POKA-YOKE

OBJECTIVE
To know and discuss about
Poka-Yoke The error proofing,
Poka-yoke techniques,
Steps towards Poka-yoke and
Examples of Poka-yoke in product assy lines & Component
manufacturing areas.
HISTORY
Shigeo Shingo (1909-1990) was a Japanese Industrial
engineer who was one of the lesser-known but still highly
regarded people to work with quality systems, compared to
Edwards Deming and Walter A.Shewhart.
Two major accomplishments by Shingo are Poka-Yoke
(fail-safe) devices and SMED (single-minute exchange of
dies). The latter made some change-over jobs obsolete.
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DEFINITION : ERROR PROOFING

A process improvement system, that

- Prevents personal injury,
- Promotes job safety,
- Prevents faulty products and
- Prevents machine damage

INPUTS
- FMEA
- Control Plan
- Incoming parts rejection details
- Inline rejection details
- Warranty rejection details
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DEFINITION : ERROR

When any of the conditions necessary for successful processing are

improper or absent.

Everyday Examples Of Defects And Errors

Defect - Result Error - Cause

Burnt toast Timer

improperly set
Blank copies Original placed
incorrectly
No date code on Stamp out of
product ink
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Defects And Errors Are Not The Same
Defects are results
Errors cause results
Cause Result

Errors Defects

Some Common Errors Some Common Defects

Processing omissions
Damaged parts/product
Processing errors
Foreign matter present
Error in setting up the work piece
Misaligned parts
Assembly omissions (missing
Cannot be assembled
parts)
Inconsistent test results/test
Inclusion of improper part/ item
failure
Adjustment, measurement,
dimensional errors Bad incoming material
Errors in equipment maintenance Wrong material/parts
Error in preparation of Jigs& Wrong or inconsistent
Fixtures, or tools dimensions
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FIVE ELEMENTS OF PRODUCTION

Machines
Operator

Method

Materials Information

Quality problems originate in each of the five elements of production.

Improvement requires root cause analysis within all of these elements.

05MP69
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ERROR PROOFING LEVELES

Level 1
Eliminate
the Error

Level 2
Detect the Error

Level 3
Detect the Defect

BASIC FUNCTIONS OF POKA-YOKE

Poka-Yoke have three basic functions to use against defects
1. Shutdown Normal functions stopped when Defects predicted /
detected
2. Control - Errors are Impossible / Defective items cannot pass
3. Warning - Signals the error about to occur / Defects have occured
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FIVE BEST POKA-YOKE

1. Guide pins of Different sizes

2. Error detecting alarms

3. Limit switches

4. Counters

5. Check lists
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POKA-YOKE HINTS

1. Identify items by their characteristics

(a) By Weight
(b) By dimension
(c) By Shape
2. Detect deviation from procedures or omitted processes
(d) Process sequence method
(e) Process to process sequence method
3. Detect deviation from fixed values
(f) Counters
(g) Odd-part out method
(h) Critical condition detection
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DETECTION DEVICES TO USE FOR POKA-YOKE

1.Contact devices Micro switches & Limit switches

They can detect the presence of items such as Work pieces, Dies or
cutting tools and are very flexible. Limit switches can be used to ensure that
a process does not begin until the work piece is in the correct position

2. Noncontact devices Photoelectric switches & sensors

There are 2 types of detection possible.
(a) Transmission type : In this type 2 units are used , one to transmit a light
beam, the other to receive the light beam.
When Light is unobstructed Normally ON
When Light is obstructed Normally OFF
(b) Reflecting type : This type of Photoelectric sensor responds to light
reflected from an object its presence.