TVS - MOTOR CO.

Poka Yoke

llhll

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

A Strategy for Performance Excellence

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TO ACHIEVE

ZERO DEFECT

ZERO WASTE
ZERO DELAY

TVS - MOTOR CO.,

The Approach
Elimination of
wastes
KAIZEN

Continuous
Improvement

Poka Yoke

PED - DESIGN CENTER

The Strategy

One piece flow

SMED
Visual Controls
Workplace
Organization
Kanban
Standard Work
Process Control
TPM
Poka-Yoke

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

What.?
Why.?
Who.?

Where.?
When.? How.?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Let us discuss some

day to day life examples

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

How to insert a floppy in a computer

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

In which way it has to be inserted

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

What will happen if we insert in

the wrong way

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Wrong loading is not possible

How ?

Poka Yoke

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Iron box

The lady is watching her child

during ironing a cloth ?
What would have happened.

TVS - MOTOR CO.,

Poka Yoke

Iron box

PED - DESIGN CENTER

Cloths burnt due to overheating

How to avoid ?

TVS - MOTOR CO.,

Poka Yoke

Iron box

PED - DESIGN CENTER

Provide auto off when overheated.

How ?

Poka Yoke

TVS - MOTOR CO.,

Poka Yoke

Hair drier

PED - DESIGN CENTER

Switch
If you forget to switch off
What will happen?
Energy loss , Motor overheat ,
life is reduced

How to avoid ?

TVS - MOTOR CO.,

Poka Yoke

Hair drier

PED - DESIGN CENTER

Limit switch trigger

Auto off after keeping on holder

Poka Yoke

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

Story

Letter delivered to wrong person

To
To
Rajesh
M/s R.K Industry
Bangalore - 35

How to avoid ?

R. Suresh
D.No-86 II nd cross ,
M.G Road,
Hosur - 635109

Poka Yoke

TVS - MOTOR CO.,

Post cover

PED - DESIGN CENTER

Provide Window cover for address

Avoids wrong posting , time saving.

To
R. Suresh
D.No.86, II nd cross ,
M.G Road,
Hosur - 635109

Poka Yoke

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Wash basin

Blockage in the main drain.

If you forget to close the tap. What will happen ?
Water over flow and spills on floor

How to avoid ?

TVS - MOTOR CO.,

Poka Yoke

Wash basin

PED - DESIGN CENTER

Over flow hole provided

to avoid dropping on floor

Poka Yoke

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

CAR PARKING

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

CAR PARKING

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Think Simple

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Use Sensors to Prevent

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

POKA YOKE CHUTE

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Simple Design change

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Make Symmetry

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Make Asymmetry

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TOPIC
INTRODUCTION
POKA YOKE
QUALITY AND PRODUCTIVITY
USER & PRODUCER
DEFECT & ERRORS
CAUSE AND EFFECT
STANDARD,EFFECTIVE STANDARD,STANDARDISATION
5 LEVERL OF QUALITY ASSURANCE
3 ZEROS
POKA YOKE- WHAT?WHY?WHEN?HOW? WHERE?WHO? TYPE?

TYPE OF ERRORS
EXPLANTION WITH EXAMPLES
GEMBA VISIT AND END OF SESSION

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

POKA YOKE
POKA means INADVERTENT ERRORS
YOKE means TO AVOID
POKA -YOKE TO AVOID INADVERTENT
ERRORS
TERM COINED BY Dr. SHIGEO SHINGO

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

QUALITY AND PRODUCTIVITY

IMPROVEMENTS ARE EVRYBODYS
RESPONSIBILITY.

THESE WILL HAPPEN

ONLY WHEN EMPLOYEES GET DIRECTLY

INVOLVED IN THE PROCESS OF
CONTINUOUS IMPROVEMENT THAT

ELIMINATES/SOLVES PROBLEM

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

USER & PRODUCER

THE BEST DISCOVERER OF DEFECTS IS THE USER

THE BEST EXPERT IN CREATING DEFECTS IS THE PRODUCER.

