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1、,Poka-yoke and Jidoka: Continuous improvement to Zero Quality Control,Introduction to Poka Yoke,Quality and Human Error,“To err is human” Alexander Pope Human beings make mistakes, human beings sometimes forget. If you rely on a human being to produce quality product and not make a mistake or not fo
2、rget sometimes Then you really do not care to make a quality product. ADDRESS QUALITY ISSUES THROUGH THE PROCESS.,Evolution of Key “Lean” Concepts,1945: Just In Time,1948: Pull: Withrawal by subsequent processes,1953: “Supermarket” systems,1947: Dual machine handling, “L” shaped layout,1953: Work ce
3、lls in “U” shaped layouts,1950: Multi (3-4) machine handling, rectangular or “U” shaped layout,1955: Water spider concept,1962: Kanban, company wide, internal,1965: Kanban, external suppliers,1950: Andon, visual control,Set-up reduction: internal & external, 1st stages of SMED: 1950,Shigeo Shingo be
4、gins consulting relationship with Toyota: 1954,Inspired by Toyota “Foolproofing” measures, develops methodology to apply techniques to source inspection: 1965,SMED methodology formalized: 1969,1950: Fool proofing techniques and the concept of “autonomation” (Poka-yoke),“Zero Defects” concept: 1975,Z
5、ero Quality Control concept: 1977,Shigeo Shingo,Toyota & Taichii Ohno,= Concepts related to Poka-yoke,Contents,Introduction to Poka-yoke and types of inspection systems Poka-yoke Systems Poka-yoke Methods Common Mistake Proofing Devices Poka-yoke exercises Shingo Quiz,Poka-yoke and Jidoka: Simple &
6、Clear,Poka-yoke: Poka-yoke prevents defects from being made Jidoka: Prevents defects from being passed on to the next step in the process,Human Inspection Human Intervention Mistake Proofing with machine assist,Toll-gate Inspection at Finished Goods or the end of main processes,In-Process Inspection
7、 Final Inspection may decrease, operators may do required process inspections,Visual Inspection & Jidoka The beginning of autonomation - significant defect reductions,Poka-yoke Evolution toward Zero Quality Control - Operator Time dedicated to Continuous Improvement,Three Basic Types of Inspection,T
8、here are three basic types of inspection techniques Judgment Inspection Human, visual, possibly measured Only discovers defects after production Informative Inspection Statistical Quality Control: flow charts, control charts Theoretical sampling techniques Self check inspection, Successive Inspectio
9、n Inspects products to help control the process Source Inspection Process focused To correct operating conditions Root causes are eliminated or corrected Before production occurs,Will not reduce defects,A Short Story Yamada Electric, Nagoya, Japan,The Plant manager: “One of the operations we do invo
10、lves the assembly of an extremely simple push-button device that we deliver to our parent company, Matsushita Electric. The device is composed of two buttons, and on button and an off button, under each of which we have to enclose a small spring. Sometimes, though, one of our workers forgets to put
11、in a spring. When Matsushita electric discovers a switch without a spring, we have to send an inspector all the way to Kyusha to check every switch that was delivered. This is a real pain in the neck, so whenever it happens, we tell workers to be particularly careful and for a while things improve a
12、 bit. The same thing happens again before long, though, and these chronic defects are getting to be a nuisance. Matsushita gets mad at us every time for making mistakes in such a simple operation, and I recently had to go to Kyusha myself to apologize. Is there anything we can do to keep these defec
13、ts from happening?”,A Short Story Yamada Electric, Nagoya, Japan,The Consultant and the Plant Manager: C: “What does it mean for a human being to forget something?” PM: The plant manager looked puzzled “To forget means well it just means to forget something, doesnt it?” When the Consultant asked the
14、 Plant Manager to explain, he was unable to answer. So he suggested to him that there were really two kinds of forgetting. The first involves simply forgetting something. Since people are not perfect, they will, on rare occasions, simply forget something. It is not intentional, it just happens. C: “
15、The second type of forgetting, involves forgetting that one has forgotten. We are all familiar with this kind of forgetting. It is the reason, for example, that we make checklists for ourselves. You can apply the same thing to this operation, rather than thinking that your people should assemble swi
16、tches perfectly, every time, you should recognize that being human, they will, on rare occasions forget things. Why not take the idea of the checklist and incorporate it into your process.”,Question: Have you ever forgotten anything?,A Short Story Yamada Electric, Nagoya, Japan,The Current State: The operator assembles two switches at a time, places the finished switches into a box that holds one hundred. Before shipping, a QC inspecto
