Welcome

to the training

Error Proofing (Poka Yoke)

Aims of the Seminar
• Create an awareness of errors.

• Handling errors: prevent, recognize, eliminate

• Know and understand the aim and the purpose of Error

Proofing (Poka Yoke)

• Recognize and realize the opportunities for an

implementation in your company

• Handling Error Proofing Systems (examples)

• Develop solutions in a team

Error Proofing (Poka Yoke)

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Contents

• Supplier Quality Improvement Process

• What are errors?

• Error Proofing (Poka Yoke)

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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Supplier Quality Improvement Process

Determination of new suppliers

Top Management Meetings
Quality workshops
Additional control, step 2 (GP-5)
Additional control, step 1 (GP-5)
Problem Report PR&R (GP-5)
Control of quality figures
Continuous improvement (GP-8)
Stricter control before SOP (GP-12)
Zeit
Capacity test (GP-9) Life cycle of part
Approval of serial parts (PPAP)
Sampling of prototypes (GP-11)
Kick-off meeting
- P-FMEA
Advanced Product Quality Planning - Control Plan Error Proofing
Decision by Purchasing
Assessment of potential suppliers

START OF PRODUCTION

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Contents

• Supplier Quality Improvement Process

• What are errors?

• Error Proofing (Poka Yoke)

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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What are Errors?

Every-day-life errors:

• Forgotten to refill the tank

• Left the keys in the car
• Did not observe the traffic light
• Did not disconnect the coffee machine
• Set the temperature of the washing machine too high
• Entered the wrong PIN number „Errare
humanum est“
• Forgot the shopping note
• Did not make a back-up of important data

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What are errors?

• Intuitively everybody seems to know what errors are.

But when you are asked, it is not so easy to define the
term „error“. Usually, people try to answer in a negative
way:

- not correct,
- not meeting the expectations,
- not functioning etc.

• Regarding Error Proofing, however, it is necessary to

give a general definition:
„An error is deemed a deviation from the desired
product!“

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Dfinition of Error

„An error is deemed a deviation from the desired

product!“

• A deviation is considered an error, if it leads to a defect.

ð This leads us to the chain of cause and effect:

Cause of error Error Effect

• Product: This may be an entire vehicle, a system,

subsystem, component or a single part.

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 Causes of Errors

Cause Error Effect

• Unsuitable standard operations, processes and methods

• Current operations imply too many variations, even in

connection with standard methods.

• Damaged materials or too large material tolerance

• Worn out machines or tools

• Human failures

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 Effects of Errors

Cause Error Effect

• Rework
• Rejects
• Functional defects
• „Walk-home“ failures
• Violation of legal requirements
• Safety risk on the shop floor
• …
The mentioned effects are extremely work and
cost intensive, therefore they are to be eliminated
for ever. If they are not recognized in the plant,
they will lead to an annoyance to the customers.

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Example1

Cause Error Effect

Chip on the surface rejects

Wrong adjustment Hole drilled at rework

of locator the wrong point

Part placed on
disassembly
the wrong side
of the part

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Zero-fault Target
• Each organization aims at working without faults.
ð It is called: the zero-fault target.

• In reality, however, there is no organization with zero faults!

ð But to limit the faults in their effects and frequency, the
zero-fault strategy is implemented in the organizations.

The zero-fault strategy aims at increasing the satisfaction of our

customers, protecting our own people and preventing rejects.

ð One element used to meet this target, is

the implementation of Error Proofing (Poka Yoke)!

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Contents

• Supplier Quality Improvement Process

• What are errors?

• Error Proofing (Poka Yoke)

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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What does Error Proofing (Poka Yoke) mean?

• Poka Yoke was developed in the sixties by the Japanese

engineer Shigeo Shingo.

ð The Japanese term „Poka Yoke“ means:

- Poka: the accidental, unintended error
- Yoke: avoidance, prevention.

ð Avoidance of accidental errors

• Error Proofing is the English term for „Poka Yoke“

(sometimes it is called „Mistake Proofing“).

ð It means: avoidance of errors

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Error Proofing Structure

Avoidance of errors Error Proofing in manufacturing

in product development

- DFM/A - Process FMEA - recognition

- Design FMEA - avoidance

An Error Proofing System consists of elements which

exclude the emergence of errors in manufacturing
processes or detect them directly after their emergence.
By the recognition of errors, immediate corrections are
possible which avoid a repetition and thus prevent the
delivery of defective products to the customers.

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Purpose and Assumptions regarding Error Proofing

Basic concept / assumptions:

• Men wish to do a good job.
• Being human, men make mistakes. („errare..“)

Purpose of the Error Proofing efforts:

• Use of simple and low-cost equipment
in the production to:
• Avoid errors from the beginning or
• Safely recognize errors emerged.

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 Target of Zero Faults

Classical avoidance of errors Error Proofing levels

No check instruction training/ visual limitation recognition of avoidance

Visual check - 100%check* errors - robust product/
support - stops the design
process - process concept

knowledge detection prevention

Target of zero faults

* 100% check for limitation should be used only temporarily.