1-10-100 Rule
The 1-10-100 rule states that as a product or service moves through
the production system, the cost of correcting An error multiplies by
10.
Activity
Cost
Order entered correctly

Rs. 1

Error detected in billing

Rs. 10

Error detected by customer

Rs. 100

Rs.1000

Dissatisfied customer shares the experience with others the costs is

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

DEFECTS AND ERRORS

DEFETS ARE RESULTS

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

DEFECTS AND ERRORS

ERRORS ARE THE CAUSES OF THESE
RESULTS

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

CAUSE AND EFFECT

MANAGING CAUSE MEANS,
MANAGING EFFECT-EVEN BEFORE IT HAPPENS.

IF WE SHIFT FROM
MANAGING OF DEFECTS
TO

MANAGING OF CAUSE

OUR FIREFIGHTING DAYS ARE OVER.

Poka Yoke

TVS - MOTOR CO.,

STANDARD
A STANDARD

= ?

PED - DESIGN CENTER

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

STANDARD
A STANDARD

=
A WORK METHOD OR PROCEDURE

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

EFFECTIVE STANDARD
AN EFFECTIVE STANDARD = ?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

EFFECTIVE STANDARD
AN EFFECTIVE STANDARD =
A RELIABLE METHOD

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

STANDARISATION
STANDARDISATION =

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

STANDARISATION
STANDARDISATION = TO IMPROVEMENT.

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

PREVENTION AND DETECTION

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

PREVENTION AND DETECTION

PREVENTION

PREVENTION IS BETTER THAN CURE

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

DETECTION

DETECTION IS A CERTIFICATE AFTER

DEATH

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

PROCESS AND RESULT

CURE THE CAUSE-NOT THE SYMPTOM

CONTROL PROCESS TO ACHIEVE

DESIRED RESULT CONSISTANTLY

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW MISTAKE IS HAPPENED?

IS IMPORTANT !
NOT
WHO HAS DONE THIS???

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TO DAYS ..!!!!!!!! Our production process are.

DIFFERENT PROCESS!!!
MANY VENDORS!!!
DIFFERNCE IN OUT SIDE COMPONENTS!!!
DIFFERENT TYPE OF MACHINES.!!!
NO. OF PERSON INVOLVEMENT.!!!
VERY BIG COMPANY.!!!
HIGH PRODUCTION..!!!
SO,
DEFECT IS NOT POSSIBLE TO AVOIDE ! SOME % WILL BE THERE !!!

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

MAN Vs DEFECTS/ERRORS

FIRST VIEW.
IF MAN IS THERE MISTAKE WILL BE THERE !

NO OTHER WAY!
WE HAVE TO BARE THIS!
NOT POSSIBLE TO AVOIDE 100%!

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

MAN Vs DEFECTS/ERRORS
POSITIVE ATTITUDE
TO ERR IS HUMAN!
WHILE TO ERR IS HUMAN, THE ABILITY TO PREVENT

ERRORS FROM LEADING TO DEFECTS IS ALSO HUMAN

POSITIVE ATTITUDE

Training
Discipline
POKA YOKE

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

WHAT IS CALLED A DEFECT FREE PORDUCT?

A PRODUCT AGAINST WHICH EVEN ONE

CUSTOMER IS UNABLE TO FIND

A SMALL ERROR.

WHAT IS CALLED A HIGH QUALITY PRODUCT?

A PRODUCT WHICH IS FULLY ACCEPTED
BY ALL CUSTOMERS.

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

5 LEVELS OF QUALITY ASSURANCE ACHIEVEMENT

1. FACTORY DISPATCH DEFECTIVE PRODUCTS

2. DESPATCH DEFECT FREE PRODUCTS(RETAIN THE

DEFECTIVE PRODUCTS)
3. REDUCING DEFECTS

4. PROCESS CONTROL (DEFECTIVES DO NOT GET

PASSED ONTO THE NEXT PROCESS)
5. PROCESS DO NOT CREATE WASTE (WHEN AN ERROR
OCCURS, THE PROCESS DOES NOT PRODUCE
DEFECTIVES)

