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Product Marketing
Lean Marketing
Poka Yoke
Business901
Product Marketing
Lean Marketing
Business901
Product Marketing
Lean Marketing
Henry Ford said: If you would have asked the customer, he would have just wanted a faster horse! As a company we cannot totally rely on our customer feedback. Many times, they will not have the capacity to know the latest technology and trends effecting the products or services that they use. What they do know is their business needs and requirements. So concentrating on where his business is going is an important function of marketing. But can we have mistake-free marketing? I think there is 2-ways to discuss mistakefree marketing: The strategic side and the tactical side. The strategic side would be your marketing messages and the tactical side, producing these messages. I will spend time on the strategic side deciding; how to facilitate that interaction with the customer and also discuss the tactical side; how to implement a mistake-free marketing system. The tool I will use to achieve this is defined by the Lean term, Poka-Yoke. Poka-Yoke emphasizes the detection and correction of mistakes. It puts special attention on the one constant threat to any process: human error. Careful attention is also placed on every activity in your process and instantaneous feedback tools are utilized as the key to successful implementation.
Business901
Product Marketing
Lean Marketing
Business901
Product Marketing
Lean Marketing
I approach this subject because as we install a component of Lean, Poka-Yoke into your company, we are raising the stakes and not accepting general improvement. We are looking initially for breakthrough strategies and after that continuous improvement. So ask yourself, and from the strategic side, are you customer driven?
Business901
Product Marketing
Lean Marketing
Business901
Product Marketing
Lean Marketing
Business901
Product Marketing
Lean Marketing
Secondly, we will examine areas that we may find errors in our process that would improve items such as delivery, taking on a job we may not qualify for and/or not have the proper equipment. In our post, we will break down these errors defining them further to see if we can control them. Thirdly, we must get to the root of the problem to ensure that the improvement method we choose can be applied as a real solution, and not just a bandage. We typically use a fishbone diagram, to help prompt us to ask why at least five times. This will enable us to discover the root of the problem. Only then ask, how do we fix it and put the solution into practice Only at the time, do we determine how to create the basic improvements for our desired outcomes and create a roadmap to start and more importantly maintain the value stream created.
Business901
Product Marketing
Lean Marketing
Business901
Product Marketing
Lean Marketing
The basic functions of Poka-yoke control are stop doing it(shutdown), control(make adjustments) and warning(red flags occurring). Maybe, more important, is the two terms, prediction and Detection. Prediction states that something is about to occur and Detection is something has occurred. The closer the source to the mistake that it is discovered the less costly is the problem. The whole point of Poka-yoke is to instill the process detection, this will drive better feedback which generates the proper actions. This is a continuous process that once installed continues on and on.
Business901
Product Marketing
Lean Marketing
Common Red Flag Conditions: These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first WHY in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing. 1. 2. 3. 4. 5. Frequent changes to a job Complex processes Lack of Standards Lack of measurement systems Lack of training 6. Long cycle times 7. Infrequent jobs 8. High output 9. Environmental conditions 10. Attitude ( Motivation)
Handling Mistakes: Use this diagram as a reminder on what not to do with a mistake.
Business901
Product Marketing
Lean Marketing
The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.
Business901
Product Marketing
Lean Marketing
Finishing the Poka-Yoke Job We have found the root cause but how do we correct it? The correction may seem easy at this point but how do we know it is just not a bandaid. My preference is to go back to the Fishbone diagram and use the same method we use in discovering the root cause to discover the best solution. I also use the matrix to visualize and confirm the final choice. One of the important things you now must do is to consider the control device you will use to monitor the progress. In manufacturing we consider limit switches, stop/no go gauges. However, in service industries it can be much more difficult. In event planning though it could be something like an ineffective advertisement. You could build into it milestones that if it not achieved that certain positive or negative consequences occur.
Business901
Product Marketing
Lean Marketing
Another example may be in developing advertisement copy; you may have certain acceptance criteria that are built into the process. It could be time sensitive, for example. You must remember even what seems like the best solution, if is uncontrollable will not lead to good results. You may want to consider another alternative and a result is that the perceived best action may change or become clearer as you improve. The method 1. Start with the Root Cause of the mistake. Brainstorm ways to eliminate the mistake(Fishbone). 2. Note on each idea how you will handle the mistake: Dont Accept, Dont Make, Dont Pass On. 3. Consider the cost and time of solving the problem 4. Place in matrix on Easy/Hard to do, Big/Low Payoff. 5. Review the controls to use. 6. Make your choice. 7. Proceed and monitor.
Business901
Product Marketing
Lean Marketing
Joseph T. Dager Ph: 260-438-0411 Fax: 260-818-2022 Email: jtdager@business901.com Web/Blog: http://www.business901.com Twitter: @business901