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Mistake Proofing

MistakeProofing

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Sameer Sutar
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110 views

Mistake Proofing

MistakeProofing

Uploaded by

Sameer Sutar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 20

Mistake Proofing

(Poke Yoke)
Learning Objectives

By the end of this module participants should be able to:


• Identify the concept and importance of mistake
proofing (poke yoke)
• Apply Poke Yoke methods as a control on identified key
Xs to reduce or eliminate process errors and defects
from occurring
• Select the appropriate strategies and methods for
mistake proofing based on DMAIC Implementation
road map
The DMAIC Process with Tools
DAY 3
Define
PHASE 5
Measure
Tools:
• Controls Plans
• Lean Visual Controls
Analyze • Mistake Proofing (Poke Yoke)

Improve

Control
What is Mistake Proofing (Poke Yoke)?

 Japanese phrase:

Yokeru Poke Poke Yoke


(to avoid) (errors)
Concept of Mistake Proofing (Poke Yoke)

 A strategy for preventing errors in processes


 Makes it impossible for defects to pass unnoticed and corrects
them immediately
 Technique detects defects and prevents them from moving
into next area
 Developed by Dr. Shigeo Shingo to achieve zero defects

Mistake Proof devices cannot be implemented until the key Xs


needing to be controlled have been identified and settings
established
Importance of Mistake Proofing
 Improved quality and customer
satisfaction
 Prevents error occurrence 30-50 Inputs

 Prevents defect occurrence 10-15 Xs

 If defects occur, ensures effective 8-10 KPIVs

action
 Little or no formal training 4-8 Key KPIVs
 Cost effective 3-6 Key KPIVs

 Easy to implement
Y

Apply Mistake Proofing to key Xs or directly to the Y to ensure


metrics remain at optimum project defined settings.
Basics Of Mistake Proofing

Effective Mistake Proofing requires two basic


concepts
1 A focus on controlling the factors which cause errors
• Not fixing the resulting defective output

2 Inspection which is effective and tireless


• This IS NOT a traditional 100% inspection by inspectors.
• This IS a mechanical or process improvement that
automatically performs the inspection with little to no human
interaction.
Basics Of Mistake Proofing
 Anybody can and should practice poke yoke in the workplace.
 It’s not rocket science!
 Sometimes it just needs common sense and the appropriate
poke yoke device.
 Poke yoke devices should have the following characteristics:
 Useable by all workers
 Simple to install
 Does not require continuous attention from the operator
(ideally, it should work even if the operator is not aware of it)
 Low-cost
 Provides instantaneous feedback, prevention, or correction. A
lot of Shingo's poke yoke devices cost less than $50!
Common Examples Of Mistake Proofing

 Home
 auto shut off on iron
 Auto
 car won’t start unless transmission is in park/neutral
 Sport/Recreation
 dead man’s lanyard on personal watercraft
 Amusement Parks
 sensors on roller coaster tracks
 Work/Commerce
 pull down menus on forms
Mistake Proofing Business Processes

Mistake Proofing is the primary means of control


for many business processes.

 Spell check
 Checklists
 Color coding
(boxes, work areas,
products, components)
 Pull down menus
 Required fields
Error Proofing In Action

 What are the error opportunities in this everyday item?


 How has it been error proofed?
 How could it be further error proofed?
Evolution Of Defectives And Application
Of Mistake Proofing

ERRORS DEFECTS DEFECTIVES

Prevention Detection in Detection After


Process: Mistake:
• Elimination • Catch errors • Detect
of issues at during defects
the source, processing before they
or before move to
prevention becoming a next step
of errors problem
from
occurring

Best Good
(prevention) (detection)
Human Errors That Lead To Potential
Key X Variation
1. Forgetfulness Prevention
2. Errors due to misunderstanding
3. Errors in identification
4. Errors made by untrained workers
5. Willful errors (ignore rules) Detection in
Process:
6. Inadvertent errors (distraction, fatigue)
7. Errors due to delay in decision making
8. Errors due to lack of standards
9. Surprise errors (malfunctions) Detection After
Mistake:
10. Intentional errors (sabotage)

Also consider Mistake Proofing against these having any


impact on your Key Xs.
Red Flag Condition

What is a Red Flag condition?


 You will find that in some projects, after you have identified the
Key Xs and their optimal settings, one or more of them may be
extremely difficult to control. The control plan should attempt to
provide robust control mechanisms, however it may be difficult
to do so without Mistake Proofing. Some examples:
 Training was found to be critical, but the operation has 150% turnover
 Cycle Times are very long, so the operators tend to lose concentration
and Key X breakdowns may not be observed even though gages/process
measurements show the issue

Mistake Proofing is a good control application for conditions


such as these.
Implementation Road Map For
Mistake Proofing
(Define)
Describe the defect or potential Apply 5 Why analysis to the error
defect including the rate conditions to determine root
causes
(Measure)
Identify where the defect is likely
(Improve/Control)
to occur
Identify (using a team approach)
(Analyze) Mistake Proofing strategies
Analyze current tasks associated
with the operation

(Control)
Identify error conditions Verify the efficiency of the
contributing to the defect Mistake Proofing actions
Mistake Proofing Considerations

 Create an environment that…


 Emphasizes quality work

 Promotes involvement and


creativity

 Strives for continuous


improvement
Mistake Proofing Considerations

How to create an environment ?


 Eliminate, simplify, or combine operations

 Use one piece flow rather than process


batch flow

 Beware of overproduction and inventory


 (high inventory makes poor quality difficult to
see)
 Involve everyone in error and defect
prevention
 (standard practices, daily improvements,
training, and incentives)
Exercise # 1:
1. Going around the class, name a Mistake Proofing idea from one of the
following:
- Home, e.g., auto shut off on flat iron
- Auto, e.g., car won’t start unless transmission is in park/neutral
- Sport/Recreation, e.g., dead man’s lanyard on personal watercraft
- Amusement Parks, e.g., sensors on roller coaster tracks
- Work/Commerce, e.g., pull down menus on forms
- Etc.
2. Break into your groups and pick one project per group.
- Identify a common, recurring issue within the project and list the defects
contributing to it. Then, determine the errors that cause the defect and
brainstorm for potential mistake-proofing on all levels.
 Are you Preventing, Detecting During the Process, or Detecting After the
Process?
Summary
 Mistake Proofing (Poke Yoke) is a strategy for preventing
errors in processes.
 Effective Mistake Proofing requires two basic concepts:
 1. A focus on controlling the factors which cause
errors
 2. Inspection which is effective and tireless
Thank You

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