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Ä Automation with a human touch

Ä Practice of stopping a manual line or process when

something goes amiss

Ä Quality built-in to the process

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Ä [idoka helps to detect a problem earlier and avoids the

spread of bad practices.

Ä [idoka results in high-quality products and makes

improvement in productivity.

Ä [idoka is sometimes called autonomation, meaning

Dzautomation with human intelligencedz.

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Ä ïhen a machine breaks down or when defective parts

are produced). This auto-nomation (as it is also called)
allows machines to run autonomously, as they will stop
when a problem occurs. Ultimately, it is about
transferring human (or better) intelligence to
machines.
Ä Textile Industries
Ä KESC
Ä Bank Alarms/Fire Alarms Alerts
Ä The phrase poka-yoke originates from the [apanese word:

Yokeru = to avoid Poka-Yoke

oka = inadvertent errors

Ä It is a methodology that is used to strive toward zero

defects by either preventing or automatically detecting
defects.

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Ä Êachine have limit switches connected to a warning

light that tell operators when parts are positioned
improperly on the machine.
Ä Fast food restaurants use automated french-frying
machine that be operated one way ; the French fries
are prepackaged and automated to reduce the chance
of human error.
Ä Electronics Industries
Ä Car Êanufacturing Industries

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Basically Poka yoke is same as the Six Sigma Concept :

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Äm
m  is a business management strategy originally developed by

Êotorola, USA in 1981.

ÄSix Sigma seeks to improve the quality of process outputs by identifying

and removing the causes of defects (errors) and minimizing variability in
manufacturing and business processes.

ÄA six-sigma process is one in which 99.99966% of the products

manufactured are statistically expected to be free of defects (3.4 defects
per million).

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Ä Kaizen is the name given by the [apanese to

continuous improvement. Continuous improvement
really means Dzcontinuous incremental improvement.dz

Kai = change
Zen = good

Ä Kaizen means making changes for the better on a

continual, never-ending basis.
Ä Kaizen refers to improvement of both processes and
people.

Ä In fact Kaizen philosophy aims at improving all aspects

of an organization all the time.

Ä Good is never good enough; kaizen is a never-ending

journey to excellence.

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Ä Toyota production system known for kaizen, where all

line personnel are expected to their moving
production line in case of any abnormality and, along
with their supervisor, suggest an improvement to
resolve the abnormality which may initiate a kaizen.
Ä Êicrosoft
Ä Google
Ä ïikipedia
Ä Rolls-Royce
Ä Ferrari
Ä Ford
Ä   is a traditional [apanese term for an activity that
is wasteful and does not add value or is unproductive.

Ä Any element of processing or distribution that add no

value to the final product(services)-waste only adds
cost time and (frustration).

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Î Printing paperwork (that might change) before it is needed. Processing an
order (that might change) before it is needed. Any processing that is done
on a routine schedule - regardless of current demand.
Ä  
 ;
Î purchasing or making things before they are needed (think office supplies,
literature...). Things waiting in an (electronic or physical) In Box. Unread
email. Any form of batch processing (e.g. transactions, reports...)
Ä Ô

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Ä   is a traditional [apanese term for unevenness,
inconsistency in physical matter or human spiritual
condition.

Ä Strive to reduce variation/fluctuation to a bare

minimum.

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Ä Êura in its simplest form means Dzunevenness.dz For

example, Êura results when your operators are told to
work like crazy early in the morning only to stand
around and do nothing late in the day.
Ä Office Clerical Staff
Ä To work like donkeys first without forecasting demand
and later become lazy (like Rabbit and Turtle)
Ä Êura is the unevenness or fluctuation of the schedule.
Variabilityǥ So, in the example Êura is looking at the
imbalance in the assigned task.
Ä  ¢made up of the ideograms representing
Dz nonedz + Dzlogicdz, literally means unreasonable, or
overburden/overdoing.

Ä Êuri is about being smooth, and doing things the

logical way.

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Ä Êuri means to Dzoverburdendz equipment or operators.

For example, if your entertainment center is only
meant to hold 200 pounds and you place your new 425
pound super duper HD Ready TV on it we have muri.

Ä ïe also have other issues like a very real safety

concern! Êuri is the overburdening of your people or
equipment. So, in the example muri is looking at
demanding that a forklift carry X+ weight when it is
rated to carry X weight.

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Ä The º 
 is a question asking method used to
explore the cause/effect relationships underlying a
particular problem.

Ä Ultimately, the goal of applying the 5 ïhys method is

to determine a root cause of a defect or problem

Ä This technique explores deeper and deeper levels until

one gets to a level where proactive counter-measures
can be applied.

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A typical Example on www.wikipedia.org

The car does not start.
Ä ïhy? - The battery is dead
Ä ïhy? - The alternator is not functioning
Ä ïhy? - The alternator belt has broken
Ä ïhy? - The alternator belt was well beyond its useful
service life and has never been replaced
Ä ïhy? - I have not been maintaining my car according
to the recommended service schedule

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Ä ÷ is a workaround for uneven demand. It is

the bridge between how customers order and how a
Lean company operates.

Ä DzThe distribution of production volume and mix

evenly over timedz

Ä Heijunka converts uneven Customer Pull into even

and predictable manufacturing process.
Ä For example, weekly demand over a 3 week period
might be 200, 218, 197-fairly close. The Êonday
demand for those same three weeks could be 37, 61,
47-not quite as stable. And day-to-day demand might
fluctuate even more wildly-ïednesdays might be the
day that three of your biggest customers all place their
orders (hey, not everyone is lean, right?).

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Ä Sort : All unneeded tolls, parts and supplies are removed from
the area.

Ä Set in Order : A place for everything and everything is in its

place.

Ä Shine :The area is cleaned as the work is performed.

Ä Standardize : Cleaning and identification methods are

consistently applied.

Ä Sustain : 5s is a habit and is continually improved.


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