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PPT MISTAKE PROOFING POKA YOKE Power. Point presentation free to download. Title MISTAKE PROOFING POKA YOKE 1. MISTAKE PROOFING POKA YOKEPresented To Prof. Raj Mukundan Group Number 1. Poka Yoke. Poka means Mistakes Yoke means Avoid. Its objective is to achieve Zero Defects. Poka yoke is a quality assurance technique ,the aim of poka yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Term adopted by Dr. Shigeo Shingo as part of the Toyota Production System in 1. It was originally described as baka yoke, but this name mean Fool Proofing so the name was changed to the Poka yoke. DEFECTS AND ITS IMPACTDefect free product is a necessity to compete in the market place. YKzuF0IoM/hqdefault.jpg' alt='Animated Curtains Powerpoint Slides Free Download' title='Animated Curtains Powerpoint Slides Free Download' />Every Customers has a right to demand 1. Bad products hurt both reputation and bottom line Scrap, rework, warranty. Defects have a direct impact on process yield affecting speed and flow of the product to the customer. Typical Errors. Processing errors Missing Operation Inappropriate procedures Missing parts Missing information. Wrong parts Damaged materials Tools or equipment improperly prepared or setup Human Errors 5. HOW TO USE MISTAKE PROOFING Identify the process. Process can fail Decide right poke yoke approach Use of checklist Trail the method Train the operator 6. PRINCIPLES OF POKA YOKE 7. Why is Zero Defects an Important Concept Maintain Customer Satisfaction Loyalty Happy Customers mean more sales COSTS There is always a cost associated with manufacturing defects DEFECT DETECTION AND PREVENTION STRATEGIESSuccessive Checks Each process inspects previous process Typically, 3 or less critical checks per step Effective with small transfer quantities from process to process. Self Checks Find defects as they exit process, Immediate feedback corrective action. Stops adding value to defective product. Prevent the defect from occurring in the first place or to make it immediately evident. UvBnFy3k6U/0.jpg' alt='Animated Curtains Powerpoint Slides Free Download' title='Animated Curtains Powerpoint Slides Free Download' />Poka Yoke 9. SOME MISTAKE PROOFING STRATEGIESMake it harder to create the error Make it possible to reverse the error Make it obvious that the error has occurred Detect deviations from procedures or fixed values e. Number of parts Design Design process so it tolerates the error and doesnt result in a defect Design process to decrease complexity 1. APPROACHES TO MISTAKE PROOFINGControl approach Shuts down the process when an error occurs High capability of achieving zero defects ie robust design that can tolerate variation or eliminates variation or assembly mistakes Warning approach Signals the operator to stop the process and correct problem or check for a problem ie are parts still ok, is oil level ok Sometimes an automatic shutoff is not an option Dials, lights, and sounds to bring attention to the problem 1. Mistake Proofing Devices. Types of mistake proofing devices within control or warning approach can be of Contact type The contact type makes contact with every product or has a physical shape that inhibits mistakes. Example Fixed diameter hole through which all products must fall and an oversize product does not fall through and a defect is registered. Fixed value type The fixed value method is a design that makes it clear when a part is missing or not used. Example Egg tray used for supply of parts, Motion step type The motion step type automatically ensures that the correct number of steps have been taken. Example An operator is required to step on a foot pedal every assembly cycle, Correct sequence for switches that do not work unless the order is correct. EXAMPLES OF SOME USEFUL MISTAKE PROOFING DEVICESGuide pins, to assure that parts can only be assembled in the correct way. Mutilate A Doll 2. Limit switches, that sense the presence or absence of a part. Mistake proofing jigs, detect defects immediately upstream of the process ensuring that only the correct part reach the process. Counters, that verify that the correct number of parts or steps have been taken. Checklist, that reminds operators to do certain actions. Summary of Mistake Proofing Types Control Warning Contact Parking height bars Shop entrance bell Fixed Value French fry scoop Trays with indentation Motion Step Foot pedal operated Machine Beepers on ATM 1. EVERYDAY EXAMPLES OF MISTAKE PROOFINGHome Automated shut offs on electric coffee pots Child Proof caps on mediations Ground fault circuit breakers for bathrooms or outside electric circuits Office Spell check in word processing Question prompt Do you want to deleteDownload the free trial version below to get started. Doubleclick the downloaded file to install the software. This free Kermes background for PowerPoint is a very simple kermes template with green borders and white background color. Delete button on your computer. Factory Dual palm button and light curtains on machines Retail Tamper Proof packaging Bar coding at checkout. I have an extra part. I must have omitted a step CONTROL APPROACH Automobile controls have a mistake proofing device to insure that the key is in the on position before allowing the driver to shift out of park. The keys cannot be removed until the car is in park. Electronic door locks can have three mistake proofing devices Insures that no door is left unlocked. Doors automatically lock when the car exceeds 1. Lock wont operate when door is open and the engine is running. CONTROL APPROACH Manhole covers are round because if they were of any other shape Ex Square it would be possible to accidentally drop one through the hole while removing it. WARNING APPROACHWarning lights alert the driver of potential problems. These devices employ a warning method instead of a control method. Seatbelts, High engine temperature, Low oil pressure 1. TYPES OF SENSING DEVICESSensing devices that are traditionally used in poka yoke systems can be divided into three categories 1. Physical contact devices 2. Energy sensing devices 3. Warning Sensors Each category of sensors includes a broad range of devices that can be used depending on the process. PHYSICAL CONTACT SENSORSThese devices work by physically touching something. This can be a machine part or an actual piece being manufactured. In most cases these devices send an electronic signal when they are touched. Depending on the process, this signal can shut down the operation or give an operator a warning signal. TOUCH SWITCHUsed to physically detect the presence or absence of an object or item prevents missing parts. Used to physically detect the height of a part or dimension. ENERGY SENSORSThese devices work by using energy to detect whether or not an defect has occurred. Vegas Poker Solitaire. Fiber optic. Vibration. Photoelectric 2. 2 WARNING SENSORSWarning sensors signal the operator that there is a problem. These sensors use colors, alarms, lights to get the workers attention These sensors may be used in conjunction with a contact or energy sensor to get the operators attention. Color Code. Lights. Lights connected to Micro switches timers 2. The Seven Guidelines to Poka Yoke Attainment. Quality Processes Design Robust quality processes to achieve zero defects. Utilize a Team Environment leverage the teams knowledge,experience to enhance the improvement efforts. Elimination of Errors Utilize a robust problem solving methodology to drive defects towards zero. Awesome explosion animated powerpoint slide. This explosion animated slide is great when used either as a reveal or to get the audiences attention. Chart and Diagram Slides for PowerPoint Beautifully designed chart and diagram s for PowerPoint with visually stunning graphics and animation effects. Download unlimited PowerPoint Templates, Presentation Clipart and 3D Animations. Create stunning PowerPoint presentations and graphics. Animated Curtains Powerpoint Slides Free Download' title='Animated Curtains Powerpoint Slides Free Download' />Eliminate the Root Cause of The Errors 5. Do It Right The First Time Utilizing resources to perform functions correctly the first time. Eliminate Non Value Added Decisions Dont make excuses just do it 7. Implement an Incremental Continual Improvement Approach implement improvement actions immediately and focus on incremental improvements efforts do not have to result in a 1.