What
Poka-Yoke devices and procedures are very effective in breaking cause chains. Poka-Yoke is a process that gives a structure for designing a failure mode out of a product or process. They frequently consist of straightforward, low-cost tools that either stop errors from happening or identify problems that have already happened.
Why
Make it simpler to find the mistakes that do happen.
Make it possible to "undo" errors so that they can be corrected.
Make mistakes more challenging or impossible to make.
When
The requirement for worker vigilance (manual operations)
Positioning errors can happen.
A change is necessary.
SPC is inefficient or difficult to implement.
Attributes are crucial, not measures.
Both employee turnover and training costs are significant.
Mixed model production takes place.
When clients make errors, they criticize the service provider.
Particular reasons recur.
Field malfunctions are very expensive.
How
To distinguish between errors that lead to flaws and actual defects.
To pinpoint particular circumstances that lead to errors.
To understand what a Pokayoke is, distinguish between the two varieties, and comprehend the connection between Pokayoke components and flaws.
To recognize the main Poka-yoke components.
Contact Method This method identifies orientation, size, or shape non-conformances.
interference pins, an original part design, and matched feature sizes.
By counting the quantity of movements or components, the Fixed Value Method can identify faults. Welder counts welds, torque wrench counts the number of uses, and the parts kit has the right amount of components.
Discovers deviations from predetermined sequencing or cycle time. Smart bins control contacts on the fixture to ensure the right pieces are assembled in the proper order.
To comprehend and be able to use efficient Poka-yoke tools or techniques.
