Poka Yoke: Presented By: Darpan Shah (24) Prinka Mittal (01) Priyanka Chaudhary
Poka Yoke: Presented By: Darpan Shah (24) Prinka Mittal (01) Priyanka Chaudhary
Prinka Mittal(01)
Priyanka Chaudhary(19)
Poka-yoke
What is Poke-yoke? A method that uses sensor or other devices for catching errors that may pass by operators or assemblers. Poka-yoke effects two key elements of ZDQ: Identifying the defect immediately ( Point of Origin Inspection)
Poka-yoke
Mistake-proofing systems The fourth of the 4 basic elements of ZDQ. Does not rely on operators catching mistakes Inexpensive Point of Origin inspection Quick feedback 100% of the time
The machine shut down. We must have made an error!
BEEP!
BEEP!
Most Poka-yoke devices are sensor or jig devices that assure 100% compliance all the time!
BEEP!
Poka-yoke
Poke-yoke and Point of Origin Inspections( Proactive Approach):
A fully implemented ZDQ system requires Poka-yoke usage at or before the inspection points during the process.
Poka-yoke will catch the errors before a defective part is manufactured 100% of the time.
Poka-yoke
Poka-yoke and Informative Inspection( Reactive Approach):
Check occurs immediately after the process.
Can be an operator check at the process or successive check at the next process. Not 100% effective, will not eliminate all defects.
Although not as effective as the Source inspection approach, this methodology is more effective than statistical sampling and does provide feedback in reducing defects.
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Control System
Takes human element out of the equation;does not depend on an operator or assembler.
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Warning System
Sometimes an automatic shut off system is not an option. A warning or alarm system can be used to get an operators attention. Below left is an example of an alarm system using dials, lights and sounds to bring attention to the problem. Color coding is also an effective non automatic option.
BEEP! BEEP!
BEEP!
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irregularities.
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Contact Method
A contact method functions by detecting whether a sensing device makes contact with a part or object within the process.
Cylinder present Missing cylinder;piston fully extended alarm sounds
An example of a physical contact method is limit switches that are pressed when cylinders are driven into a piston. The switches are connected to pistons that hold the part in place. In this example, a cylinder is missing and the part is not released to the next process.
Contact Method using limit switches identifies missing cylinder.
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Transmitter
Receiver
Object
Contact Device
An example of a contact device using a limit switch. In this case the switch makes contact with a metal barb sensing its presence. If no contact is made the
process will shut down.
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Contact Methods
Do not have to be high tech!
Passive devices are sometimes the best method. These can be as simple as guide pins or blocks that do not allow parts to be seated in the wrong position prior to processing
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Counting Method
Used when a fixed number of operations are required within a process, or when a product has a fixed number of parts that are attached to it. A sensor counts the number of times a part is used or a process is completed and releases the part only when the right count is reached.
In the example to the right a limit switch is used to detect and count when the required amount of holes are drilled. The buzzer sounds alerting the operator that the appropriate amount of steps have been taken in the process.
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Counting Method
Another approach is to count the number of parts or components required to complete an operation in advance. If operators finds parts leftover using this method, they will know that something has been omitted from the process.
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Motion-Sequence Method
The third poka-yoke method uses sensors to determine if a motion or a step in a process has occurred. If the step has not occurred or has occurred out of sequence, the the sensor signals a timer or other device to stop the machine and signal the operator. This method uses sensors and photo-electric devices connected to a timer. If movement does not occur when required, the switch signals to stop the process or warn the operator.
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Motion-Sequence Method
In order to help operators select the right parts for the right step in a process the sequencing aspect of the motion-step method is used. This is especially helpful when using multiple parts that are similar in size and shape.
In this example, each step of the machine cycle is wired to an indicator board and a timer. If each cycle of the machine is not performed within the required time and sequence, the indicator light for that step will be turned on and the machine will
stop.
Machine
Indicator Board
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3. Warning Sensors
Each category of sensors includes a broad range of
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In most cases these devices send an electronic signal when they are touched. Depending on the process, this signal can shut down the operation or give an operator a
warning signal.
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Touch Switch
Used to physically detect the presence or absence of an object or item-prevents missing parts. Used to physically detect the height of a part or dimension.
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Energy Sensors
These devices work by using energy to detect whether or not an defect has occurred.
Fiber optic
Vibration Photoelectric
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Warning Sensors
Warning sensors signal the operator that there is a problem. These sensors use colors, alarms, lights to get the workers attention ! Color Code
These sensors may be used in conjunction with a contact or energy sensor to get the operators attention. Lights connected to Micro switches & timers
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Lights
Company profile
An automotive part assembling factory Specializes in the assembly of wire harness Japanese automobile models and some local models Products - automotive cables, high tension ignition cables (HTIC) and wire harnesses Study focuses on sub-assembly line
Manufacturing process
Starts from accepting single wire from the warehouse Wire insert
Problem identification
Methodology
Observation of current operations and production line Company documentation study Unstructured interview Data collection analysis
Problem identification
Kinds of defects
Dislocation
Productivity performance - 21 subsets versus 16 subsets Quality awareness - self relying versus relying on follow
worker
Analysis
Systematic approach Several criteria based Logical and practical HR perspective Focus on prevention
Introduction
The present case study was taken up in a manufacturing company. The company was facing problems due to breakdowns, equipment defects and poor working conditions. The management of company took a decision to overcome these problems by implementing TPM concepts.
Continued..
A team was developed headed by Senior Manager, with a leader (Supervisor) and members consisting of operators. The reasons for choosing the shot-peening machine are: Poor performance among the other shot -peening machines Oldest machine Dusty and dark atmosphere Poor house-keeping Poor safety
Objectives
The objectives of this case study were: Improve equipment reliability and maintainability. To cultivate the equipment-related expertise among operators Maximize OEE, through total employee involvement. Create an enthusiastic work environment
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