Looking For Training That Really Works?

Poka Yoke Methodology A Quality

Investment.

(100% Mistakes Proofing For Zero

Defects )
A Quality Workshop From ZenPower International, Your Regional Expert in TPM Quality & Productivity.

Singapore Oct 11/12 KL Oct 14/15

Rendezvous Hotel Sheraton Hotel, S. Jaya

MURPHY’S LAW – IF ANYTHING CAN GO WRONG, IT WILL GO WRONG!!

Do Quality Issues still disrupt your production lines and upset your Customers? Too much is at stake. Take no chances and
make no compromises with Quality. Poke Yoke is at the heart of World-Class TPM and a central tool in the cutting-edge
Six-Sigma program. Learn the complete Poka Yoke methodology Design principles in this 2-Day Intensive Workshop.

THE POKA YOKE METHODOLOGY

What cause defects? Defects are caused by “Mistakes”. What then are mistakes? A MISTAKE is an ACTION or IN-
ACTION by MAN which sets off a chain of events resulting in the defect. Poka Yoke begins by identifying all the possible
mistakes in a process causing defects and implementing mistake-proofing measures to prevent Man from making mistakes.
If the Poka Yoke Design is comprehensive, a zero-defect process is not just a theory, but in fact achievable.

PRINCIPLES OF POKA-YOKE DESIGN FOR ZERO DEFECTS

Achieving Zero Defects through Poke Yoke depends on a STRUCTURED APPROACH that singles out every possible MISTAKE
for MISTAKE-PROOFING. Make your factory A Mistake-Free Defect-Free World Class Manufacturer starting with this Workshop.

THERE ARE AT LEAST 11 TYPES OF BASED ON CASE STUDIES, LEARN TO DESIGN

MISTAKES: POKE-YOKE FOR THE ENTIRE PROCESS.
ALL Problems can be traced to MISTAKES due to MAN’s 1.
Finding all Mistakes in any Process.
actions or in-actions. 2.
Finding the most suitable and minimum number
1. Worker is Forgetful. of Poke Yoke devices for 100% Mistake Proofing
2. Worker misunderstands. of any processes.
3. Worker misjudges.
LEARN THE FIVE GENERIC POKA YOKE
4. Worker lacks skills.
5. Worker is absent-minded, day-dreaming SOLUTIONS:
6. Worker willfully breaks work rules. 1. Guide Pins.
7. Worker is slow. 2. Error Sensing devices & alarms.
8. Worker deliberately sabotage.
3. Limit switches
9. Method is not suitable.
10. Machine sudden breakdown. 4. Counters and timers.
11. Material quality inconsistent. 5. Checklists and schedules.

Problems In A Process 4Ms Mistakes Analysis. Generate Poka

* Defects Yoke Solutions For
All Machine, Method, Man,
* Breakdowns whole Process To Prevent
Material Causes of the Problems
* Administrative Errors. Mistakes from happening.
are analyzed to find the Root
* Accidents.
Causes known here as
 Phase 1 Phase 2 Phase 3

Poke Yoke Design Methodology For A 100% Mistake-Free Process

THESE POKA YOKE DESIGN PRINCIPLES ARE APPLICABLE TO ALL TYPES OF MANUFACTURING & SERVICE INDUSTRIES.

Plant Quality 4Ms Analysis: Machine-Quality Matrix:

Assurance Matrix:
*Each Process’ defects are
All defects in the factory are analyzed for their 4Ms causes in
identified to the processes the sequence of Machine,
where they originate and Method, Man and Material.
appraised for further actions. *Fishbone & Why-Why Tools.
*P-M Analysis Tool specifically
for chronic problems.
Set equipment conditions that preclude
quality defects, by maintaining perfect
equipment for perfect quality of
processed goods and products. The
precision conditions are checked that
measured values are within standard
values for early countermeasures.