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TO ACHIEVE BEST LEVELS OF QUALITY ASSURANCE

i.e,

To Achieve 3 Zeros

ZERO DEFECT

ZERO WASTE
ZERO DELAY
Learn and understand about Quality,Productivity,
User,Producer,Defect,Cause,Prevention,Detection,Error etc.,

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

1. WHAT IS POKA YOKE?

2. WHY POKA YOKE IS ESSENTIAL?
3. WHERE TO IMPLEMNT POKA-YOKE?
4. WHEN TO IMPLEMENT POKA - YOKE?
5. HOW TO IMPLEMENT POKA - YOKE?
6. WHO HAS TO IMPLEMENT POKA YOKE?

7. TYPES OF POKA - YOKE?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

WHAT IS POKA YOKE CONCEPT?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

POKA YOKE
POKA means INADVERTENT ERRORS
YOKE means TO AVOID
POKA -YOKE TO AVOID INADVERTENT
ERRORS
TERM COINED BY Dr. SHIGEO SHINGO

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

(what?)

POKA YOKE ..CONCEPT

POKA-YOKE System is a Technique

to achieve zero Defect in the Product.

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

WHAT IS POKA YOKE CONCEPT?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

OTHER NAMES..
POKA YOKE..?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

(what?)

FORMER (OTHER) NAMES OF

POKA YOKE

1. FOOL PROOFING SYSTEM

2. MISTAKE PROOFING SYSTEM

3. FAIL SAFING SYSTEM

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

POKA YOKE OTHER NAMES?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

WHY..?
POKA YOKE..

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

(what?)

POKA YOKE ..CONCEPT

Process with Zero Defects
Detect Error

Feedback/Corrective
Action

1. POKA-YOKE is to achieve ideal

Production System.

2. To carry out 100% inspection and

immediate feedback in system.

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

(why?)

POKA YOKE ..CONCEPT

1. Detect Errors & Eliminate Before they Become

Defects.

2. Install a system / Device which detects Errors

forgotten by the Producer, Thereby Preventing Defects
from occurring.

TVS - MOTOR CO.,

Poka Yoke

WHY POKA YOKE ?

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW TO IMPLEMENT POKA YOKE?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW TO IMPLEMENT POKA YOKE?

PROBLEM LIST
ANALYSIS

RESPONSE
IDENTIFICATION FOR POKA YOKE
ACTION
RESULT

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW TO ANALYSIS..?????
HOW TO RESPONSE..?????

IN WHAT STAGE..?????
WHERE..?????

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW TO ANALYSIS..?????

TO IDENTIFY THE
ROOT CAUSE OR ERROR

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

DEFECTS AND CAUSES(Errors)

ELEMENTS AT GEMBA (4M & I)
Errors

MAN

MACHINE
MATERIAL
METHOD
INFORMATION

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

ALL THE CAUSES ARE RELATED WITH VARIOUS FACTORS.

THE MAIN FACTORS ARE GIVEN IN THE DIAGRAM
DEFECTIVE PRODUCT

MAN

MACHINE
METHOD
PROCESSING

MATERIAL INFORMATION

WE HAVE TO AVOID DEFECTS BY ELIMINATING THE

ERRORS IN ALL THE ABOVE FACTORS.

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

TYPES OF ERRORS CAUSED BY PROCESSING

(MACHINE + METHOD)
DEFECTIVE PRODUCT

PROCESSING ERROR

PRIMARY DEFECT

MACHINE + METHOD

MACHINE + METHOD

OPN. OMITTED

= PROCESSING
ERROR

OPN. ERROR

SECONDARY DEFECT
ADJUSTMENT
ERROR

WORK-PIECE
SETUP ERROR

OPERATIING WRONG
WORK PIECE

INCORRECT
EQUIPMENT SETUP

IMPROPER
TOOLS AND JIGS

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TYPES OF ERRORS CAUSED BY INFORMATION

