (contd.)
Mistake proofing recognizes that every
human will make mistakes and tries to set up
systems that minimize or eliminate those
mistakes.

20
Poka Yoke (contd.)

21
 Different techniques
Brakes Software warning
Sensors Reminder
Switches Light
Child resistant Checklist
Shape Visual aid
Size Sounds
Color Barrier
Door mechanism
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 Effectiveness of Poka Yoke
Dana corporation has reported a $500,000 savings
resulting from a $6 device. (83,000:1)
AT&T Power Systems (Lucent Technologies)
reported net saving of $2545 per device (3300
devices) [Marchwinsky, 1997]. (25:1*)
Weber Aircraft reports saving $350,000 during
their first year of implementation of
approximately 300 devices. (11:1*)
*Assumes and average devise cost $100

END OF THE CHAPTER 23