(Northern Region)

Training Programme On POKA-YOKE

Faculty : Mr. Rakesh Gupta, Senior Counsellor , ACMA Centre for Technology Email : rakesh.gupta@acma.in, rakesh137@gmail.com 12th March 2010, New Delhi

Poka- Yoke

Lets First Understand some Basics

Poka- Yoke

Customer Requirements Q : Quality ( Zero Defect with reliability) C : Cost (Least Price)

D : Delivery (On time delivery, every time)

Poka- Yoke

Company : Basic Performance Parameters

P Q C D S M E

: : : : : : :

Productivity Quality Cost Delivery Safety Morale Environment

Poka- Yoke

3M
MUDA Waste / Non- value adding : MURA : Unevenness / Inconsistency /Imbalance

MURI : Overburden / Strain

Poka- Yoke

Waiting

Overproduction Transportation

Wastes
Processing

Defects

Basics of TPS

Motion Poka- Yoke

Inventory

7 Types of Waste
Types of Waste
1. Overproduction 2. Inventory/ Stock 3. Correction/ Defective 4. Transportation 5. Waiting 6. Motion / Movement 7. Processing itself

Description
Producing more, sooner and faster than required by the next process Maintaining excess inventory Rejection/rework to fulfill the customer requirements Any material movement that does not add value to the product Operator or machine idle time Any wasted motion to do a Job. Also wasted walking. Doing more work than necessary
Poka- Yoke

First Principle of Quality :

Start with the Customer

Objective : To give Zero Defect Products & Services to Customer. How ??.......

Poka- Yoke

3 Aspects of Quality 1

Supplier

Manufactu -ring
3

New Product Quality

Quality is common in all the three aspect. Issues are different for the above 3 Aspects. Poka- Yoke 9

Issues of Manufacturing Q

and

New Product Q

Man Issues ufact uring Q

1. Deviations, 2. Damages, 3. Poor workmanship 4. Less / More Quantity

Root Cause

1. Discipline Issues 2. Manpower skill related issues. 3.Planning related issues 4. Maintenance of machines, Jigs & Fixtures 5. Silly mistakes

Counter measure

1. Follow the Rules 2. Multi-skilling 3. Improve Planning 4. Do TPM Step 1,2,3 & PM of machines, Jigs & Fixtures 5. Do Poka-Yoke

1.Launch Date Failure New Issues 2. Design Related Produ Issues ct 3. Product Performance Q related

1.Procurement of Gauges, Fixtures. 2.Machines Availability. Counter Root 3.Process stability measure Cause during production process. 4.Standardization of toolings

1.Plan for procurement of Gauges, Fixtures. 2.Plan for Machines availability. 3.Ensure process stability during production process. 4. Do Standardization of toolings

Poka- Yoke

Quality Pyramid
ThumbRuleofQualityPyramid

Customer 1 PPM

Company

100 PPM

Supplier

500 PPM

Poka- Yoke

Cost of Quality : (1-10-100 Rule)

Prevention

10

Stages

Correction

Rs Rs

Rs
Rs
100

Failure

Rs

Rs

Which is better ?? Correction or Prevention

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Poka- Yoke

Cost of rectifying defect

Rs

Rs

Quality
Customer requirement : Zero Defect Is it Possible to achieve ?? Yes / NO If No Do we have the Choice ?? If Yes How to achieve it ??
13
Poka- Yoke

3 Steps to achieve Zero Defect

1. Self Inspection 2. Sequential Inspection 3. Source Control

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Poka- Yoke

Zero Defect : How to achieve?

Sampling Inspection 100% Inspection SPC 7 QC Tools Quality Circle
Do the above methods guarantee Zero Defect ?? 15
Poka- Yoke

Zero Defect
Is 100% Inspection a Guarantee for Zero Defect ?

Solution : Build Quality in the Process What is the meaning ?? How to build Quality in the process?? ..

16

Poka- Yoke

Concept of 100% Inspection:---100% Inspection---- Easiest way of giving Zero

defect product to Customer.

What is 100% Inspection ??.... Is it really easy & practically possible ??....

