Poka Yoke Principles Quiz

Questions and Answers

What is poka yoke?

Mistake proofing

Why do manufacturers use the poka yoke principles?

To make defects impossible

What are the 5 types of inspection systems defined by Shingo?

Judgement Inspection, Informative inspection, Successive checking, Self-checking, Source inspection

What is judgement inspection?

After processing, at end of production line to see if defective Signup and view all the answers

What is informative inspection?

Statistical process control (SPC) Signup and view all the answers

What is successive checking?

Next operator on production line checks workpiece Signup and view all the answers

What is self-checking?

Inspection by operator after they have done the work Signup and view all the answers

What is source inspection?

Detect mistakes, stopping them from being made in the first place Signup and view all the answers

How does mistake proofing stop defects?

Designing products and processes so that mistakes cannot be made. Signup and view all the answers

What are 10 sources of defects?

Omitted processing, Processing errors, Errors in setting up work pieces, Missing parts, Wrong parts, Processing the wrong workpiece, Miss operation, Adjustment error, Equipment incorrectly set up, Tools and jigs improperly used Signup and view all the answers

What are the 10 error types?

Forgetfulness, Misunderstanding, Identification, Lack of experience, Wilful errors, Inadvertent errors, Slowness, Lack of standards, Surprise errors, Intentional errors Signup and view all the answers

What does the term 'Red Flag Condition' mean?

It means there is a place for possible errors, and something needs to be done or changed Signup and view all the answers

What are the 12 potential points of red flag conditions in production?

Adjustments, Tooling change, Critical conditions, Mixed up parts, Multiple steps, Infrequent production, Lack of standard procedures, Symmetry, Asymmetry, Rapid repetition, High volume production, Environmental conditions Signup and view all the answers

When incorporating poka yoke what should be considered?

Sources, Error types, Red flags in the process Signup and view all the answers

What are the 3 rules of poka yoke?

Don't wait for the perfect poka yoke, do it now; If the poka yoke idea has 50% or higher chance of working then do it; Improve later, do now Signup and view all the answers

Examples of poka yoke devices?

Jigs, Error detection alarms, Limit switches, Counters, Checklists, Photo electric devices Signup and view all the answers

Study Notes

Poka Yoke Overview

Poka yoke refers to mistake-proofing techniques that aim to prevent defects in manufacturing processes.
Manufacturers utilize poka yoke principles to eliminate the possibility of defects in production.

Types of Inspection Systems

Five types of inspection systems according to Shingo:
- Judgement Inspection: Conducted at the end of production to identify defects.
- Informative Inspection: Involves statistical process control (SPC) to monitor processes.
- Successive Checking: Each operator checks the previous workpiece for errors.
- Self-Checking: Operators inspect their own work immediately after completion.
- Source Inspection: Aims to detect and prevent errors from happening initially.

Mechanism of Defect Prevention

Mistake-proofing involves designing products and processes to eliminate opportunities for human errors since mistakes are inevitable when humans are involved.

Sources and Types of Defects

Common sources of defects include:
- Omitted processing
- Processing errors
- Setup errors and missing or wrong parts
- Incorrect processing or operation
- Adjustment and equipment setup errors
Types of errors in production characterized by:
- Forgetfulness and misunderstanding leading to misidentification.
- Deliberate or inadvertent errors caused by lack of experience or slowness.
- Lack of standardized procedures contributing to variability and mistakes.

Red Flag Conditions

A "Red Flag Condition" indicates a potential area for errors where preventive measures are required.
Twelve potential red flag points in production include:
- Small adjustments and critical conditions affecting specifications.
- Similar parts causing confusion and the complexity of multiple operational steps.
- Infrequent production, lack of standard procedures, and environmental factors affecting consistency.

Implementation Considerations

Important factors to consider when incorporating poka yoke:
- Identification of sources and types of errors.
- Awareness of red flags in the production process.

Poka Yoke Rules

Key rules for effective poka yoke implementation:
- Execute improvements without waiting for perfect solutions.
- Pursue ideas with a 50% or higher chance of success.
- Focus on immediate implementation and enhance over time.

Examples of Poka Yoke Devices

Common poka yoke devices include:
- Jigs and limit switches to guide operations.
- Error detection alarms and counters to monitor processes.
- Checklists to ensure compliance and photoelectric devices for non-contact inspection.

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Description

Test your knowledge of Poka Yoke principles and their application in manufacturing. This quiz covers definitions and types of inspection systems that help in mistake proofing processes. Perfect for students and professionals in quality management and lean manufacturing.