DEFECTIVE PRODUCT

INFORMATION ERROR

WRONG
INFORMATION

INADEQUATE
INFORMATION

VERY
COMPLICATED
INFORMAITON

NO
INFORMATION

INFORMATION ERROR

INFORMATION
NOT CLEAR
TO UNDERSTAND

NO
STANDARDS
IN
INFORMATION

INFORMATION
NOT VISIBLE

INADEQUATE
INFORMATION

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

TYPES OF ERRORS CAUSED BY MATERIAL

DEFECTIVE PRODUCT

MATERIAL ERROR

MATERIAL ERROR

PRIMARY DEFECT
MACHINE + METHOD
WRONG PARTS

MISSING PARTS
SECONDARY DEFECT

BLOW
HOLES

POROSITY

ONE PART
MISS IN SUB
-ASSEMBLY

ONE PART
WRONG IN SUBASSEMBLY

MATERIAL
SHORTAGE

WRONG
WRONG B. O.
MATERIAL COMPONENTS

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

TYPES OF ERRORS CAUSED BY HUMAN ERRORS

DEFECTIVE PRODUCT

HUMAN ERROR

FORGETFULNESS

ERRORS DUE
TO MISUNDERSTANDING

ERROR DUE TO
SLOWNESS

HUMAN ERROR

ERRORS IN
IDENTIFICATION

ERROR DUE
TO LACK OF
STANDARDS

ERRORS MADE BY
AMATEURS

SURPRISE
ERROR

WILLFUL
ERRORS

INTENTIONAL ERROR

INADVERTENT
ERROR

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

TO PREVENT THESE ERRORS

i.e,

MAN ERROR
MACHINE ERROR
MATERIAL ERROR

METHOD ERROR
&
INFORMATION ERROR
POKA YOKE SYSTEM .

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

THREE POINT TO RESPONSE

URGENCY
DIFFICULTY

COUNTERMEASURE
Total points = Urgency x Difficulty x Countermeasure Method

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

HOW TO ANALYSIS.
HOW TO RESPONSE..

IN WHAT STAGE..?????
WHERE..?????

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

IN WHAY STAGE?.WHERE.?
POKA YOKE ?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

THE BASIC FUNCTIONS OF

POKA YOKE
DEFECTS ARE EXISTING IN TWO STAGES:ABOUT TO OCCUR
IN THE NEXT PROCESS
- CALLED AS PREDICTION
STAGES OF
DEFECTS
ALREADY OCCURRED IN
THE PREVIOUS PROCESS
- CALLED AS DETECTION

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

THE BASIC FUNCTIONS OF

POKA YOKE
POKA YOKE HAS THREE BASIC FUNCTIONS TO USE
AGAINST DEFECTS
SHUT DOWN

BASIC
FUNCTIONS

CONTROL

WARNING

Poka Yoke

TVS - MOTOR CO.,

A
1

PREDICTION
PREVENTION

PED - DESIGN CENTER

SHUT DOWM
CONTROL
WARNING

POKA YOKE
A
DETECTION

SHUT DOWM

B
CONTROL

II
C
WARNING

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

WHAT ARE BEST POKA YOKE ?

TO AVOID DEFECTS CAUSED BY
HUMAN ERRORS

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

FIVE BEST POKA YOKE TO AVOID

DEFECTS CAUSED BY HUMAN ERRORS
FIVE EXAMPLES OF POKA YOKE FOR DETECTING OR AVOIDING DEFECTS
CAUSED BY HUMAN ERRORS

1.

GUIDE PINS OF DIFFERENT SIZES

2.

ERROR DETECTION AND ALARMS AUTOMATICALLY BY A

MISIC/SOUND OR BY A LIGHT

3.

LIMIT SWITCHES

4.

D AUTOMATIC COUIGITALNTER

5.

CHECK LIST

TVS - MOTOR CO.,

1.

Poka Yoke

GUIDE PINS OF DIFFERENT SIZES

PED - DESIGN CENTER

TVS - MOTOR CO.,

2.

Poka Yoke

PED - DESIGN CENTER

ERROR DETECTION AND ALARMS AUTOMATICALLY BY A

MISIC/SOUND OR BY A LIGHT

TVS - MOTOR CO.,

3.