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Exercise on 100% inspection

Creating a Poka-Yoke world Machine vision technology cuts down installation and maintenance time of zero defects systems. Poka-Yoke techniques are now widely prevalent amongst manufacturers all over the world and across industry verticals. While majority of Poka-Yoke systems are based on basic mechanical jigs and fixtures, there is increasing popularity for more versatile and instantly reconfigurable machine vision based Poka-Yoke systems. In the early 1960s quality guru Dr. Shigeo Shingo combined the concepts of Self, Sequential and Source inspections with Toyotas in-house foolproofing techniques and devised the famous Quality Assurance philosophy Poka-Yoke (POH-kah YOH-keh), a tool to achieve and sustain zero defects. It implies absolute elimination of defects in the production process. Defect free supplies are not just a desired goal, but in many instances essential for suppliers. Hence, in order to eliminate manual errors, automation is gaining popularity in quality control and inspection processes.

Your task : Count the No. of e in the above 18 lines

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 100% Inspection means Inspection of all the

CTQs in each piece of the product.

Example:A Company produces Control cables = 50,000 nos./ day. There are child parts attached to each cable = 10 nos./ cable No. of CTQs per part = 5 nos./ Part. Therefore, total CTQs to be checked / day = 25Lakhs Let us consider average Inspection time = 15 sec./ CTQ Therefore, Total time required for all the CTQs/ day = 46 man hrs ( i.e. 6 Men per 8 hours shift.)

Conclusion:1)Practically it is not possible to do 100% inspection. 2)Since, Practically it is not possible to do 100% inspection, therefore, you are sacrificing the Quality.
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Defects classification
A - Type defect
OK NOT OK

B - Type defect
OK NOT OK

C - Type defect
NOT OK

Action taken by operator

No action by operator

OK

Action taken by operator

LSL

OK

USL

LSL

OK

USL

LSL

OK

USL

The output is (OK) initially becomes (NG). Corrective action is taken by operator becomes (OK) Use Why Why Analysis

The output is (OK) initially becomes (NG). No action taken by operator becomes (OK). Analyze machine parameters and process parameters

The output is (NG) initially Action taken by operator becomes (OK) (setting rework /scrap)

Poka- Yoke

Prevention of Defects

Work Procedure

Machine or human error

Detecterror

Take corrective action

Zero Defect

Modifywork procedureto preventsucherrors

Analyze for preventive action

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Poka- Yoke

PossibleRootCausesforNonConformance/Defects 6MFactors Man Material Machine Method MeasuringEquipment MaterialHandlingEquipment

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Poka- Yoke

5S
Meaning Benefit
Space recovered

1S 2S 3S 4S 5S

Sorting, Wet to Dry ( Keep Wanted things and remove unwanted things from the work place) Arrangement, A place for every thing and every thing in its place , Pre- fix location, labelling, marking, Set Limits Cleaning Standardisation Discipline ( Habit- Follow the above 4S)

Search time elimination Shining everything Holding the Gains Sustenance

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Poka- Yoke

Defects Vs Errors
It is important to understand that defects and errors are not the same thing. A defect is the result of an error, or anerroristhecauseofdefect. Cause
Error

Result
Defect

We should take Action on Defect or Error ?? 24

Poka- Yoke

What is an Error?
Errors are inadvertent, unintentional, accidental mistakes made by people because of the human sensitivity designed into our products and processes Errors result in those once in a while defects that we always find difficult to control. Defects make Customer unhappy
Inadvertent errors are not only possible but inevitable

Poka- Yoke

Poka- Yoke

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Poka- Yoke

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Even an individual on the job all day every day for a month faces many distractions that can divert his/her attention and therefore errors are inevitable to occur in his/ her work.
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We deal with lot of people every day. Interruptions from rotations, relief breaks, overtime coverage, transfers, and shift to shift variation result in different methods, training levels, knowledge of Operator.

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Are Errors Unavoidable ?

Errors are Inevitable

Poka- Yoke

Errors can be Eliminated 30

In a Factory various Kinds of Errors happen

Forgetfulness Part missing. Errors due to misunderstanding wrong orientation. Errors in identification similar looking parts. Errors due to lack of standard.

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What Do We Do?

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Error Proofing
Poka- Yoke

Murphys Law
If any thing can go wrong, It will go wrong !

POKA YOKE :
Rewrites the Murphys Law. If any thing can go wrong, It can be prevented !
Mind set is necessary to have strong conviction that mistakes can be eliminated thereby achieving Zero Defect is Possible.

Poka- Yoke

Poka Yoke : Some common examples

3.5 inch diskette cannot be inserted unless diskette is oriented correctly.