Poke-Yoke Application
- Types, design and
function of Poke-Yoke
Poke Yoke Process Design for
devices. 4Ms Mistake Analysis:
Zero Defects.
- Appropriate choice of For each Process perform Why-
- Process/Mistakes Attribution
Poke-Yoke devices Why Analysis of all
- Defects prioritization and 4Ms for the Root Causes which
-Verifying Poke Yoke
Critical Value Evaluation are Man-Mistakes.
Base-lining for before / after
solutions and revisit Plant
comparison.
QA Matrix

Example: FISHBONE ANALYSIS to identify WHY-WHY ANALYSIS for each 4M The

the 4Ms Causes of the ‘End Crack’ Defect. Causes to Pin-Point the MISTAKES MISTAKE
FOUND!!

Case: Cylinder does not operate smoothly.

Cylinder. Question Answer Short-term
No Immediate Actions
jerky
Procedures
1. Why is cylinder The oil strainer is Clean the strainer.
Hole operation not smooth? clogged.
Oil
Strainer
End 2. Why is the oil The oil is dirty. Drain oil, clean
Method MC Crack strainer clogged? and replace.

Man Material 3. Why is the oil dirty? Dirt has entered Prevent surrounding
the tank. dirt from scattering.
Dusty
4. Why did dirt get Upper plate of Plug the hole
Careless Dirty into the tank? tank has a hole.
oil
5. Why is the hole there? Standardize future
Repair error repairs.
by Maintenance.
WHO SHOULD ATTEND?
All Supervisors, Technicians, Engineers, Trainers, Managers
Directors from various functions including Production,
Maintenance, Process, QA, TQM, TPM, HRD Personnel, 6-Sigma
Black Belters responsible for Quality.

SPECIAL TRAINING PACKAGES

• Customized Corporate Workshops Poke Yoke
• Train-the-Trainer Package for In-house competency.
Please Call Today For Any Enquiries on above packages