Poka Yoke

LIMIT SWITCHES & SENSORS

PED - DESIGN CENTER

Poka Yoke

TVS - MOTOR CO.,

PED - DESIGN CENTER

Energy Sensors
These devices work by
using energy to detect
whether or not an defect
has occurred.

Fiber optic
Vibration
Photoelectric

TVS - MOTOR CO.,

4.

Poka Yoke

DIGITAL AUTOMATIC COUNTER

PED - DESIGN CENTER

TVS - MOTOR CO.,

5.

CHECK LIST

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

POKA YOKE Practical Examples

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

02 - 03

Wk. 3
Eliminate Outer tube scrap due to axle bracket
miss location
Axle
bracket

Axle
bracket

Fixture accepts
wrong loading

Fixture will not

accept wrong
loading

Qty in nos

Outer tube scrap due to axle bracket

miss location

Axle bracket located wrongly in the

fixture

SS,MSR,PP,PR,CC

Wk. 3

20
10
0

Before

After

Not applicable

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Fixture accepts wrong loading

Poka Yoke

TVS - MOTOR CO.,

Equipment failure loss

PED - DESIGN CENTER

Fab-1

JH

02 - 03

Wk. 36
Eliminate Oil fork production loss due to torch
damage

Wk. 36

Torch
Damage

SS,MSR,PP,PR,CC

Production loss due to torch damage

eliminated
Sensor

Provide Proper sensor interlock

ar

Not applicable

No interlock

After

Ja
n

Axle bkt locating pin not removed after

clamping

15
10
5
0

Before

No
v

Torch hit on axle bkt locating pin in

auto cycle

Break down in hr

Oil fork rotary torch damage

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 39
Eliminate Oil fork scrap due to Outer tube miss
location in Reaming

SS,MSR,PP,PR,CC

Wk. 39

Oil fork scrap due to Outer tube miss

Fork tube Position OK

Fixture

Position NOT Anchor bracket

OK

Fork tube Position OK

Anchor
bracket

Fixture

Oil fork scrap due to outer tube miss

location

Fixture accepts wrong loading

Qty in nos

Component loaded wrongly in fixture

Pokayoke
stopper

Before

After

4
3

Not applicable

2
1
0

No pokayoe stopper

Provide Proper Pokayoke stopper

location in Reaming is eliminated

Nov

Dec

Jan

Feb

Mar

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 19
Eliminate Oil fork scrap due to Outer tube
length oversize

Fork tube

Length
oversize

Fixture

SS,MSR,PP,PR,VNSR

Wk. 20

End stopper

Fork tube

Oil fork scrap due to Outer tube length

Oversize problem eliminated

Fixture

Outer tube scrap due to length oversize

Defective Component loaded in fixture

Fixture accepts defective component

Qty in nos

50

Before

After

40
30

Not applicable

20
10
0

No pokayoe stopper

Provide Proper Pokayoke stopper

Jun

Jul

Aug

Sep

Oct

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 39
Eliminate Oil fork scrap due to Outer tube miss
location inRotary

Stabilizer mtg bkt

Fork tube

MSR,PP,PR,VNSR,SSK

Wk. 39

Stabilizer mtg bkt

OK
position

Oil fork scrap due to Outer tube miss

OK
position

location in Rotary operation is eliminated

Poka yoke
topper

NOT OK
position

Fork tube

Oil fork scrap due to outer tube miss

location

12

Before

After

Fixture accepts wrong loading

Qty in nos

10

Component loaded wrongly in fixture

8
6

Not applicable

4
2
0

No pokayoe stopper

Provide Proper Pokayoke stopper

Aug

Sep

Oct

Nov

Dec

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 6
Eliminate fuel tank scrap due to wrong
loading at inlet hole piercing

Wk. 6

MSR,PP,PR,VNSR,SSK

Fuel tank scrap due to wrong loading at

inlet hole piercing is eliminated

Punch

Punch
Outer assy

No
stopper

Die

Outer assy
Stopper
provided

Component loaded wrongly in press tool

Qty in nos

Outer assy scrap in

inlet hole piercing due to miss location

20
10
0

Die

Before

After

Introduced in sport model

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Press tool accepts miss location

