Documente Academic
Documente Profesional
Documente Cultură
OR
QUALITY BY MISTAKE PROOFING DESIGN
AND CONSTRUCTION SYSTEMS
Ir is D. Tommelein 1
ABSTRACT
The Japanese concept poka yoke, translated into English as mistake proofing, has
been mentioned at previous IGLC conferences. This notwithstanding, mistake
proofing appears to not have been (nor be) systematically researched or practiced in
the lean construction community. To raise awareness of opportunities provided by
thinking with mistake proofing in mind as a means to build quality into project
delivery, this paper summarizes the philosophy that underlies mistake proofing.
Examples illustrate how mistake proofing applies to the work done within one
specialty trade, how manufacturers and fabricators can design their products so they
cannot be constructed defectively, and how architects and engineers may conceive of
system designs that are less likely to fail during construction or in a products life
cycle. Reader contributions to an online repository of mistake proofing applications in
the architecture-engineering-construction (AEC) industry, posted at
http://p2sl.berkeley.edu/pokayoke/, will be gratefully acknowledged.
KEY WORDS
poka yoke, mistake proofing, jidoka, autonomation, design, engineering, system,
specification, construction, safety, quality, constructability, tolerance management,
life-cycle performance, lean construction
translated as autonomation in
INTRODUCTION AND English, as together they form a pillar
DEFINITION of the Toyota Production System.
Shingo (1986), a master mind of the Autonomation refers to machines
Toyota Production System, introduced built to detect problems and stop by
the concept of poka yoke in themselves, so as to relieve the
Japanese, translated as mistake burden of constantly supervising a
proofing in English, in his book titled machine, and allow [people] to use
Zero Quality Control: Source their talents for more beneficial things
Inspection and the Poka-yoke System. (like adding value) (Liker and Meier
This concept goes hand-in-hand with 2006 p. 177) The purpose of
the concept of jidoka in Japanese, autonomation is the rapid or immediate
address, identification and correction
1
Director, Project Production Systems Laboratory, http://p2sl.berkeley.edu/, and Professor,
Engineering and Project Management Program, Civil and Environmental Engineering Department,
215-A McLaughlin Hall, University of California, Berkeley, CA 94720-1712, Phone +1 510/643-
8678, FAX +1 510/643-8919, tommelein@ce.berkeley.edu
195
Poka Yoke or Quality by Mistake Proofing Design and Construction Systems
Iris D. Tommelein
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 1: Color coding of design drawing shows Figure 2: Color coding shows locations for sheet
different wall types for drywall cost estimate metal straps and pipe hangers on metal decking
(Source: DPR, Inc., Camino Medical Project) (Source: John Mack, Southland Industries, Inc.,
presentation at 2007 Annual Conference of the Lean
Construction Institute, San Francisco, CA)
hose that solves a typical fit-up
E XAMPLE 1: C OLOUR C ODING TO
problem. At one end, the toilet bowl
I MPROVE I DENTIFICATION
(commode) is seated on waste-water
Figure 1 shows colour codes a pipe located in the floor, and the water
construction estimator has assigned to tank rests on and connects to that base
distinguish various wall types. This of the fixture. At the other end, the
helps in clarifying and categorizing the water supply pipe runs in the wall and
design requirements specified by the stubs out of it, ending with a valve.
architects, in performing a quantity The challenge is to connect the pipe at
take off and preparing a cost estimate, this valve to the entry into the water
and in planning the work. Figure 2 tank, recognizing that all construction
shows colour codes being used on site, work that precedes this connection step
to highlight which metal-decking is subject to dimensional variation
inserts belong to which trade. This (tolerances), that is, things do not get
helps, among other things, in making it physically located exactly where
easy to assess whether or not all inserts drawings or computer models showed
are in place prior to casting the them to be. Rather than requiring
concrete slab on this decking. These bending of more rigid tubing or pipe
two examples illustrate mistake and cutting it to size, a flexible hose of
proofing approaches that help reduce approximate (standard) size suits this
the likelihood of occurrencethough purpose without requiring accurate
not 100% preventionof mistakes. measurement.
