Poka Yoke Report

In 1961, Dr. Shigeo Shingo, an industrial engineer at Toyota Motor, introduced the concept of Poka Yoke. Since then Poka Yoke has been an inevitable part of manufacturing system. Manufacturing often introduce new models/variants represents a frequent improvement in error-free production. Increasing the complexities of product, raising quality production and replenishing the growing commodity market are only possible by adopting all the stages of `total quality` of manufacturing process. In manufacturing process, the concept of quality control and zero faults are related to the creation of mistake proof system which should assure product and services complying to or even surpassing the customer requirements. Preventing the error is better than detecting them and much better than detecting faults. It is vital to supervise the manufacturing flow and to detect or control the errors before coming to rejects. In order to achieve this objective, the anti-error technique, called Poka Yoke is used. It act as quality management system and which will represents `nullifying accidental errors`, ‘eliminating the errors`. In Poka Yoke simple devices of fixing, warning, assembling, and other related devices which prevent people to make mistakes, even if they wanted to. Such devices are known as Poka yoke and used for stopping and warning the operator if something is not right. Before getting into deep about poka yoke we should understand influence of various processes on products.

Station stopping devices that are interlocked with signaling to prohibit rolling stock from gaining access to shaft compartments.

2. Rolling stock devices to prevent hands from coming between couplings.

3. Winder safety interlocks for proper maintenance.

4. Guide pins used in stamping dies for correct alignment

5. Small mirror is used below the pointer to avoid paradox error

6. The socket for USB is designed is such way that one way insertion of pen drive is possible.

7. MS-Word asks for save it or cancel dialogue if we want to close any file in operating software.

Conclusion

To err is human. But, like err intelligence is also one of the traits of human beings, so human can dominate err by intelligence. Poka Yoke is just face of that intelligence. We can avoid the errors at the source itself by the proper implementation of Poka Yoke technique in various manufacturing process. Poka Yoke is one of the important tools in TQM. Successful implementation of poka yoke results in increased productivity, quality with minimum waste. The ultimate purpose of Poka Yoke is to achieve condition of `Zero Defects`. It is the preventive actions for systematic movement for achieving higher level of performance. Greater vigilance is required from everyone in the process for Poka Yoke