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 6
Eliminate fuel tank Outer scrap at adopter hole
piercing stage

Die
Outer

Wk. 6

Die
Outer

Clamp

MSR,PP,PR,VNSR,SSK

Clamp

Pot magnet provided

Possibility of slipping
from location

Component loaded wrongly in press tool

Qty in nos

Outer assy scrap in

inlet hole piercing due to miss location

40
20
0

Before

After

Introduced in sport model

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Press tool accepts miss location

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

02 - 03

Wk. 3
Eliminate Outer tube scrap due to axle bracket
miss location
Axle
bracket

Axle
bracket

Fixture accepts
wrong loading

Fixture will not

accept wrong
loading

Qty in nos

Outer tube scrap due to axle bracket

miss location

Axle bracket located wrongly in the

fixture

SS,MSR,PP,PR,CC

Wk. 3

20
10
0

Before

After

Not applicable

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Fixture accepts wrong loading

Poka Yoke

TVS - MOTOR CO.,

Equipment failure loss

PED - DESIGN CENTER

Fab-1

JH

02 - 03

Wk. 36
Eliminate Oil fork production loss due to torch
damage

Wk. 36

Torch
Damage

SS,MSR,PP,PR,CC

Production loss due to torch damage

eliminated
Sensor

Provide Proper sensor interlock

ar

Not applicable

No interlock

After

Ja
n

Axle bkt locating pin not removed after

clamping

15
10
5
0

Before

No
v

Torch hit on axle bkt locating pin in

auto cycle

Break down in hr

Oil fork rotary torch damage

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 39
Eliminate Oil fork scrap due to Outer tube miss
location in Reaming

SS,MSR,PP,PR,CC

Wk. 39

Oil fork scrap due to Outer tube miss

Fork tube Position OK

Fixture

Position NOT Anchor bracket

OK

Fork tube Position OK

Anchor
bracket

Fixture

Oil fork scrap due to outer tube miss

location

Fixture accepts wrong loading

Qty in nos

Component loaded wrongly in fixture

Pokayoke
stopper

Before

After

4
3

Not applicable

2
1
0

No pokayoe stopper

Provide Proper Pokayoke stopper

location in Reaming is eliminated

Nov

Dec

Jan

Feb

Mar

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 19
Eliminate Oil fork scrap due to Outer tube
length oversize

Fork tube

Length
oversize

Fixture

SS,MSR,PP,PR,VNSR

Wk. 20

End stopper

Fork tube

Oil fork scrap due to Outer tube length

Oversize problem eliminated

Fixture

Outer tube scrap due to length oversize

Defective Component loaded in fixture

Fixture accepts defective component

Qty in nos

50

Before

After

40
30

Not applicable

20
10
0

No pokayoe stopper

Provide Proper Pokayoke stopper

Jun

Jul

Aug

Sep

Oct

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 39
Eliminate Oil fork scrap due to Outer tube miss
location inRotary

Stabilizer mtg bkt

Fork tube

MSR,PP,PR,VNSR,SSK

Wk. 39

Stabilizer mtg bkt

OK
position

Oil fork scrap due to Outer tube miss

OK
position

location in Rotary operation is eliminated

Poka yoke
topper

NOT OK
position

Fork tube

Oil fork scrap due to outer tube miss

location

12

Before

After

Fixture accepts wrong loading

Qty in nos

10

Component loaded wrongly in fixture

8
6

Not applicable

4
2
0

No pokayoe stopper

Provide Proper Pokayoke stopper

Aug

Sep

Oct

Nov

Dec

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 6
Eliminate fuel tank scrap due to wrong
loading at inlet hole piercing

Wk. 6

MSR,PP,PR,VNSR,SSK

Fuel tank scrap due to wrong loading at

inlet hole piercing is eliminated

Punch

Punch
Outer assy

No
stopper

Die

Outer assy
Stopper
provided

Component loaded wrongly in press tool

Qty in nos

Outer assy scrap in

inlet hole piercing due to miss location

20
10
0

Die

Before

After

Introduced in sport model

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Press tool accepts miss location