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Poka Yoke : Some common examples

Simple Instruction is also a Mistake Proofing method. For some file cabinets, opening one drawer locks all the rest, reducing the chance of the file cabinet tipping.
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Poka Yoke : Some common examples

Fueling area of car has three Mistake Proofing devices: 1. Filling Pipe insert keeps larger, leaded- fuel nozzle from being inserted. 2. Gas cap tether does not allow the motorist to drive without cap. 3. Gas cap is fitted with ratchet to signal proper tightness and prevent over tightening.

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Poka Yoke : Some common examples

Electronic door locks can have three Mistake-Proofing devices: 1. Ensures that no door is left unlocked. 2.Doors automatically lock when the car exceeds 25 Km per hour. 3.Lock wont operate when door is open and the engine is running.

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Poka Yoke : Some common examples

Bathroom sinks have a mistake-proofing device. It is the little hole near the top of the sink that helps prevent overflows.

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Poka Yoke : Some common examples

This Iron turns off automatically when it is left unattended or when it is returned to its holder.

Poka- Yoke

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Poka Yoke : Some common examples

The dryer stops operating when the door is opened, which prevents injuries.

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Poka Yoke : Some common examples

The sink is fitted with Light sensor. This sensor ensures that the water is turned off in the sink.

Poka- Yoke

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Poka Yoke : Some common examples

The urinal are fitted with light sensor. These sensor ensure that the urinal is flushed.
Poka- Yoke

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Poka Yoke : Some common examples

This device continuously monitors the water level. If the level is too low, a valve opens to add water to the pool.

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Poka Yoke : Some common examples Hotel rooms are equipped with a room key holder which turns off the power when the key is removed. This ensures no electricity flows to the room while it is vacant.

Poka- Yoke

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Poka Yoke : Some common examples

New Lawn Movers are required to have Safety Bar on the Handle that must be pulled back in order to start the engine. If you let go, the Mover blades would stop in 3 secs.

Poka- Yoke

What is Error Proofing?

It is a system that reduces the probability and cost of errors and helps us reach our goal of Zero Defects.
1. prevents personal injury 2. prevents faulty products 3. reduces non-value added activities

Poka- Yoke

What does Error Proofing do? The ideal operation is error proofed at 3 stages: Input, process and output. Complete Operation

1. Input

2. Process

3. Output

Ideal: 1. Will not accept any bad parts 2. Will not make any bad parts 3. Will not pass on any bad parts
Poka- Yoke

Error Proofing Approaches

Prevent defects from occurring: Identify the potential of error, before it occurs, and prevent it Detect the defect: Error has already occurred, detect and remove the defective product Loss control: -- Potential for defect exists, potential exists for not detecting: Minimize damage from the defect

All These Approaches Overlap, No Clear Boundaries

Poka- Yoke

Example Fire Proofing a New Building

Prevention: 1) Use only non-combustible material for construction (steel,
concrete, etc.) 2) Do not allow smoking, 3) Use proper electrical system and components

Detect:
1) Install smoke detectors and fire alarms

Loss control:
1) Install sprinkler system, fire extinguishers, fire hoses

Poka- Yoke

Poka- Yoke : A Japanese word

Poka Yokeru = = Inadvertent Errors To Avoid

Poka + Yoke = To avoid inadvertent errors Some Questions to think . What is the meaning of Inadvertent Errors?? Why do these errors occur ?? In a company who makes these errors ??

Poka- Yoke

Poka- Yoke

Dr. Shigeo Shingo

The term is coined by Dr. Shigeo Shingo. It is a simple technique to avoid simple human error at work. Part of Zero Defect Quality Control. Identifying defects at the source lowers the cost. For poor design of product/process we will need to strengthen the design. For human error we will need to implement Poka -Yoke.
Poka- Yoke

Poka- Yoke
Ensures defect free component / product/ service

ZERO DEFECT - QUALITY COST REDUCTION

Eliminates / reduces rejection/ scrap

Poka- Yoke
SLIDE NO 10

Poka - Yoke
It is one of the tools to build quality in the process

How a Poka- Yoke helps to build quality in the process ??

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Poka- Yoke

Basic Classifications of Poka-Yoke

Two Types 1. Prevention type Poka- Yoke. 2. Detection type Poka - Yoke

A defect exists in one of two states:

1) It is either about to occur, or 2) It has already occurred.

