3Poka Yoke - Fail SafePOH-kah YOH-keh - means "fail-safing" or "mistake-proofing”“Poka” – Inadvertent mistake“Yoke” – PreventionConcept by Shigeo Shingo (1909 ~ 1990) – World’s leading expert on Mfg Practices – Shingo Prize – Lean Mfg PracticesA methodology to Detect & Prevent causes of DefectsZQC – (Zero Quality Control)Most mistakes – committed by workers / errors in the production systemsFeedback control and action system at the error stageHi-Tech Gears Limited – Manesar, Haryana
4Poka Yoke Principles Elimination Eliminate the possibility of Errors.Redesign of the Process or Product s –No need to inspectReplacement Substitute a more Reliable Process for the existing one. - Use of Robots or AutomationEliminationReplacement213Mitigation5MitigationMinimizing the effect of Error. - Protection, Safety DevicesFacilitationFacilitationMake work easier to perform such as color coding, combining steps,..4DetectionDetectionDetect error before further processing. Software interlocks which notifies an Operator for wrong inputs.
5Product s & Services Design Principles - Fundamental Basic FunctionalitySafetyPoka Yoke (Mistake Proofing)Ergonomic DesignSimplicityFlexibilityRobustness & ReliabileEase of UseEase of Maintainability …..Product s & Services
12Errors@Work – Examples Missing Parts Forgetting to assemble a part – Screws, Washers, labels, etc.,Misassembled Parts Misassembly – loose parts, upside down, not aligned – Ex: Brackets (Reverse), seals not aligned, screws (Loose), Labels (Upside Down)Incorrect Processing Disposing of a part rejected at test to the wrong pileIncorrect Parts Retrieving and assembling the wrong part from a model mix selection – seals, labels, brackets, cses…
13Fail Safe Assembly - Turbochargers Concept of FailSafe – Prevention & Detection DevicesGuided Part PickingVerification of the picked partVerification of the AssemblyInterlocking of checking systemsElimination – Eliminating the chance of errorFacilitation – Guidance Methods to minimise errorMitigation – Lessen the effect of the errorFlagging – Methods for capturing all defects prior to shipmentReplacementEliminationMitigation215FacilitationDetection34
26Fail Safe – Poka Yoke Approach 100% On-time delivery irrespective of variantsFlexibility in Assembly lineConsistency in Output with high QualityBest in class Ergonomics (man material movement)High Safety Standard ComplianceZero accidents, less fatigue, maxi efficiencyBuilt in Sequential disciplined work approach - HMINo missing Parts / Parts pick sensingVision check failsafe through CameraQuick changeover (< 1 min)Part IdentificationIntegration of each station – EthernetData Acquisition, transfer, storage & analysis