STM Quality Limited

Poka-Yoke

TOTAL QUALITY MANAGEMENT

Poka-Yoke
Power Solutions ABSL STM Quality Limited 2007

What is Poka-Yoke?

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This is known as MISTAKE-PROOFING From Japanese: Yokeru (avoid) Poka (inadvertent errors)

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What Does Poka-Yoke Do?

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Eliminates the cause of an error at the

source;

Detects an error as it is being made; Detects an error soon after it has been

made but before it reaches the next operation.

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Are Errors Unavoidable?

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There are two approaches to dealing

with errors:
1. ERRORS ARE INEVITABLE! 2. ERRORS CAN BE ELIMINATED!

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1. Errors Are Inevitable

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People always make mistakes.

While we accept the mistakes as natural,

we blame the people who make them. With this attitude, we are likely to overlook defects as they occur in production. They may be detected at final inspection, or worse still, by the customer.
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2. Errors Can Be Eliminated

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Any kind of mistake people make can

be reduced or even eliminated.

People make fewer mistakes if they are

supported by proper training and by a production system based on the principle that errors can be avoided.

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Inspection

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One method of detecting errors is

inspection. There are two major types of inspection.

1. SAMPLING INSPECTION.

2. 100% INSPECTION.

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Sampling Inspection

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In some factories, the attitude is: It may take all day to inspect all

product. There may be a few defects, but sampling is the most practical way to check.
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Sampling Inspection - Reflection

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Think about sampling.

With sampling, there is a chance that

an error may go undetected.

Even if 1 part in 1000 is defective, the

customer who buys that part has a 100% defective product!

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Sampling Inspection - Reflection

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SAMPLING INSPECTION MAKES SENSE ONLY FROM THE MANUFACTURERS VIEW, NOT FROM THE CUSTOMERS!

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2. 100% Inspection

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In the best factories, the attitude is: We wont tolerate a single defect!
We will organize production so that

100% of the product can be easily inspected. That makes the most sense.
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100% Inspection - Reflection

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Think about 100% inspection.

Even one defective product is enough to

destroy a customers confidence in a company. To stay competitive a company must supply good product in thousands. The best way to achieve this is to organize production to inspect 100% of the products.
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The User Is The Best Inspector

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No one intends to make mistakes.

While we are working, errors can show

up without us noticing. How can we catch these errors before they turn into defective products?

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Finding Defects in the Subsequent Process

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We dont expect to find defects, but if a

product we use doesnt do what it is supposed to do, then we know it is defective.

Users are the best at discovering

defects!

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Finding Defects in the Subsequent Process

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Since subsequent processes are also

users of the product being manufactured, they are also expert at finding defects. If products are produced in a flow, each product is sent to the next process as soon as it is finished and defects are therefore found immediately.
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Two Strategies for Zero Defects

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1. DONT MAKE IT!

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1. Dont Make It!

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Dont make product you dont need. The more you make, the greater the

opportunity for defects.

Follow just-in-time principles by only

making what is needed, when it is needed in the amount needed.

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Two Strategies for Zero Defects

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2. Build Safeguards

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2. Build Safeguards

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The user is an expert in finding defects. Therefore build safeguards into the

production process.
Quality can be built into products by

implementation of Poka-Yoke.
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Poka-Yoke Devices

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Human errors are usually inadvertent.

Poka-yoke devices help us avoid

defects, even when inadvertent errors are made.

Poka-yoke helps build quality into

processes.
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Poka-Yoke Devices Error Detection and Alarms

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Poka-Yoke Devices Checklists

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Poka-Yoke Example

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It is possible to mount the blank the

wrong way onto the pierce tool.

BLANK

PIERCED BLANK

INCORRECT

As the blank can fit the pierce tool in

many ways, how can this be prevented?

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Poka-Yoke Example

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By fitting a block into the pierce tooling,

the blank plate can only go on one way.

BLOCK
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Poka-Yoke

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POKA-YOKE MEANS ZERO DEFECTS

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