Unit V- CVV Question Bank Define Poka Yoke.

. Poka Yoke is a bunch of small devices like fixtures, jigs, gadgets, warning signals, paper systems and the like which are used to detect or prevent defects from occurring in the first place before additional value is added to the parts/products List out the Levels of Poka Yoke? Eliminating spills, leaks and accidental losses Detecting unintended loss that is in the process of occurring Detecting loss after it has occurred How will you classify Poka Yoke? Poka Yoke can be classified into prevention based poka yoke and detection based poka yoke. The prevention based poka yoke is further classified into control method and warning method. Control method, the problem is sensed and if necessary a product line or a process will be stopped so that corrective action can take place. The warning method signals the occurrence of a deviation or trends of deviation through an escalating series of buzzers, lights or other warning devices. The detection based poka yoke is further classified into contact method, fixed value method and motion step method. The contact method detects any deviation in shape, dimensional characteristics or other specific defects through mechanisms that are kept in direct contact with the part. Fixed value method is used in operations in which a set of steps is sequentially performed. Motion step method ensures that a process or operator does not mistakenly perform a step that is not part of the normal process. Mention the places where Poka Yoke Works Well. Manual operation where worker vigilance is needed. Where miss positioning and misalignment can occur. 33(4) Quality Management Unit-V Prepared by Anbarasan.R, MBA, M.Phil, / Lecturer/MIT/MBA Dept. Page 1

Unit V- CVV Question Bank Where adjustment is required. Where team needs common sense tools. Where employees turnover and training cost are high. What are the Principles of Poka Yoke? Build quality into process All inadvertent errors and defects can be eliminated Stop doing it wrong and start doing it right, now. Seek out the true cause(s) if a defect occurs. Give some Examples of Poka Yoke Devices. A red alert, as long as the fuel level is below reserve level in automobile. An electronic gadget to fill air in automobiles which takes the desired pressure. The design aims to avoid mistakes by designing items so that they can only be assembled in certain way, called idiot-proof. Eg. Plug and Socket. What are the Benefits and limitations of Poka Yoke? Reduction in waste and associated machining Reduction of inventory holdings Improvements in customer satisfaction levels because better quality product is delivered to them. Limitations: It increases the time of inspection that the operator would spend on his job. In short time, there will be a sharp increase in scrap materials cost. Define TPM. Total Productive Maintenance (TPM) is a management system for optimizing the productivity of manufacturing equipment through systematic equipment maintenance involving the employees at all levels. List out the objectives of TPM 1. Aim at the creation of collective culture relating to the attainment of maximum efficiency throughout the production process. 33(4) Quality Management Unit-V Prepared by Anbarasan.R, MBA, M.Phil, / Lecturer/MIT/MBA Dept. Page 2

Unit V- CVV Question Bank 2. Use the system so as to prevent losses and to reach the Zero accident, Zero defect and Zero Breakdowns, in the manufacturing process.

What are the Wastes Eliminated in TPM? Breakdowns, Set ups and changeovers, Idling and minor stoppages, Reduced equipment speed, Defects and rework and Start-up losses. What are the Equipment Maintenance Techniques? Preventive Maintenance, Corrective Maintenance, Maintenance Prevention and Breakdown Maintenance. What do you mean by Periodic or Time Based Maintenance? Periodic or Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent failures and process problems. What do you mean by Corrective Maintenance? This means that the equipment with design weakness are redesigned to improve reliability or maintainability. Maintenance Prevention: It is to design and install new equipments that are maintenance-free based on the study of the weakness of current equipments. Breakdown Maintenance: It is to repair equipment quickly after they breakdown. List out the Benefits of TPM Increased equipment productivity Lower maintenance and production cost 33(4) Quality Management Unit-V Prepared by Anbarasan.R, MBA, M.Phil, / Lecturer/MIT/MBA Dept. Page 3

Unit V- CVV Question Bank Approaching zero equipment-caused defects Rectified customer complaints Reduced accidents

What do you mean by Overall Equipment Efficiency (OEE)? OEE is a combination of the uptime (Availability of the equipment), cycle time efficiency (production efficiency) and quality output of the equipment. List out the 8 Pillars of TPM 5 S, Jishu Hozen (Autonomous Maintenance), Kaizen, Planned Maintenance, Quality Maintenance, Training, Office TPM, Safety, Health & Environment. What do you mean by 5 S? 5 s is the house keeping technique which helps to keep the work environment clean and tidy. The five s are Seiri, Seiton, Seiso, Seiketsu, Shitsuke. What is Jishu Hozen or Autonomous Maintenance System? The autonomous maintenance is a system which aims for uninterrupted operation of equipments, flexible operators to operate and maintain other equipments, and elimination of defects at source through active employee participations. What is Office TPM? Office TPM mainly aims to improve the productivity and efficiency in the administrative functions by identifying and eliminating losses in them. This is achieved by analyzing processes and procedures for enhanced office automation. Define Lean Manufacturing Lean Manufacturing is a systematic approach to identify and eliminate wastes of all non-value added activities through continuous improvement that is being adopted by world 33(4) Quality Management Unit-V Prepared by Anbarasan.R, MBA, M.Phil, / Lecturer/MIT/MBA Dept. Page 4

Unit V- CVV Question Bank class, high performance firms to produce remarkable results. It is also called as a manufacturing system in which friction is absent. What are the Steps involved in Lean Manufacturing? i) ii) iii) iv) v) Precisely specify value by specific product Identify the value stream for each product Make the value flow without interceptions Let the customer pull value from the producer Pursue perfection

List out the Components of Lean Manufacturing Standardized Production, Continuous improvement (Kaizen), Just-in-Time (JIT) Production, Design for Manufacturing (DFM), Poka Yoke (Error Proofing), Cellular manufacturing, Single-Minute Exchange Die (SMED), Flexible workforce. What is DFM? Design for Manufacturing (DFM) is a process in which after careful examination, all useless parts should be eliminated in the product and the parts which are retained/newly designed and added in that product must be easily made with the existing infrastructure of the company or its supplier firms. What do you mean by JIT? JIT Stands for Just in Time and in this type of production, each station makes only the item in the required quantity when it is needed. It strives hard to reduce its inventory or it aims to have Zero Inventory.

33(4) Quality Management Unit-V Prepared by Anbarasan.R, MBA, M.Phil, / Lecturer/MIT/MBA Dept. Page 5