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Production System
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We need
need to
to be
be able
able to
to do
do three
three things
things well,
well, all
all at
at the
the same
same time!
time!
We
Improve Quality
Faster
Better
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Reduce Cost
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Production Costs
Customer Price
Net Margin
Cheaper
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KAIZEN in Just-In-Time
Production System
Jay-eye-tea
JIT
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C
lier
Supp ships
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Relat
Visual
Controls
Multi-
Time
ation
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Aut
Sa
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Ma
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Work
Cells
Ta k t
Process
Lev
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5S
Dem
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S
Lot
Size
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Sy
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Pu
Spiri
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up
S et
ion
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Red
On
Pie e
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Flo e
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Sta
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Wo
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Ba Lin
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Qualit
an ce
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A
Attack
On
Waste
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Mis
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Pro
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Opportunity
Lead Time
$
$ $
$
$
Same Value-Add
Result: Shorter
lead times,
reduced costs.
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Kanban
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Is a signal that:
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Authorizes production
Authorizes movement
Limits inventory
Card
Square
Box
Pigeon hole
Light
Etc.
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Units in Pipeline
= Number of Kanbans
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Kanban
1
Work
Center A
Kanban
2
Work
Center B
Kanban
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Work Flow
Hasan Haider, NPO Pakistan
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Push System
Pull System
Push and Pull System
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KANBAN
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Poka-Yoke
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Mistake-proof (Poka-yoke)
Note: Poka ----- Carelessness; Absent-mind
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Yoke----- Elimination
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Purpose
The mistake-proofing process
prevents mistakes before they
create defects.
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Mistake-Proofing
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Why do mistake-proofing?
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Improve quality
Eliminate rework
Reduce cost
Improve schedule performance (especially
in relation to the predictability of cycle
times
Zero Quality Control (Zero Defects)
Total Customer Satisfaction
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Mistake-Proofing
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Benefits
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Improves quality
Reduces costs
Improves on-time delivery
Reduces or
eliminates accidents
Improves morale
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Microwave ovens that will not start with the door open
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Beeper to Indicate the Lights Are Left on When the Keys Are
Removed From the Ignition Switch
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Cruise Control Which Shuts off When the Brakes Are Applied
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Carrier Produces:
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In Manufacturing:
Safety Devices on Presses
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Palm Buttons
Light Curtains
Brake Monitors
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Scrap
Rework
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Missed Schedules
Lean Manufacturing Will Not Tolerate Mistakes
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John Foster
3-21-92
Quality Engineer
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John Foster
3-21-92
Quality Engineer
Date
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Ill do better
next time!
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Defectives:
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Defect - (Effect)
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Template
Limit Switch / Microswitch
Counter
Odd-part-out Method
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3.
4.
5.
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7.
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9.
Sequence Restriction
Standardize and Solve
Critical Condition Indicator
Detect Delivery Chute
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GUIDE PINS
LOWER DIE
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PRESS
LIMIT SWITCH DETECTS
CORRECT PLACEMENT
PRODUCT
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TO OPERATING
CIRCUIT
CLEAR BUTTON
Counters
DIGITAL COUNTER
Checklists
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Before Mistake-Proofing
Locating
Angles
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Locating
Angles
After Mistake-Proofing
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Correct
Locating
Angles
Guide Pin
Incorrect
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After Mistake-Proofing
Omitted Washer
Container
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Fire
Extinguisher
Reservoir
Bottles
After Mistake-Proofing
Hose to Area B
Hose to Area A
Hose to Area A
Fire
Extinguisher
Reservoir
Bottles
Hose to Area B
Incorrect
Fire
Extinguisher
Reservoir Hose to
Area B
Bottles
Female
Male
Different size
connectors
Hose to Area A
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After Mistake-Proofing
Panel Trim
Lines
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After Mistake-Proofing
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Poka-yoke Example 1
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Poka-yoke Example 2
Fool-proof device
Non-defective
Defective
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Analysis of Carelessness
Kanebo Chemical, 1989
Wrong operations
23%
Negligence
(Forgetfulness)
48%
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Auto-nomation (Jidoka)
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I dont know.
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Jidoka
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Simple automation
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Stamping Machine
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Advanced Preparation
Hasan Haider, NPO Pakistan
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Masking
tape
Paint an arrow
Trash can
Spreadsheet
Example (1)
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Pear-shaped holes
Example (2)
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Seven Wastes
1.
2.
3.
4.
5.
6.
7.
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