Introduction_to_Poka_Yoke防错技术培训和案例

Set-up reduction: internal & external,
1950: Fool proofing techniques and the concept of “autonomation” (Poka-yoke)
1st stages of SMED: 1950 1950: Andon, visual control
1950: Multi (3-4) machine handling, rectangular or “U” shaped layout
1948: Pull: Withrawal by subsequent processes 1947: Dual machine handling, “L” shaped layout
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Poka-yoke and Jidoka: Simple & Clear
Poka-yoke: Poka-yoke prevents defects from being made
Jidoka: Prevents defects from being passed on to the next step in the process
SMED methodology formalized: 1969
Inspired by Toyota “Foolproofing” measures, develops methodology to apply techniques to source inspection: 1965
1965: Kanban, external suppliers
ADDRESS QUALITY ISSUES THROUGH THE PROCESS.
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Evolution of Key “Lean” Concepts
= Concepts related to Poka-yoke
Shigeo Shingo
Zero Quality Control concept: 1977 “Zero Defects” concept: 1975
1945: Just In Time
Toyota & Taichii Ohno
>源自文库
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Contents
Introduction to Poka-yoke and types of inspection systems
Poka-yoke Systems Poka-yoke Methods Common Mistake Proofing Devices Poka-yoke exercises Shingo Quiz
Introduction to Poka Yoke
Poka-yoke and Jidoka: Continuous improvement to Zero Quality Control
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Quality and Human Error
“To err is human…” …Alexander Pope
Quality Control Operator Time dedicated to
Continuous Improvement
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Three Basic Types of Inspection
There are three basic types of inspection techniques
may do required process inspections
Visual Inspection &
Jidoka The beginning of autonomation significant defect
reductions
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Mistake Proofing
Poka-yoke Evolution toward Zero
1962: Kanban, company wide, internal
Shigeo Shingo begins consulting relationship with Toyota: 1954
1955: Water spider concept
1953: “Supermarket” systems 1953: Work cells in “U” shaped layouts
Human beings make mistakes, human beings sometimes forget. If you rely on a human being to produce quality product and not
make a mistake or not forget sometimes….. Then you really do not care to make a quality product.
Will not reduce defects
Judgment Inspection – Human, visual, possibly measured – Only discovers defects after production
Informative Inspection
– Statistical Quality Control: flow charts, control charts
Human Inspection
Human Intervention with machine assist
Toll-gate Inspection
at Finished Goods
or the end of main processes
In-Process Inspection
Final Inspection may decrease, operators
– Theoretical sampling techniques
– Self check inspection, Successive Inspection