Poka Yoke

TVS - MOTOR CO.,

Defect and rework loss

PED - DESIGN CENTER

Fab-1

HH

01 - 02

Wk. 6
Eliminate fuel tank Outer scrap at adopter hole
piercing stage

Die
Outer

Wk. 6

Die
Outer

Clamp

MSR,PP,PR,VNSR,SSK

Clamp

Pot magnet provided

Possibility of slipping
from location

Component loaded wrongly in press tool

Qty in nos

Outer assy scrap in

inlet hole piercing due to miss location

40
20
0

Before

After

Introduced in sport model

Provide Stopper to avoid wrong loading scrap

Ju
l

ay
M

No stopper provided

ar

Press tool accepts miss location

POKA-YOKE STEPS IN TVS-M

PED - DESIGN CENTER
Poka Yoke

TVS - MOTOR CO.,

POKA-YOKE

Existing Process

New Process, Machines

Process Design - PFMEA

Problem list

(Ensure provision of necessary Poka-Yoke in process by

existing problem,customer complaint.) TSPS NO:003

Analysis

New Machine Enquiry

(Poka-Yoke check list sent with enquiry) TSPS NO:003

Identification for
POKA-YOKE
Action

New Machine Ordering

(Poka-Yoke check list sent with ordering) TSPS NO:003

Machine Design DFMEA/DAP TSPS NO:003

(Ensure provision of necessary Poka-Yoke in design)

In house fixture and gauges

(Poka-Yoke check list for Design Fixtures and Gauges)

Result

Machine Trials at supplier end

(Check effectiveness of Poka-Yoke provided
and necessity of new Poka-Yoke) TSPS NO:003

Standardisation

Productionising Trials (EJO) Check sheet

(Check effectiveness of Poka-Yoke provided
and necessity of new Poka-Yoke identification in GEMBA

ISSUED BY :E.Tamilselvan PED/TDO Ex: Ph:No:2808

YOUR SUGGESTION FOR IMPROVING THIS ARE WELCOME.

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

PED - DESIGN CENTER

Poka
Yoke
POKA YOKE : IMROVEMENT IN UPSTREAM PROCESSES

TVS - MOTOR CO.,

Practice
Up Stream Process

Present

Fixture/Gauge Design

POKA YOKE thought by Designer but not listed.

Bought out Machine DAP Approval

POKA YOKE Discussed with M/c Supplier but not listed.

Process FMEA

Machine Trials

POKA YOKE is not a specific step.

POKA YOKE checking is not Recorded Meticulously.

To be changed to
* List

POKA YOKES Provided in Drawing.

List
POKAS Identified but Yoke not provided.
*

* List

Poka Yokes Considered.

* List

Pokas identified and yoke not provided.

* List

Poka Yokes provided.

* List

Pokas identified but Yoke not possible.

* Check

Effectiveness of Poka-Yokes.

* Identify any new Pokas required to be found.

* List

QP Trial

NO List of POKA YOKE.

and check effectiveneess of POKA

YOKES provided in earch machine.
* Identy any new pokas/ or declare as 100%
Poka Yoke station.

Review of Shop Floor POKA YOKE

Kaizens by PED

Not Systematically done.

* Review

More insight into Defects - Causes &

appropriate Poka yoke solution.

Issued by: E.Tamilselvan ph : 2808

and revise the check list.

* New

list of possible defects/causes/yoke

provided to design engineers and methods
engineers.

YOUR SUGGESTION FOR IMPROVING THIS ARE WELCOME

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

ZERO DEFECT

JUST IN TIME

IS IT POSSIBLE
ONLY IN
JAPAN.?

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS TEAM WILL ACHIEVE

TVS - MOTOR CO.,

Poka Yoke

ANY DOUBT?

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

THANK YOU

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

Dont make the

mistake of thinking that the concept can only be applied to manufacturing it
applies to all functions and processes in a business: sales, marketing,
distribution, R & D, manufacturing, warehousing, billing, and customer service.
Trough which

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER

TVS - MOTOR CO.,

Poka Yoke

PED - DESIGN CENTER