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 Recognition of Errors

• In order to correspond to the target of zero faults, checking mechanisms

are to be implemented which recognize faults.
ð They are divided into:
• Statistical controls (each nth part is controlled) and
• 100% controls (each part is controlled).

• A statistical means (e.g. a quality control chart) can only be used if the
process can be controlled statistically. It means, the process concerned
is linear (predictable) within certain tolerances. A control of the nth part
permits to make a statement on the previously produced parts.

• Regarding a 100% control, each part is to be checked for its correctness.

This means that the process “leaps“ and a check of the nth part does not
permit to make a statement on the previously producted parts.

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 Statistical Process Control

• The tolerances are specified in the given drawing.

Tolerance according to the drawing:

100 + / -1

99 100 101 variance

100% Cpk*=1 3s
87% Cpk=1,33 4s
67% Cpk=1,67 5s
50% Cpk=2,0 6s

* Cpk = process capability index

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Process Control

• If the process concerned is a linear one, a statistical

approach to inspection may be used (even tool wear).

Control Chart
? / [mm]

upper specification
upper control limit
Production
100%
tolerance
lower control limit
lower specification

time / volume

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Example: Holes on the wrong place

Before the improvement After the improvement

A part is not properly placed into a Drills do not operate before the
bracket. part is placed properly.
As a result, holes are drilled at the
wrong place.

Recognition by a sensor (switch)

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Design determined Avoidance of Errors (DFM/A)

• Influence the cause, and not the effect!

Factors considered as potential causes:

ð Locating pin
ð Twist protection on a plug
ð Asymmetrical fit
ð Combine single parts
ð …

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Design determined Avoidance of Errors: FMEA

• Consideration of single parts

• Discussion of the product features, defined in a drawing
(dimensions, material properties, surface quality, tolerances
etc.)
• Description of the effects which defective single parts may
have on the entire system
• It is carried out simultaneously with the design.
• The question of the basic manu-
facturability is also part of the analysis.

• For example: single parts of

the front structure (sheet metal)

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Error Avoidance by a Process FMEA

• Consideration of the entire process required for the part or

system to be assembled or produced
• focused on the potential errors which may emerge when
operating the machines, selecting the parts or, in general,
on human factors.
• As far as possible, machine characteristics should be taken
over from the machine FMEA
Messen
(with 3rd / 5th gear wheel)
• based on the Process Drehen

OP 10 OP 120

Flow Diagram, Fräsen

Waschen
(with 3 rd / 5 th gear wheel)

OP 20 OP 110

• e.g. flow diagram of the reverse Büsten und Entgraten Schleifen & Drehen

gear of the F40 transmission OP 30

Waschen
OP 100

(with 4 th & 5 th gears) Wärmevergüten

OP 40 OP 70 - 90

Pressen Drehen
(with 4 th & 5 th gears) (with 4 th & 5th gears)

OP 50 OP 60

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Error Avoidance by Error Proofing

Error avoidance in
Error Proofing in manufacturing
product development

- DFM/A - process FMEA - recognition

- Design FMEA - avoidance

Basically, Error Proofing is a plausibility check of the manu-

facturing process. It serves not only to check the human work,
but at the same time may be regarded as a valuable instrument
to achieve a flawless result.
In many cases Error Proofing solutions are the result of a team
of all parties concerned on site.

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Contents

• Supplier Quality Improvement Process

• What are errors?

• Error Proofing (Poka Yoke)

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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Problem solving Process

In order to solve a problem, it is necessary

to find its cause, i.e.

„to eradicate the evil“.

To get down to the roots is the only way of solving the problem
once and for all.
After the root cause analysis, other steps follow to solve the
problem.

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Solution in a Team

When each member of the team expresses her or his point of

view, in this way contributing to the solution, all potential weak
points may be seen and avoided.

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Problem solving Process

continuous
improvement
standardization possibilities

avoidance selection
5. evaluate 1. identify

People
&
4. implement Teamwork
2. analyze

3. plan

correction
containment

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Contents

• Supplier Quality Improvement Process

• What are errors?

• What does Error Proofing (Poka Yoke) mean?

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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Drilling

before the improvement after the improvement

right

wrong

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Contents

• Supplier Quality Improvement Process

• What does Error Proofing (Poka Yoke) mean?

• What are errors?

• Error Proofing

• Problem solving process

• Appendix A: exercises

• Appendix B: forms

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Aims of the Seminar

• Know and understand the aims and

the purpose of Error Proofing (Poka Yoke)

• Recognize and realize the opportunities of an

implementation in your company

• Create an awareness of errors

• Handling errors: prevent, recognize, eliminate

• Handling Error Proofing Systems (examples)

• Develop solutions in a team.

Error Proofing (Poka Yoke)

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 Thank you for your attention.

Error Proofing (Poka Yoke)

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