Poka- Yoke

Basic Classifications of Poka-Yoke

Prevention Poka- Yoke . When a Poka-Yoke is designed in a way that it helps the operator to recognize the defect before it is about to occur , it is called a Prevention type poka-yoke. Detection Poka- Yoke When a Poka-Yoke helps the operator to know immediately on occurrence of the defect then it is called Detection type poka-yoke. Detection is After the defect is produced. The merit of this type of poka-yoke is based on the stage at which the defect is detected. In simple language Earlier the Better.
Poka- Yoke

Example: Prevention type Poke-Yoke

Pins

Pins

Fig. 1A

Fig. 1B

Figure 1A : Shows that positioning Figure 1B : Shows that Prevented

holes are wrongly drilled due to incorrect of plate. incorrect positioning of the plate is by locating 4 reference pins. The cause of

Incorrect Drilling ( incorrect position ) is prevented.

Poka- Yoke

Example: Detection type Poke-Yoke

Pins

Fig. 2A

Fig. 2B

Figure 2A : shows that plate with 4 holes is drilled , is to be dispatched to the Customer. Customer complaint show many plates with 3 holes drilled. Figure 2B : shows the mistake of less drilled holes is Detected through a check by using 4 locator pins on a gauge. Poka- Yoke

Basic Classifications of Poka-Yoke

Poka-Yoke have three basic functions to use against defects :

1. Alarm 2. Shutdown 3. Control.

Poka- Yoke

Basic Classifications of Poka-Yoke 1. Alarm

Signals in the form of buzzers , blinking lights are used to warn when an abnormality has occurred (detection) / about to occur (Prevention).

2. Shutdown
Normal function of machine or process is stopped when defect is detected/ prevented.

3. Control
a)In Prevention type Poka- Yoke, Control means that even intentional errors are impossible or methods by which the cause of a defect if it starts happening, then it is automatcally prevented from happening(feedback mechanism). b)In Detection type Poka Yoke, Control means that the process is not stopped but the defective items are automatically separated out and are not allowed to pass on to the next stage. Poka- Yoke

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Poka Yoke or Error Proofing Techniques

Poka- Yoke

Five Examples : Poka-Yoke

Here are five simple examples of Poka-Yoke for detecting or avoiding defects caused by human errors.

Poka- Yoke

Poka- Yoke Devices

Poka- Yoke

Types of Sensing Devices

We have many sensing devices 1. Limit switches, Microswitches 2. 3. Proximity Switches Photoelectric Switches

4. Beam Sensors 5. Sensor to detect changes in Physical condition like temperature, pressure etc. (Pressure switches, thermostats etc.)

Poka- Yoke

Processing Error Including Safety Errors

Processing Error occurs due to operators mistake where some process step is partially or incorrectly done For Example : Sometimes the drill is raised back before drilling the required depth (thru). A Proximity Switch has been provided to sense the coming thru of drill to indicate completion of drill operation.

Job Job

Fixture Job Without Thru Hole

Fixture

Proximity

Job With Drilled Thru Hole

Poka- Yoke

Processing Error
Problem : During the mounting operation, plastic covers were scratched when screwdriver slipped out of screw slots Before Cassette covers were frequently scratched when the screwdriver slipped out of the screw slot and slid against the plastic covers. After A change was made in the shape of the screw slot to prevent the screwdriver from slipping. Scratches caused by the screwdriver slipping has been completely eliminated.

Key Improvement : Screw slot shape modified to protect it from damage Poka- Yoke

Assembly Error
Assembly errors occur when operator by mistake does partial or incorrect assembly. For Example : During Assembly of a gear on the shaft for two similar models, Gear B is assembled on the Shaft a instead of Gear A. Gear A & B are similar looking gears differing only in the number of teeth. To eliminate this error a Mating part is installed on the Assembly fixture corresponding to A to ensure that only gear A is loaded
Mating Part for A

Shaft a Before Gear B Installed Wrongly After Only Gear A Can Be Installed

Poka- Yoke

Assembly Error
Problem : Shaft scratched due to improper insertion into jig Before If the shaft was not inserted straight into the receiving jig, the shaft scraped against the jig and was scratched. After A magnet was mounted to ensure that the shaft is inserted in the jig in a perpendicular position. Scratching is completely eliminated.

receiving jig

magnet pulls shaft straight to avoid scratching

scraping results in scratches

Key Improvement : Jig modified to guarantee correct positioning Poka- Yoke

Assembly Error
Problem : During Bending, Work pieces were mounted upside down in the jig
Before The work pieces were sometimes processed upside down. The defects were discovered only at assembly, causing delays in delivery.
correct

