Poka_yoke

Table of Content.

IntroductionвЂ¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦.3

What is Poke-Yoke?

The first Device: mistake-proofing of gas pumpingвЂ¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦5

The second device: the use of RFID in cars securityвЂ¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦...8

Reference: вЂ¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦10

Conclusion вЂ¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦Ð²Ð‚¦.11

"Defects arise because errors are made; the two have a cause-and-effect relationship. ... Yet errors will not turn into defects if feedback and action take place at the error stage"[Shingo, 1986, p. 82]

According to Shingo, there is a close relationship between defect and error. However, an error goes through a long process to become a defect. During this long process many action can be made to prevent the error to become a defect. Shingo and Deming found in this long process a chance to correct the errors made at the production or managerial level. They made up a system called “Poka-Yoke”, a Japanese name for mistake-proofing.

Shigeo Shingo, a Toyota industrial engineer, is indeed the founding father of the Poka-Yoke. A device expected to prevent defects, Poka-Yoke is extended to inspect the quality of products. Hence, the use of this technique cost Toyota no more than 150$ for each mistake-proofing device. The technique, indeed, reduced the cost of errors to a lower level at an inexpensive cost.

A technique which began in the 1960’s, poka-yoke is used widely by companies now a day around the world. Leading organizations throughout the world, seeking to promote quality ownership and prioritizing customer satisfaction, widens the use of mistake-proofing in their hierarchical scale. In this sense, the technique leaded to the creation of software poke-yokes which are simple, specific, attributes, acts early, responsive, and can be used for new purposes.

The following pages of this paper will present two devices of mistake-proofing. I will define each device separately and subjectively. Each device will be accompanied with illustrations and description. I will try to describe each device according to my personal knowledge and the citation materials in my hand, and give evidence of each description.

Earlier in this paper, I tried to introduce and define poka-yoke. The current section will present the first device. But first, I will show characteristics of poke yoke devices.

What are the characteristics of good poka-yoke devices?

Good poka-yoke devices, regardless of their implementation, share many common characteristics [Chase and Stewart, 1995, P29]:

they are simple and cheap. If they are too complicated or expensive, their use will not be cost-effective.

they are part of the process, implementing what Shingo calls "100%" inspection.

they are placed close to where the mistakes occur, providing quick feedback to the workers so that the mistakes can be corrected.

Judged by these criteria, the "small dish" solution to the missing-spring problem is an excellent poka-yoke device:

It was simple.

It was cheap, involving only the cost of a small dish.

It provided immediate feedback about the quality of the work; corrections could be made on the spot.

In this sense, the small dish method became later the first mistake-proofing device:

In the old method, a worker began by taking two springs out of a large parts box and then assembled a switch.

In the new approach, a small dish is placed in front of the parts box and the worker's first task is to take two springs out of the box and place them on the dish. Then the worker assembles the switch. If any spring remains on the dish, then the worker knows that he or she has forgotten to insert it.

While browsing the internet, I found many examples of mistake-proofing. The one that attracted the most my attention is one related to Diesel and Unleaded Fuel use.