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

CERTIFIED LEAN SIX SIGMA PHASE CONTROL  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in pro...

CERTIFIED LEAN SIX SIGMA PHASE CONTROL  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in process performance improvement is to be through the use of the methodologies of Six Sigma, Lean and Process Management. By taking this course you will have a well rounded and firm grasp of many of the tools of these methodologies. We firmly believe this is one of the most effective classes you will ever take and it is our commitment to assure that this is the case. CONTROL PHASE Mistake Proofing (Poka- Yoke)  WHY IS MISTAKE PROOFING IMPORTANT?  Improved quality and customer satisfaction  Prevents error occurrence  Prevents defect occurrence  If defects occur, ensures effective action  Little or no formal training  Cost effective  Easy to implement Mistake Proofing is one of the most cost effective and reliable controls that can be used to assure that our key Xs remain at our optimum project defined settings. It can also be used directly on the Y.  WHAT IS MISTAKE PROOFING (POKA-YOKE)?  Japanese phrase:  Yokeru (to avoid), Poka (errors)  A strategy for preventing errors in processes  Makes it impossible for defects to pass unnoticed  Corrects problems as soon as they are detected  Technique detects defects  Prevents defects 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 (Establish Operating Tolerances, Step 11).  THE SECRET OF DR. SHIGEO SHINGO “It is not one Poka-Yoke device, but the application of hundreds of these very simple fail-safing mechanisms that, day after day, has brought the quality miracle to industries around the world. Each one is relatively simple – Something you easily could do on your own. But it is the totality, the hundreds of devices, that is almost frightening to behold.” Dr. Shigeo Shingo  POKA-YOKE When to use mistake proofing? When a process step has been identified where human error can cause mistakes or defects to occur, especially in processes that rely on the worker’s attention, skill, or experience In a service process, where the customer can make an error which affects the output At a hand-off step in a process, when output (or for service processes, the customer) is transferred to another worker When a minor error early in the process causes major problems later in the process When the consequences of an error are expensive or dangerous  POKA-YOKE Defect Detection According to the TPS, Poka-Yoke is the use of any type of automated device or other method that either stops a process if an error is about to be made or makes it known immediately that an error has happened. Examples of poka-yoke include: When filling out forms online, software programs will not let users hit the submit button until they have filled every required field. Chiming or alarm sounds at an ATM machine indicating the customer should retrieve their debit card has greatly reduced a once-frequent problem – people driving off and forgetting their card in the machine The “spell check” function on most programs created for writing, including Word, Google docs and PowerPoint has helped limit the number of spelling errors  POKA-YOKE Error Proofing POKA-YOKE  BASICS OF MISTAKE PROOFING Effective Mistake Proofing requires two basic concepts A focus on controlling the factors which cause errors (Six Sigma Concept) – Not fixing the resulting defective output 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 Cannot do it wrong. Can only do it one way. If wrong, detected 100%. Cannot be passed into next area.  COMMON EXAMPLES OF MISTAKE PROOFING  Guide pins of different sizes  Checklists  Optical magnification  Asymmetric parts  Build error checking into  Different colored tags for control logic pressure ranges  Exact part count  Look up tables for data  Overlay templates base entry  Color coding (boxes,  Spell check work areas, products,  Limit switches components)  Error alarms  Counters MISTAKE PROOFING BUSINESS PROCESSES yj Xdthx th __ fy jdty j_ dxr t____ xth ___ rtjh Mistake Proofing is the primary means of control dxrtj__ ety d tsthy s drtudrtud ___ _______ for many business processes. Check digits Pull down menus Check sheets One over One Required fields  MISTAKE PROOFING IN ACTION  What are the error opportunities in this everyday item?  How has it been designed to prevent it from being inserted or used incorrectly?  How could it be further mistake proofed? A means to prevent the possibility of incorrect use or failure  MISTAKE PROOFING IN ACTION  What are the error opportunities in this everyday item?  How has it been Mistake Proofed?  How could it be further Mistake Proofed? EVOLUTION OF DEFECTIVES AND APPLICATION OF MISTAKE PROOFING ERRORS Th e DEFECTS Va lu e of M is ta DEFECTIVES ke Pr oo fin g  TEN COMMON ERRORS THAT LEAD TO DEFECTS ( TH I N G S T H AT C A N C A U S E YO U R K E Y X T O G O A S T RAY ) Errors are the cause of defects 1. Processing errors ERRORS 2. Error in setting up job 3. Processing omissions DEFECTS 4. Assembly omissions (missing parts) 5. Inclusion of incorrect component 6. Incorrect job DEFECTIVES 7. Operation error 8. Tool or equipment error Consider Mistake Proofing against 9. Defects in job components these having any impact on your 10. Measurement error Key Xs.  HUMAN ERRORS THAT LEAD TO POTENTIAL KEY X VARIATION 1. Forgetfulness 2. Errors due to misunderstanding ERRORS 3. Errors in identification 4. Errors made by untrained workers DEFECTS 5. Willful errors (ignore rules) 6. Inadvertent errors (distraction, fatigue) 7. Errors due to delay in decision making DEFECTIVES 8. Errors due to lack of standards 9. Surprise errors (malfunctions) Also consider Mistake Proofing 10. Intentional errors (sabotage) 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 gauges/process measurements show the issue Mistake Proofing is a good control application for conditions such as these.  IMPLEMENTATION ROAD MAP FOR MISTAKE PROOFING (Key X) Describe the defect or Apply 5 Why analysis to the potential defect including error conditions to determine the rate root causes (Process Map) Identify where the defect is likely to occur Identify (using a team (Process Map) approach) Mistake Proofing Analyze current tasks strategies associated with the operation (FMEA) Identify error conditions Verify the efficiency of the contributing to the defect Mistake Proofing actions  MISTAKE PROOFING STRATEGIES Detect defects before they move to next step Detect errors during processing Prevent errors from occurring Good Best  MISTAKE PROOFING CONSIDERATIONS  Don’t make surplus products (high inventory makes poor quality difficult to see)  Eliminate, simplify, or combine operations  Use one piece rather than process batch flow  Involve everyone in error and defect prevention (standard practices, daily improvements, and Mistake Proofing)  Create an environment that emphasizes quality work, promotes involvement and creativity, and strives for continuous improvement  CLASS EXERCISE Round Robin: Let’s go around the class twice. 1.The first time each participant will list 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.The second time around, you will be asked to identify a possible Mistake Proofing for some potential vital X from your project  24 THANK FOR YOUR ATTENTION!!! 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