After Two pins were mounted in the jig making it impossible to set up the work piece upside down and eliminate defective items.
pin to prevent upside down mounting

defective

Key Improvement : Jig modified to include guide pins to guarantee correct positioning

Poka- Yoke

Inspection Error
Inspection error consists of examples which are related to rejected components going down the line or to the customer. These errors are due to monotony and fatigue faced by the inspector. The operator is not sure of the completion of leakage test and passes them to the bin meant for keeping jobs that have passed leakage test.
Leakage Testing Done Seam welded jobs waiting for leakage testing

Before

Jobs without Leakage Test is kept in the OK tray on the left.

Poka- Yoke

Operators are sometimes not sure of having completed the leakage test and keep untested products in the OK bin.

Head that stamps part number Advances when it senses no leakage

After

Now Head for stamping added at leakage testing station, only after leakage has been tested OK job will be stamped by the Head for stamping

Poka- Yoke

Inspection Error
Problem : Backward rotating fans not detected
Before The direction of rotation was tested after installation of the blades by checking the direction of air flow. However, some backwards-rotating fans were being shipped to customer.
nondefective Item

After Before mounting the blades, a generator is placed against the fan motor shaft and the motor is operated. If the motor rotates backwards, the polarity of the generator output is wrong, and a light and a buzzer notify the inspector.
motor

generator air flow defective Item

control box

air flow

Key Improvement : Inspection method changed and procedure modified to detect defective parts.

Poka- Yoke

Processing Omissions
Processing omissions occur when the operator misses out few steps of the process. For Example:

Four holes to be drilled

Three holes drilled because of mistake

Now the drilling operation has been provided with counter and the job will not be unclamped unless, the counter with drilling machine reads four.

Poka- Yoke

Processing Omissions
Problem : Holes not drilled during the drilling operation Before The additional sometimes omitted. holes were After The jig in the next process was modified with a pin to detect omitted holes. Omissions are always detected.
additional pin on jig next process detects workpieces with drilling omitted

Manually drilled hole

Key Improvement : Jig modified to detect defective parts Poka- Yoke

Assembly Omissions occur when an assembly part is not assembled by the operator by mistake and the assembly goes to next station. For Example : In an assembly operation washer were missed before providing nut. To remove this problem washer picking was sensed to give a start to nut runner.
Proximity which senses picking of washer gives signal to Nut Runner
Nut Runne r

Assembly Omissions

Picking

Nut

Washer Sometimes missed

PICKING OF WASHER WILL BE SENSED TO ALLOW THE START OF NUT RUNNER

Poka- Yoke

Packing / Pasting / Labelling Error

As the name suggests this Error is in Packing/Pasting/Labeling. For example: A Carton goes with a filled medicine bottle inside. Due to mistake the packer missed to fill a bottle in the carton. Now a draft of fan has been provided below the conveyor, carrying cartons with bottle, which is strong enough only to blow an empty carton.

Poka- Yoke

Dimensional Error / Mis-orientation /Misalignment

This section consists of errors because of misaligned / misoriented job loaded on a process leading to slightly offset operations. For example:
Movement of notch milling Movement of notch milling

RIGHT Notch to be made on the side with one hole

WRONG Notch made on the side opposite to one hole

Poka- Yoke

Now at notching operation the fixture has been made with 3 pins as shown. Job with wrong orientation cannot be loaded for Notch operation.

Not possible to load Fixture for Notch operation

Poka- Yoke

POKA - YOKE

COMPONENT PILLAR DIA 25 mm PILLAR DIA 45 mm

Poka- Yoke

Effectiveness of POKA YOKE

To ensure effectiveness of POKA YOKE we need to.

Have Visual Control on all POKA YOKE Stations like Lights Stickers or any other visuals Conduct Audits to validate the functioning of PY using Good and Bad Samples Daily - start of the shift audit by operator Mid-day audit by Quality inspectors Random audit by Production supervisors, Managers. The daily audit by operators have to be recorded in the Daily check sheet displayed in the work station

Visual Display - Stickers

Master Samples

Daily Checksheet

Poka- Yoke

Opportunities for Poka- Yoke

Manual operations where worker vigilance is needed Where mis-positioning can occur Where adjustment is required Where Teams need commonsense tools and not another buzz word. Where SPC is difficult to apply or apparently ineffective. Where attribute and not measurements are important. Where Training Cost and Employee turnover are high Where mixed model production occurs Where special causes can re-occur Where external failure costs dramatically exceed Where customers make mistakes and blame the service provider
Poka- Yoke

3 Rules of Poka -Yoke

1. Dont wait for the perfect Poka -Yoke. Do it now! 2. If your Poka- Yoke idea has better than 50% chance to succeedDo it! 3. Do it now.improve later!