CONTACTS CAN BE MADE AT

Hph M’sia: 019-5433188 Mr. Arthur
Hph Spore: 02-96916334 Ms. Arlene
Enquiries E-mail: zentan@singnet.com.sg
 DAY - 1
A) Evolution of Poke Yoke in Ultimate Quality Control.
- Judgment Inspection – most common and un-productive.
- Informative Inspection – its practices and limitations.
- Source Inspection – checks for mistakes, not defects.
- Definitions of Mistakes & Poke-Yoke.
- The 11 Types of generic mistakes leading to defects.
- The Five Generic Poke Yoke devices and their Applications.
B) Poke Yoke Process Step:1 - Process Selection.
- Poke Yoke Implementation: Ad-Hoc or Company-wide strategy?
- Establish the Factory QA (Quality Assurance) Matrix.
- Establish the likelihood of defects’ occurrence.
- Establish the Mistake-Proofing level for each defect-type.
- Perform Critical Value Evaluation for each defect-type
(Application 1: Group Exercise & Shared Learning)
Participants will be grouped and asked to establish a partial QA
Matrix under guidance based on their actual work-place experiences.
C) Poke Yoke Process Step:2 – Defects 4Ms Cause Analysis
- How to extract list of defects in Process from QA Matrix..
- Nature of and Guidelines to separate between the sporadic
and chronic defects.
- Pre-requisite of Effective Problem Solving depends on
thorough hands-on and on-site Investigation of the 3 Actuals.
- Identifying the 4Ms for each chronic defect through
Fishbone Analysis and Why-Why Analysis.
(Application 2: Group Exercise & Shared Learning)
Groups will select one of their Processes to identify the 4Ms of defects
in their chosen Process under guidance.
D) Poke Yoke Process Step:3- Analyze 1st M Machine Causes
- Identifying machine Q-components affecting quality through
applying Why-Why Analysis.
- Identifying optimal conditions of these machine part. Methods of
measurements for parts with function-loss and function reduction.
- Monitoring these parts through Inspection & Precision
checks. Merge items into SPC and PM Checklists.
(Application 3: Group Exercise & Shared Learning)
Groups will identify Machine components affecting quality. They will
apply the above tools under guidance.
Poke-Yoke Methodology Workshop Registration form.
Tick one: [ ] Singapore Seminar 11/12 Oct 2004
Name : ______________________Position:________________
Name : ______________________Position:________________
Name : ______________________Position:________________
Contact Person : ____________________________________
Tel:____________ Fax:________________
Position_______________________ Dept:_______________
Company:_________________________________________
Address :__________________________________________ (Check Payable To ZenPower International)
Please tick if Hotel reservation is required ( ) If Yes, indicate the number of rooms. ( ) Dates (
PLEASE FAX YOUR REGISTRATION EARLY TO AVOID DISSAPOINTMENT
ZenPower International Fax: 02-64545402
Mailing Address For Checks : ZenPower Int’l., No.5 Tagore Avenue, Singapore 787645
(ZenPower International is a company registered in Singapore since 1995)
Note: We reserve the right to postpone or cancel the Workshop in which case a full refund will be made. We can assist your HRDF applications.
DAY - 2
E) Poke Yoke Process Step:4 – Process Mistakes Analysis
- Reasons for addressing 1st M-Machine before the other 3Ms
(Method, Man, Materials)
- Definition of Mistake Versus 4Ms causes of Defects.
- Detailed technique of Why-Why Analysis in find Man-Mistake.
(Application 4: Group Exercise & Shared Learning)
Groups will use Why-Why Analysis to discover the underlying
Mistakes of the 4Ms of defects identified in Application 2.
- Treatment of Chronic Defects for Mistake-Proofing.
- Brief Introduction to the P-M Analysis methodology for solving of
Chronic defects to identify the 4Ms causes.
- Case Study and example of a chronic defect resolution using P-M
Analysis.
- Chronic defects with both independent and overlapping causes.
F) Poke Yoke Process Step:5 – Process/Mistake Analysis
- Criteria for identifying the Auto and Manual Process sub-steps.
- Use of the Poke Yoke Process/Mistake Worksheet to match where
and when Mistakes can happen.
- Critical Value Evaluation for prioritizing defects.
- Defining the requirements for a Mistake-Free Quality Process.
(Application 5: Group Exercise & Shared Learning)
Groups will use Mistakes identified in Application 4 to design the
requirements of a Mistake-Free zero defects process.
G) Poke Yoke Process Step:6 – Poke Yoke Applications
- Some common daily examples of Mistake-Proofing.
- The PDCA Cycle and the Source Inspection Principle of Poke-Yoke.
- The three Levels of Mistake-Proofing.
- Common Mistake-Proofing Poke Yoke devices.
- Formulating suitable Mistake-Proofing measures from Mistakes
identified from Step-5.
- The Mistake-Proofing Poke Yoke Worksheet.
(Application 5: Group Exercise & Shared Learning)
Groups will use the Mistake-Free process specifications designed in
Application 5 to conceptually come up with various Mistake-Proofing
measures using different Poke-Yoke devices.)
H) Final Q&A.
[ ] KL Seminar 14/15 Oct 2004
Contact Tel ______ext____
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Payment Plan
Check Mailed ( ) Yes Check # _____________
Date of Mailing : ____________
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E-mail: zentan@singnet.com.sg
 Professional Bio-data of Workshop Leader

Career Brief.
Moses Tan (MSc, BIT, Dip Electronics, Cert-Tech Ed.) an Industry TPM Consultant, started his career as a Technical Sales Training Instructor at Singapore
Electronics & Engineering Ltd in 1981. In this position, he compiles training manuals and conducts on-site training of Radar & Communications
Equipment for its Clients from the aerospace industry. Subsequently, he moved into the Electronics and Semiconductor Industry. He last spent 10 years at
Silicon Systems, a Semiconductor manufacturer with full capabilities from design, foundry, assembly and testing. During this time, he was assigned
various roles in HRD, Production and TPM (Total Productive Maintenance). His last position was 6 years as TPM Training Manager under the direct
supervision of TDK advisory staff located on-site in Singapore. He also worked with TPM counterparts in the United States.

Academic Credentials.
His academic credentials are a balance of the hard and soft skills – MSc (TQM Major) from Leicester University; BIT (University of S Queensland), Dip.
In Electronics (Singapore Polytechnic) and Cert-Ed (Technical Training) from the Institute of Education, Singapore. He is also a certified ISO Certified
Lead Assessor,

Professional Experiences & Services Summary.

