Five Best Poka-Yoke

1) Guide Pins of Different sizes

2) Error Detection And Alarms

3) Limit Switches

4) Counters

5) Checklist

TYPES OF HUMAN ERROR 1) Forgetfulness (not concentrating) 2) Errors due to misunderstanding

CAUSES OF DEFECTS 1) Process omissions 2) Process errors

(jump to conclusions)
3) Errors in identification (view incorrectly...too far away) 4) Errors made by untrained workers 5) Willful errors (ignore rules) 6) Inadvertent errors (distraction, fatigue) 7) Errors due to slowness (delay in judgment) 8) Errors due to lack of standards (written & visual) 9) Surprise errors (machine not capable, malfunctions)

3) Error in setting up the

workpiece 4) Assembly omissions 5) Wrong parts

6) Wrong workpiece
7) Operations errors 8) Adjustment, measurement, dimensional errors 9) Error in equipment maintenance 10) Error in preparation of setup or tool adjustments

The Connection
Misidentification Forgetfulness No standards
Human Error Cause of Defect Omitted Processing Processing errors Error in setting up the workpiece Missing parts Inclusion of wrong part / item Wrong workpiece Operations errors Adjustment, measurement, dimensional errors Error in equipment maintenance Error in preparation of setup or tool adjustments

Misunderstanding

Inadvertent errors

Slowness

Amatures

X X # X X #

# X # # X X

# # #

# X # #

# X

X X X

# X #

# X # # X # # X

# X X

X X X #

X #

X #

# X

X Strongly Connected

# Connected

Surprise
# X #

Willful

The Basics
A mistake proof system exists in two states.
Prediction - Catch a defect that is about to occur. Detection - Catch a defect that has already occurred.

Three Basic Functions of a Mistake proofing device.

Control - Removal of defect from system.

Warning - A signal to attract attention to defects.

Shutdown - A restricting tool to stop the process when a defect occurs.

Control Devices
Removing the Defect from the system

DETECTION A fruit orchard that takes great pride in its oversized apples, assures only the biggest ones get to customers by passing all apples through a sizer. Those that dont make it are sent to the discount outlet.

PREVENTION At gas stations diesel pump nozzles and the hole for the tank are larger than the ones for gasoline.

Warning Devices
A signal to attract attention to defects.
Detection Prevention

Lights turn off after a few minutes without the owner having to turn them off.
The computer barks when the wrong command is entered

Shutdown
A restricting tool to stop the process when a defect occurs.

Prevention : A microwave will not start if the door is

open.

Detection: A microwave will stop if the door is opened

during operation.