Poka-Yoke Training: Poka-yoke is a technique for avoiding inadvertent human error in the workplace.
Also known as mistake-proofing, goof-proofing and fail-safe work methods, poka-yoke can yield many positive results, including:
- Elimination of setup errors and improved quality
- Decreased setup times with associated reduction in production time and improved production capacity
- Simplified and improved housekeeping
- Increased safety
- Lower costs
- Lower skill requirements
- Increased production flexibility
- Improved operator attitudes.
Poka-yoke is based on prediction and detection. It’s a process for recognizing that a defect is about to occur or recognizing that a defect has occurred.
There are two basic types of poka-yoke systems:
- Control poka-yoke – This does not allow a process to begin or continue after an error has occurred. It takes the response to a specific type of error out of the hands of the operator. For example, a nozzle for diesel gasoline is designed to not fit in gas tanks for cars that only take non-leaded. Or a 3.5-inch floppy disk will not work if inserted backward.
- Warning poka-yoke – This type of poka-yoke provides some kind of warning when an error is detected. This type does not prevent the error but immediately stops the process when an error is found. A warning poka-yoke is useful for mass production environments with rapid processing as the device prevents mass production of scrapped material.
Poka-yokes can be as simple as a steel pin on a fixture that keeps incorrectly placed parts from fitting properly, or they can be as complex as a fuzzy logic neural network used to automatically detect tool breakage and immediately stop the machine.
There are three recognized categories of poka-yokes to reduce rework and defects. The constant number (or fixed-value) method alerts the operator if a certain number of movements are not made. Counters could also be a fixed number of parts that must be used at each step. If there’s a screw left over then the product must be removed before moving on to the next production stage.
The sequence method is used in production processes where one operator needs to perform a set of operations in a specific sequence. It defines the number of steps in one operation and informs when one is forgotten.
The contact poka-yoke works by means of a sensing device. A defect is “sensed” (detected or prevented) by testing the dimensions, shape, size, color or other physical attributes of the product. It is compared to the requirements of the product.
Poka-Yoke Training
Tonex offers Mistake Proofing Training/Poka Yoke, a 2-day course that introduces you to the fundamentals, process, techniques, and devices necessary to eliminate mistakes, before they happen.
Who Should Attend
- Executers and decision makers of the organization
- Leaders
- Managers and supervisors
- Engineers
- Business process owner
- Process improvement managers and leaders
- System implementers and coordinators
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