After 20 years in employment, he left the TDK Company in 1995 and founded his own Consultancy business, ZenPower International. His goal was to
fully focus on specializing as the Best Regional provider of customized Industry TPM expertise and generic TPM training provider.

• Full TPM Implementation Services:

In the area of providing Industry TPM expertise, Moses has undertaken many various types of long and short-term on-site Industry TPM projects both in
Singapore and Malaysia. Some long-term on-site TPM Projects involves intensive hand-holding of the full TPM implementation according to the JIPM
Standards. Four such notable multi-year TPM projects involve *Companies in the Building-materials and Electronics, PCB and Semi-conductor Sub-
contracting business. Testimonies from their Clients and Suppliers were extremely positive. Bottom line results were gratifying and consistent with
expectations. Companies planning TPM Implementation will find in us a fully committed partner.

• Specific TPM Implementation Projects:

A typical medium term on-site TPM projects involve a partly Japanese-owned Automobile Company which was then preparing for the official JIPM TPM
Audit by Japanese Expert Auditors. Moses prepared them over a final period of more than 9 months and the Company was able to host the JIPM TPM
Audit successfully. Companies already with an on-going TPM Program are invited to contact us for specific assistance with special requirements.

• Specific Trouble-Shooting of Serious Chronic Problems:

Probably, the most challenging projects that prove his expertise were on-site facilitation of actual and serious Chronic Problems in terms of quality defects
and equipment failure by using P-M Analysis to help his Clients resolve. To date, he has personally under-taken on-site facilitation of more than 17
Chronic Problems at various Clients’ factories with 100% **success rate. Many of these are Industry-wide type of chronic problems in the Paper Mill,
SMT, Semi-conductor Assembly and Test and Automobile Industry, which he successfully undertook with the Clients’ technical staff. He enjoys such
challenges best. All Process, Assembly or fabrication Companies facing persistent and ‘crippling’ Chronic Problems are invited to contact us for a fast problem-
resolution proposal without obligations.

• Public and In-House TPM Methodology & Tools Training:

He also provides short-term TPM Service such as in the areas of TPM training. The training topics include TPM Introduction, Why-Why Analysis, P-M
Analysis, Poka Yoke, Office & Administrative TPM or 5S, OEE Equipment Improvements, Quality Maintenance, Planned Maintenance, SMED, Lean
Manufacturing, JIT, SMWT (Self-Managing Work Teams) , MTBA, MTBF, MTTR projects, Kai’zen Employee Suggestion Program, 360 Degrees Peer
Appraisal FB System Development, etc… He has a steady and growing Clientele base of Asian, Japanese and Western MNCs for potential Client’s
reference on request. Please enquire for details.

Notes:
• *Names of clients can be released for reference purposes on request.
• **Success Rate is measured from both the results and facilitation perspectives. There are cases where the clients have been able to fully
understand their chronic problems as well as implement full counter-measures to eliminate them. In some other cases, full counter-measures
were not able to be implemented due to technical, cost or other considerations. These were also deemed as successful where the Client have
expressed satisfaction from insights gained from the project facilitation.

Consultation, Projects and Customized Training TPM Clients List since 1996 – May 2004
SCI Manufacturing Singapore Pte Ltd; Mitshiboshi Belting Pte Ltd, Singapore; Carsem Semiconductor Sdn Bhd. Malaysia; Carsem Malaysia Sdn Bhd, NEC Semiconductor Spore Pte Ltd.; Sony
Display Device (Spore) Pte Ltd.; Showa Denko HD; Sumitomo Bakelite Pte Ltd; Singapore. Siemens Component Pte Ltd; Singapore. Malaysia Newsprint Industries Sdn Bhd; Guocera Tile Industries
(Kluang) Sdn Bhd; Johore ; Yamaha Motors Hong Leong Sdn Bhd.; Hitachi-Nippon Steel Pte Ltd, Singapore.
Taiko Denki Sdn Bhd, Senai.; Malaysia Newsprint Sdn Bhd.

{ And many other Companies who had sent delegates to our Public Seminars}