Certified Lean Six Sigma: Process Improvement
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Questions and Answers

What is the primary goal of Mistake Proofing (Poka-Yoke) in process improvement?

  • To implement complex quality control systems
  • To increase employee training
  • To reduce production costs
  • To improve quality and customer satisfaction by preventing defects (correct)

    • What is the term 'Poka-Yoke' derived from?

  • Japanese phrases for 'quality control' and 'error prevention'
  • Japanese phrases for 'defect detection' and 'zero defects'
  • Japanese phrases for 'process optimization' and 'customer satisfaction'
  • Japanese phrases for 'to avoid' and 'errors' (correct)

    • What is the prerequisite for implementing Mistake Proof devices?

  • Developing a zero defect strategy
  • Implementing a Lean Six Sigma methodology
  • Identifying key Xs needing to be controlled and establishing settings (correct)
  • Establishing a quality control team

    • What is the benefit of Mistake Proofing in terms of employee training?

    <p>It requires little or no formal training</p> Signup and view all the answers

    What is the primary focus of the Lean Six Sigma methodology?

    <p>Process-centric improvement</p> Signup and view all the answers

    What is the ultimate goal of a zero defect strategy?

    <p>To achieve zero defects</p> Signup and view all the answers

    What is the benefit of Mistake Proofing in terms of defect detection?

    <p>It makes it impossible for defects to pass unnoticed</p> Signup and view all the answers

    Who developed the concept of Mistake Proofing (Poka-Yoke)?

    <p>Dr. Shigeo Shingo</p> Signup and view all the answers

    What is the primary goal of Mistake Proofing in a process?

    <p>To eliminate all defects and errors in the process</p> Signup and view all the answers

    Which of the following is NOT a consideration for implementing Mistake Proofing?

    <p>Increase production speed to meet demand</p> Signup and view all the answers

    What is the purpose of the 5 Whys analysis in Mistake Proofing?

    <p>To identify the root causes of errors and defects</p> Signup and view all the answers

    Which of the following strategies is considered the 'best' approach to Mistake Proofing?

    <p>Prevent errors from occurring</p> Signup and view all the answers

    What is the primary benefit of involving everyone in error and defect prevention?

    <p>To promote a culture of continuous improvement</p> Signup and view all the answers

    What is the purpose of a Process Map in Mistake Proofing?

    <p>To identify where defects are likely to occur</p> Signup and view all the answers

    What is the primary goal of a zero defect strategy?

    <p>To eliminate all defects and errors</p> Signup and view all the answers

    What is the purpose of FMEA in Mistake Proofing?

    <p>To identify error conditions contributing to defects</p> Signup and view all the answers

    What is the primary purpose of mistake proofing in business processes?

    <p>To control and eliminate defects through error prevention and detection</p> Signup and view all the answers

    Which of the following is an example of a mistake proofing technique used to prevent errors in data entry?

    <p>Look up tables for data base entry</p> Signup and view all the answers

    What is the primary goal of a zero defect strategy?

    <p>To eliminate defects completely</p> Signup and view all the answers

    Which of the following is an example of a mistake proofing technique used to prevent assembly errors?

    <p>Guide pins of different sizes</p> Signup and view all the answers

    What is the primary benefit of building error checking into control logic?

    <p>It improves product quality and reliability</p> Signup and view all the answers

    Which of the following is an example of a mistake proofing technique used to prevent errors in everyday products?

    <p>Designing products to prevent incorrect use or assembly</p> Signup and view all the answers

    What is the primary goal of process optimization in the context of mistake proofing?

    <p>To reduce defects and errors</p> Signup and view all the answers

    Which of the following is an example of a mistake proofing technique used to prevent errors in data processing?

    <p>Required fields</p> Signup and view all the answers

    Study Notes

    Control Phase: Mistake Proofing (Poka-Yoke)

    • Mistake Proofing is a cost-effective and reliable control method to ensure key Xs remain at optimal project-defined settings.
    • It can also be used directly on the Y.
    • Mistake Proofing:
      • Prevents error occurrence
      • Prevents defect occurrence
      • Ensures effective action if defects occur
      • Requires little or no formal training
      • Is cost-effective and easy to implement
    • The Japanese phrase "Poka-Yoke" means "to avoid" (Yokeru) and "errors" (Poka).

    Importance of Mistake Proofing

    • Improved quality and customer satisfaction
    • Prevents error occurrence
    • Prevents defect occurrence
    • Ensures effective action if defects occur

    Implementation Road Map for Mistake Proofing

    • Describe the defect or potential defect, including the rate
    • Apply 5 Whys analysis to error conditions to determine root causes
    • Identify where the defect is likely to occur (Process Map)
    • Analyze current tasks associated with the operation
    • Identify error conditions contributing to the defect (FMEA)
    • Verify the efficiency of the Mistake Proofing actions

    Mistake Proofing Strategies

    • Detect defects before they move to the next step
    • Detect errors during processing
    • Prevent errors from occurring

    Mistake Proofing Considerations

    • Don't make surplus products
    • Eliminate, simplify, or combine operations
    • Use one piece rather than process batch flow
    • Involve everyone in error and defect prevention
    • Create an environment that emphasizes quality work, promotes involvement and creativity, and strives for continuous improvement

    Common Examples of Mistake Proofing

    • Guide pins of different sizes
    • Checklists
    • Optical magnification
    • Asymmetric parts
    • Build error checking into control logic
    • Exact part count
    • Overlay templates
    • Color coding (boxes, work areas, products, components)
    • Spell check
    • Limit switches
    • Error alarms
    • Counters

    Mistake Proofing in Business Processes

    • Mistake Proofing is the primary means of control for many business processes.
    • Examples include:
      • Check digits
      • Pull down menus
      • Check sheets
      • One over One
      • Required fields

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    Related Documents

    CP-003 Mistake Proofing (Poka-Yoke).pptx

    Description

    This course focuses on improving process performance using Lean, Six Sigma, and Process Management methodologies. Learn how to enhance business performance through process-centric approaches.

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