E XAMPLE 2: F LEXIBLE C ONNECTION Mistake proofing devices to
TO ACCOMMODATE DIMENSIONAL accommodate the manifestation of
VARIATION uncertainty in physical geometry
(dimensions and location), and
Figure 3 shows plumbing where the accumulation of that uncertainty as
mistake proofing device is a flexible work progresses, similarly exist in
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 3: Flexible hose (Source: Picture Figure 4: Connect plug and wiring of light fixtures (Source:
by Iris D. Tommelein, Boston, MA, Finelite (2001) product literature)
2007)
ballast, which is a component in a light
EXAMPLE 3: PLUGS TO ENSURE
fixture used to stabilize the current
CORRECT CONNECTIONS DURING
flow. All wires related to the ballast
ASSEMBLY
fits into the fixture and wiring can be
Figure 4 shows a connect plug that done off site. Until recently, all this
ensures the correct wiring of electrical wiring was continuous; new code
light fixtures and that, furthermore, requires the use of the plug as
greatly simplifies the work otherwise described. The challenge is that
required of a skilled field electrician maintenance personnel, who must
(Finelite 2001, 2008, Tsao and disconnect the ballast from the
Tommelein 2001). The challenge is electrical circuit prior to working on it,
that custom-wiring of light fixtures on at times would not disconnect all
site requires meticulous attention wiring properly and thus risk
(avoid cross-wiring) and work electrocuting themselves. The mistake
overhead. The plugs for each fixture proofing device is a brightly colored
are wired off-site in a shop plug that is easy to unplug and plug
environment, leaving only final back in (Figure 5). A sticker (Figure 6)
assembly to be done on site. The plug on the outside of the light fixture but
allows for only one way in which to out of sight for people occupying the
connect adjacent fixtures together. A room informs maintenance personnel
minimal investment in plugs and shop that this feature is present in that
assembly thus result in a safer, less fixture. A minimal investment in plugs
error-prone, and faster process overall. wired during off-site assembly of the
EXAMPLE 4: PLUGS TO ENSURE fixture thus results in a safer, less
CORRECT MAINTENANCE error-prone fixture maintenance
process.
Figure 5 shows a connect plug
installed in the power supply to a
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 5: Wiring plug for ballast inside light fixture (Source: Picture Figure 6: Instruction label on
by Iris D. Tommelein taken at Finelite, Union City, CA, 2008) outside of fixture (Source:
Picture by Iris D. Tommelein
taken at Finelite, Union City,
CA, 2008)
was not always of consistent and
MISTAKE PROOFING A adequate thickness. Either the panels
PRODUCT DESIGN FOR had not been tightened sufficiently
CONSTRUCTABILITY AND (uneven thickness), so the sealant left
LIFE-CYCLE PERFORMANCE gaps through which water could
Mistake proofing can be done in penetrate, or the panels had been
design. The following examples tightened too much (minimum
illustrate how a product was designed thickness not met), so the sealant had
and engineered for constructability been squeezed out, leaving too little
while targeting life-cycle performance. material to be effective. This sealant is
a mistake proofing device that curbs
EXAMPLE 5: SEALANT TO ALLOW variation in the system.
LIMITED COMPRESSION To mistake proof the tightening
Figure 7 shows the cross-section of a process, the manufacturer co-
metal roof, where two roof panels are developed with their supplier a new
joined. The challenge is to make a sealant product, in which tiny but hard
seam that is watertight. This is cubes are embedded and more-or-less
particularly important to the evenly distributed. The dimension of
manufacturer of these roofing products these cubes is commensurate with the
who guarantees long-term performance optimal thickness of the sealant
(e.g., 20 years if not more) of their application. As a result, contractors
installed products and wants to need no longer worry about overly
maintain their brand-name reputation. tightening their fasteners: the
This manufacturer studied the minimum thickness of the sealant is
performance of installed roofs and guaranteed.
found that the sealant between panels
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 7: Sealant and return leg to guarantee roof performance (Source: Butler manufacturing product
literature)
must slope slightly to allow water to
EXAMPLE 6: OVERLAPPING
run to a drain for ease of cleaning the
MATERIAL TO ACCOMMODATE
floor.
