{"id":8790,"date":"2020-12-16T12:35:38","date_gmt":"2020-12-16T10:35:38","guid":{"rendered":"https:\/\/fractory.com\/?p=8790"},"modified":"2024-02-08T11:59:43","modified_gmt":"2024-02-08T09:59:43","slug":"poka-yoke-in-manufacturing","status":"publish","type":"post","link":"https:\/\/fractory.com\/poka-yoke-in-manufacturing\/","title":{"rendered":"Poka-Yoke in Manufacturing"},"content":{"rendered":"

Most competitive studies have found that 70-100% of manufacturing incidents are due to human error. It can happen with the most well-trained and experienced person. There are many reasons for these lapses. It is important to reduce these mistakes to cut waste and maximize productivity.<\/p>\n

Interestingly, the above two goals are also the core objectives of lean manufacturing. Lean manufacturing aims to reduce seven different types of wastes in manufacturing<\/a>. Addressing them helps streamline the process and increase productivity while reducing costs and preventing incidents, accidents, and near misses.<\/p>\n

It suggests seven production concepts and tools to improve our processes. One of the lean manufacturing methods<\/a> is poka-yoke<\/strong>. Poka-yoke is a Japanese term that means mistake-proofing. It aims to reduce the number of defects as well as incidents that occur due to inadvertent actions taken by humans when working.<\/p>\n

Initially, the Japanese developed this technique for manufacturing but due to its versatile nature and the need for mistake-proofing, it soon found its way into many other industries.<\/p>\n

Origin<\/strong><\/h2>\n

The poka-yoke technique originates from Japan. An industrial engineer by the name of Shigeo Shingo developed this method while working at Toyota. He developed the guidelines to detect the defects at the source as well as methods to rectify them.<\/p>\n

The technique first caught the attention of the West in 1990 when Womack published his classic management book \u201cThe Machine That Changed the World\u201d<\/a>. It was the first book to introduce the Toyota Production System (TPS) to the world. They described the lean systems of Japan in comprehensive detail.\u00a0<\/p>\n

They also compared the lean manufacturing system with the mass production model put in use by General Motors at the time and predicted that the former production system would be more successful in the long run. In the 90s, Toyota was half the size of General Motors. Eventually, it passed GM as the largest automaker in the world.<\/p>\n

What Is the Poka-Yoke Technique?<\/strong><\/h2>\n

As discussed, poka-yoke means mistake-proofing, or sometimes described as foolproofing. In this technique, the engineers anticipate the kind of mistakes or defects that may occur in the manufacturing process as well as during the product\u2019s use and install preventive measures in the process\/product to prevent them altogether.<\/p>\n

In other words, poka-yoke is a type of quality control with the aim of ensuring that all parts function properly.<\/p>\n

A common example is how an interlock is built into top-load washing machines to prevent rotational movement while the lid is open. Or how, in front-loaded washing machines, the door can only be unlocked when the wash cycle is completed.<\/p>\n

Similar devices are built into almost every machinery to prevent unintended use. They may also prevent mistakes in manufacturing by eliminating the possibility of making that mistake or alerting the responsible person about the mistake and initiating corrective action.<\/p>\n

This reduces the number of defective parts produced, reducing costs and improving profit margins.<\/p>\n

When to Use It?<\/strong><\/h2>\n

Poka-yoke aims to reduce human errors wherever they could occur. This means there is a need for it in practically every industry. The solution to each problem is different. We can prevent such mistakes by following a set of guidelines that help us to find possible solutions.<\/p>\n

But before we get to these guidelines, let\u2019s see when and where can poka-yoke really make a difference to our processes and products. When we boil it down to the basics, three types of causes lead to mistakes.<\/p>\n

1. Faulty memory<\/h3>\n

Faulty memory can cause a person to forget important steps in the production process and cause the following types of mistakes.<\/p>\n

Missing part<\/h4>\n

During the assembling phase, the employee may forget to insert a part that should be in the final assembly.<\/p>\n

Missing step<\/h4>\n

Faulty memory can cause an employee to miss a process step such as removing a part, pressing switches, or recording measurements.<\/p>\n

2. Wrong perception<\/h3>\n

Sometimes, errors may arise due to an incorrect assessment of the situation. Examples of such errors are using incorrect parts or material quantities, wrong interpretation of procedures, and incorrect evaluation of dangerous situations\u00a0<\/p>\n

3. Incorrect execution<\/h3>\n

When there are lapses in execution, it can cause errors and lead to defects. Some examples of such errors are as follows.<\/p>\n

Setup error<\/h4>\n

This refers to errors in setting up the machine and jigs\/fixtures correctly for the workpiece.<\/p>\n

Operations error<\/h4>\n

This type includes mistakes made in step execution. Either the operator performs the step incorrectly or in the wrong sequence.<\/p>\n

Errors in measurement<\/h4>\n

Incorrect measurement of part dimensions.<\/p>\n

\n
\n Scale Your Manufacturing from Prototyping to Series<\/span>\n\n