ABSTRACT

The next tool is poka-yoke, a methodology that focuses on preventing defects and improving quality. The goal of zero defects is achievable. The Zero Quality Control system approach of mistake proofing (poka-yoke, in Japanese) prevents defects by monitoring process conditions and correcting errors at the source. It is human nature to make mistakes. In this approach, poka-yoke devices are used to perform 100% inspections and give feedback about each part or operation. Installing a poka-yoke device has a considerable effect on quality, but it can also give you a false impression that these devices alone will eliminate defects. However, if you combine poka-yoke systems with self-checks or successive checks, you can effectively obtain 100% inspections, prompt feedback, and action. To do that, it is essential for you to understand

CONTENTS

Introduction ......................................................................................................... 125 Overview of Poka-Yoke/Mistake Proofing ..................................................... 126 Inspection Techniques ........................................................................................ 126 Types of Errors ..................................................................................................... 127 Types of Defects ................................................................................................... 128 Quality Improvement Activities ....................................................................... 129 Poka-Yoke Detection Systems ........................................................................... 130

Using Contact Methods to Detect Defects or Errors ................................. 131 Using Fixed-Value Methods to Detect Defects or Errors .......................... 131 Using Motion-Step Methods to Detect Defects or Errors ......................... 131

Poka-Yoke Product Design/Redesign.............................................................. 131 Conclusion ........................................................................................................... 132 Homework Problems .......................................................................................... 132

how to use poka-yoke systems, their functions, the types of systems, and various detection methods-all of which are covered in this chapter.