DIMENSIONAL VARIATION
To complicate the situation, design
Figure 7 also shows a sealant pocket drawings showing the layout plan view
and a return leg on each overlapping of a restroom may not accurately
panel made by this manufacturer to reflect the slope of the floor towards
further ensure that the joined roof the drain (Figure 8). A builder may
panels would be water tight. have to pull information together from
different drawings and sections in the
MISTAKE PROOFING THE specifications in order to develop a
DESIGN OF A SYSTEM clearer 3-dimensional picture of the
The last example illustrates how situation (Figure 9). Because of this
designers may use mistake proofing as slope, when the designer selects sinks
a means to accommodate a variety of with an apron to hide plumbing behind
competing requirements from users it, the clearance between the bottom of
while recognizing that dimensional it and the floor will vary in the room.
variation will occur during As a result, some clearances as shown
construction, and mistakes could occur in the design may meet the ADA
as well. Consider designing and requirements whereas others in the
constructing a restroom facility with same room will not. Add to that the
sinks (wash basins). The challenge effect of tolerances that will manifest
with such facilities is that (in no themselves during construction and it
specific order of value): (1) the becomes less likely that clearances will
plumbing must be functional (i.e., the suffice (Figure 10). It is no wonder
sink drains into a pipe with a water then that quite a few facilities get built
lock); (2) designers and users may but fail to meet ADA requirements,
want sinks to be aesthetically pleasing; and following inspection thus require
(3) the sink height must be convenient rework prior to commissioning.
for hand washing; (4) in the United Practitioners are aware of these
States, public restroom facilities must challenges (conflicting values) and
meet American with Disabilities Act have developed various solutions in
(ADA) requirements (this act basically response. Figure 11 shows a bare
states that people with disabilities just sink with ugly plumbing underneath
like everyone else must be able to use of it. Figure 12 shows an
such public facilities); and (5) the floor architecturally more pleasing solution,
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 11: Bare Sink in San Francisco Airport, Figure 12: Dressed-up Sink in Mich. State Univ.
California ( 2006 Iris D. Tommelein) Conf. Center, East Lansing, Michigan ( 2007
Iris D. Tommelein)
a solution that acknowledges the
Figure 13 shows another way of
challenge. Here, the apron is cut back
covering up the plumbing, but it is
to ensure sufficient clearance, at least
unclear if this solution would meet
in a few locations.
ADA requirements. Figure 14 presents
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Figure 13: Sink with Covered Apron in Brussels Zaventem Airport, Belgium ( 2007 Iris D. Tommelein)
Figure 14: Sink with Cut-out Apron in San Francisco Figure 15: Sink with Adjustable Apron at Oakland
Airport, California ( 2007 Iris D. Tommelein) Airport, California ( 2004 Iris D. Tommelein)
Unlike other mistake proofing devices,
The example in figure 15 like that in
figure 3, showed the use of a mistake these do not in-and-by themselves
prevent or reduce the occurrence of
proofing device (flexible hose or duct,
and hinged apron) to buffer or variation in the system.
alleviate the impact of variation.
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
REFERENCES
Abdelhamid, T. and Salem, S. (2005) Lean construction: a new paradigm for managing
construction projects. Intl. Workshop on Innovations in Materials and Design of
Civil Infrastructure, 28-29 December, Cairo, Egypt, 25 pp.
Bodek, N. (1986). Page vii of Publishers Preface to Shingo (1986).
Proceedings for the 16th Annual Conference of the International Group for Lean Construction
Iris D. Tommelein
Proceedings for the 16th Annual Conference of the International Group for Lean Construction