poka yoke seminar report

1. POKA-YOKE
By
N.HARISHA
132U1A0479POKA-YOKE
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2. Introduction
(to avoid) (errors)
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 Japanese phrase:
Yokeru poke
Poke
Yoke
Geethanjali institute of science and technology

3. Also known as MISTAKE PROOFING
Poka Mistakes
YOKE Prevent
Coined in japan during 1960’s by Shigeo shingo
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Geethanjali institute of science & technology

4. Initially ‘BAKA-YOKE’ ‘fool proofing’
Dishonorable and offensive
POKE-YOKE ‘Mistake proofing’ (or) ‘Error
avoidance’POKA-YOKE
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Geethanjali Instute Of Science & Technology

5. Why is it important?
Helps people and processes.
Refers to techniques that make it impossible to make
mistakes.
Helps drive defects out of products and processes and
substantially improve quality and reliability.
Used to fine tune improvements and process designs from
six-sigma.
can eliminate both human and mechanical errors.
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Geethanjal Institute of Science & Technology

6. When to use it?
It is a technique, a tool that can be applied to any
type of process be it in manufacturing or the
service industry.
 Poka-yoke can be used wherever something can
go wrong or an error can be made.
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Geethanjali Instittute of Science & Technology

7. Contd..
Errors can be of any types:
Processing error
Setup error
Missing part
Improper item/part
Operations error
Measurement error
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Geethanjali Instittue of Science & Technology

8. What Does Poke yoke Do?
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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Geethanjali Institute of Science & Technology

9. Qualities of a good poka-yoke:
Early
Precise
Simple
Light
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Geethanjali Institute of Science & Technology

10. Methodology of Poka-yoke
Identify problem
Observe at work stations
Brain storming for idea
Select best ideas
Implementation plan and implementation
Monitoring and signoff
Geethanjali Institute of Science & Technology
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11. Are Errors Unavoidable?
There are two approaches to dealing with errors:
 1. ERRORS ARE INEVITABLE!
 2. ERRORS CAN BE ELIMINATED!
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Geethanjali Institute of Science & Technology

12. 1.Errors Are Inevitable
 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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Geethanjali Institute of Science & Technology

13. 2.Errors Can Be Eliminated
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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Geethanjali Institute of Science & Technology

14. Two types of error proofing devices
POKA-YOKE
 Control - eliminates the possibility of a mistake to occur
(automatic machine shutdown)
 Warning - signals that a mistake can occur (blinking light,
alarm, etc.)
POKA-YOKE
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Geethanjali Institute of science Technology

15. POKA-YOKE Examples
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Geethanjali Institute of science & Technology

16. Alarm Systems
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They are activated with alarms for security
purposes. If an unauthorized person enters
the
bank, or the electric circuit of the door bell
catches fire, a warning alarm rings, which
ensures
that you can take care of the problem before it
gets out of hand.
Geethanjali Institute of science & Technology

17. Connector and charger
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figure shows a charger and connector. All
the three pins need to fit perfectly within
the three slots provided. This has to be
monitored during production. And for that,
the design phase of the product needs to be
executed perfectly as well. A slight error in
the calculation of the slot-size or the pin-
size can make the device redundant or
faulty
Geethanjali Institute of science & Technology

18. Fingerprint Identification
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This is used extensively in biometrics,
forensics, detective agencies, etc.
Every fingerprint in the world is
unique, no two are ever the same. The
device is such that only the fingerprint
of that particular person will be
required as input. Trying to replicate
or use some one's fingerprint forcibly
will not work either.
Geethanjali Institute of science & Technology

19. Dialysis machine
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These machines perform the function of
the kidneys and are used for patients
suffering from CKD (Chronic Kidney
Disorder). An example of a safety device
in this machine is the efficient design of
the air bubble detector. This detector must
be fully functional and should ensure that
no air bubble passes to the patient's body.
If this occurs, the patient may have
seizures and this can prove fatal. Hence,
the detector must be equipped with a
proper mechanism to find out the
problem, and give out beeps so that
proper action can be taken immediately.
Geethanjai Institute Of Science & Technology

20. POKA-YOKE 20
Many Elevators are equipped with
an electric eye to prevent doors
from shutting on people. They also
are equipped with sensors and
alarms to prevent operation when
overloaded.
Geethanjali Institute of Science & Technology

21. Advantages:
Simple and chip
Remove defect from root cause/source
Faster defect detection and correction
Improve safety of workers
Improve equipment effectiveness and assures high
realbility
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Geethanjali Institute Of Science & Technology

22.  Making mistakes is OK; Just don’t
make them again and again. And to avoid making same
mistakes again there should be some checks or process in
a place. Poka-yoke technique is used to solve the problem
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23. THANK YOU
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