Mistake_Proofing-Poka_yoke

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1、MistakeProofing(PokaYoke)Techniquesthatmakeitimpossibletomakemistakes1Tableofcontents1)Returnsproducebymistakeproofingpage32)Whatismistakeproofingpages4-73)MistakeproofingversusStatisticalProcessControlpages84)Anewattitudetowardpreventingerrorspages9-155)Overviewofthediffer

2、entinspectiontechniquespages16-206)Theultimategoal:achievingzerodefectspages21-237)TypesofPokayokecontrolsystemspages24-268)TypesofPokayokedevicespages27-309)Typesofsensorsusedpages31-3410)Guidelinesandrulespages35-3621)Returnsproducebymistakeproofing?Mistakeproofing(PokaYok

3、e)willallowyoutodecrease:humanerrors,defectiveproductsatcustomers’,nonqualitycostsMistakeproofing(PokaYoke)willallowyoutoincreasealso:productivity,profitsAfewexamples:Danacorporationhasreporteda$500,000savingsresultingfroma$6deviceOrtho-ClinicalDiagnostics(Johnson&Johnson)sa

4、ved$75000annuallybyimplementinganewPokayokeAT&TPowerSystems(LucentTechnologies)reportednetsavingof$2545perdevice(3300devices)32)Whatismistakeproofing?Theuseofprocessordesignfeaturestopreventerrorsortheirnegativeimpact.AlsoknownasPokayoke,Japaneseslangfor“avoidinginadvertente

5、rrors”whichwasformalizedbyShigeoShingo(Toyota).Inexpensive.Veryeffective.Basedonsimplicityandingenuity.APokayokedeviceisanymechanismthateitherpreventsamistakefrombeingmadeormakesthemistakesobviousataglance4EverydayExamplesWhichdialturnsontheburner?StoveA-difficulttoswitchonS

6、toveB-simple,visuallytoswitchon5OthereverydayExamplesNewlawnmowersarerequiredtohaveasafetybaronthehandlethatmustbepulledbackinordertostarttheengine.Ifyouletgoofthesafetybar,themowerbladestopsin3secondsorless.Fuelingareaofcarhasthreeerror-proofingdevices:1.insertkeepsleaded-f

7、uelnozzlefrombeinginserted2.tetherdoesnotallowlossofgascap3.gascaphasratchettosignalpropertightnessandpreventovertightening.6CostofPokayokedevices…About50%ofPokayokedevicescostlessthan$100About90%ofPokayokedevicescostlessthan$1,000MakingprocessesbetterthankstoPokayokeleadsto

8、reduced:ReworkScrapWarrantycostsInspectioncosts...versuscostofdefects73)Mis