Details Of Poka Yoke Manual
Devices, referred to as Poka-Yoke devices, such as sensors, need to. In the world of error proofing, any manual operation has the potential to induce human error. If there are multiple details on the part to error proof, vision systems.
This article possibly contains. Please by the claims made and adding. Statements consisting only of original research should be removed. (April 2014) Poka-yoke ( ポカヨケ, ) is a Japanese term that means 'mistake-proofing' or 'inadvertent error '. The key word in the second translation, often omitted, is 'inadvertent'. There is no poka-yoke solution that protects against an operator's sabotage, but sabotage is a rare behavior among people. A poka-yoke is any mechanism in a process that helps an equipment operator avoid ( yokeru) mistakes ( poka).
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to as they occur. The concept was formalised, and the term adopted, by as part of the. It was originally described as -yoke, but as this means 'fool-proofing' (or ') the name was changed to the milder poka-yoke.
Contents. Usage More broadly, the term can refer to any designed into a process to prevent incorrect operation by the user. A simple poka-yoke example is demonstrated when a driver of the car equipped with a manual gearbox must press on the clutch pedal (a process step, therefore a poka-yoke) prior to starting an automobile. The interlock serves to prevent unintended movement of the car. Another example of poka-yoke would be the car equipped with an automatic transmission, which has a switch that requires the car to be in 'Park' or 'Neutral' before the car can be started (some automatic transmissions require the brake pedal to be depressed as well). These serve as behavior-shaping constraints as the action of 'car in Park (or Neutral)' or 'foot depressing the clutch/brake pedal' must be performed before the car is allowed to start. The requirement of a depressed brake pedal to shift most of the cars with an automatic transmission from 'Park' to any other gear is yet another example of a poka-yoke application.
Over time, the driver's behavior is conformed with the requirements by repetition and habit. History The term poka-yoke was applied by in the 1960s to industrial processes designed to prevent human errors. Shingo redesigned a process in which factory workers, while assembling a small switch, would often forget to insert the required spring under one of the switch buttons.
In the redesigned process, the worker would perform the task in two steps, first preparing the two required springs and placing them in a placeholder, then inserting the springs from the placeholder into the switch. When a spring remained in the placeholder, the workers knew that they had forgotten to insert it and could correct the mistake effortlessly. Shingo distinguished between the concepts of inevitable human and in the production.
Defects occur when the mistakes are allowed to reach the customer. The aim of poka-yoke is to design the process so that mistakes can be detected and corrected immediately, eliminating defects at the source.
Implementation in manufacturing Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. For example, a that holds pieces for processing might be modified to only allow pieces to be held in the correct orientation, or a digital counter might track the number of spot welds on each piece to ensure that the worker executes the correct number of welds. Shigeo Shingo recognized three types of poka-yoke for detecting and preventing errors in a system:. The contact method identifies product defects by testing the product's shape, size, color, or other physical attributes. The fixed-value (or constant number) method alerts the operator if a certain number of movements are not made.
The motion-step (or sequence) method determines whether the prescribed steps of the process have been followed. Either the operator is alerted when a mistake is about to be made, or the poka-yoke device actually prevents the mistake from being made. In Shingo's lexicon, the former implementation would be called a warning poka-yoke, while the latter would be referred to as a control poka-yoke. Shingo argued that errors are inevitable in any process, but that if appropriate poka-yokes are implemented, then mistakes can be caught quickly and prevented from resulting in defects.
By eliminating defects at the source, the cost of mistakes within a company is reduced. A methodic approach to build up poka-yoke countermeasures has been proposed by the Applied Problem Solving (APS) methodology, which consists of a three-step analysis of the risks to be managed:. identification of the need. identification of possible mistakes. management of mistakes before satisfying the need This approach can be used to the technical aspect of finding effective solutions during brainstorming sessions.
Benefits of poka-yoke implementation A typical feature of poka-yoke solutions is that they don't let an error in a process happen. But that is just one of their advantages. Others include:. Less time spent on training workers;. Elimination of many operations related to;. Unburdening of operators from repetitive operations;.
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Jidoka
Promotion of the work improvement-oriented approach and actions;. A reduced number of rejects;. Immediate action when a problem occurs;. 100% built-in. See also.
References. ^ Misiurek, Bartosz (2016). New York: Productivity Press. Robinson, Harry (1997). Retrieved May 4, 2009.
^; Dillon, Andrew (1989). Portland, OR: Productivity Press. Grout, Brian T. Retrieved May 4, 2009. H Robinson. Retrieved June 18, 2012. Retrieved August 20, 2012.
The Quality Portal. Retrieved May 5, 2009. Poka-yoke: improving product quality by preventing defects. Productivity Press. Ivan Fantin (2014). Applied Problem Solving.
Method, Applications, Root Causes, Countermeasures, Poka-Yoke and A3. How to make things happen to solve problems. Milan, Italy: Createspace, an Amazon company. Further reading.
Kanban
(1986).: Productivity Press. Retrieved 30 April 2009. Poka-yoke: improving product quality by preventing defects.: Productivity Press.
Hinckley, C. Barkan (1995). Journal of Quality Technology. 27 (3): 242–249. Misiurek, Bartosz (2016).
New York: Productivity Press. External links.