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Poka Yoke Sheet

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Format : PokaYoke Sheet

Zone / Machine/ Production Dept etc. Problem Origin Process Solution Key Improvement
Customer Complaint Internal Problem Process Improvement

Poka Yoke Sheet

Detection

Company Name and Logo

Alarm Control Prevention Shut Down Before After

Name / s

Date

Poka Yoke No.

Poka- Yoke

Look for Poka-Yoke Opportunities on a line

No of Opportunities Completed

S.N 1 2 3 4 5 6 7 8 9 10 11 12

Pokayoke Opportunity Damaged part Dimensional error Component Reversed Wrong operation Wrong part Wrong tooling Missing Component Mismatched Misalign Processing Ommited Breakdown Ingress of Foreign Material Total

Complet ed by Complet ed Prevent ion by Det ect ion

Every Customer Complaint must be closed by a Poka-Yoke

Poka- Yoke

Poka Yoke check sheet (Daily monitoring) POKA YOKE CHECKSHEE

Month :
S.no Machine Poka yoke Description Purpose What to check How to check 1 2 3

Starter pipe pressing stage

Jidoka type pnumatic sensor

Eliminate starter pipe reverse loading

Ensure working

By ensuring back pressure

Locating pin pressing stage

Pnuematic sensor

Eliminate locating pin reverse loading

Ensure working

By checking the Free flow in sunnex indicator

Locating pin pressing stage

Pressure sensor

Eliminate oval pin damage

Ensure working

By checking the Free flow in sunnex indicator

Locating pin pressing stage

Limit switch

Eliminate Locating pin missin operation

Ensure working

Visual

Oval pin pressing stage

Limit switch

Eliminating crimping operation missing

Ensure working

visual

Poka- Yoke

Examples

Poka- Yoke

Poka Yoke Sheet

Zone Name : Zone No :5 Problem Origin Process Solution Key Improvement
IN CONNECTOR ASSY.CAULKING HEIGHT O/S

Alarm Detection Control Prevention Shut Down After

Customer Complaint

Internal Problem

Process Improvement

DATE PUNCHING
STOPPER PLATE FIXTURE PROVIDED IN THE

PREVENTING THE HEIGHT O/S COMPONENT ENTRY IN TO THE FIXTURE

Before

Name / s

Poka- Yoke

Date

Poka Yoke No.

Zone :

Tool Room

Poka Yoke Sheet

Internal Problem Process Improvement

Problem Origin Process Solution

Miss Location
Customer Complaint

Alarm Detection Control Shut Down After

Inner Cabinet Bottom- OP 50

Stopper Plate Provided Both Sides.

Key Rejection (Miss Location )Avoided Improvement

Prevention

Before

Name

Date

Poka Yoke No.

Poka- Yoke

POKA-YOKE
POYE-YOKE No. : P 003 PROBLEM : Clamp Missing SOLUTION : Sensor provided in the Ckt. Checking Board KEY IMPROVEMENT : No circuit check un till part fitted. BEFORE Photograph Not Available AFTER DATE : PREVENT ERROR DETECT ERROR SHUTDOWN

CONTROL

ALARM

Sensor for clamp Miss

EFFECTIVENESS : INHOUSE PPM -125

EFFECTIVENESS (FROM THE DATE OF IMPLEMENTATION ) : No in-house rejection since then. 0 ppm IMPLEMENTED BY:

IDEA BY :

Poka- Yoke

POKA YOKE SHEET

PROBLEM : Component with Missed operation of 8.5 Milling passing on to next stage SOLUTION : fixture of subsequent operation modified so that component will not get fixed if 8.5 milling is not done. KEY IMPROVEMENT : elimination of chances of components with missed operation of 8.5 milling passing on to next stage. DATE: 20.10.03 LOCATION: Machine Shop PREVENT ERROR DETECT ERROR SHUT DOWN CONTROL

ALARM

BEFORE

AFTER

Locating Block

IDEA BY :

IMPLEMENTED BY :

Poka- Yoke

Thank You

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Poka- Yoke