Sps0650en Poka Yoke

Faurecia Excellence System
Group Quality Department
Quality System Efficiency
The 6 Quality Basics -> Poka Yoke

Purpose: Poka Yoke methodology
Scope: all production sites
Check that this is the latest version of this document.
FAU-S-PS-0650 / EN issue 01
1 Definition
A poka-yoke is a simple and reliable device that physically prevents: either the error leading to the defect or the transmission of the defect to the next workstation Of course, not producing the defect in the first place is always preferable to detecting the defect afterwards. (An once of prevention is worth a pound of cure, as they say.) There are two types of poka -yoke: Product: based on inherent product characteristics such as shape or symmetry Process: based on certain product characteristics in order to avoid errors in the manufacturing process. The poka-yoke must be permanent . The poka-yoke must be foolproof (i.e. it must be impossible to bypass). Only an authorized person (e.g. Gap Leader, Supervisor) may intervene. Situations to avoid: - reset button - master key - simple disconnection (e.g.from electrical outlet) The poka-yoke must be foreseen upstream, right from the product/process design phase.
Examples of poka-yokes in everyday life: 3.5 diskettes can not be inserted upside down because one corner is cut. If the cut corner is on the wrong side, it hits something and the diskette will not go all the way in. In an ATM (cash dispenser), you have to remove your credit card before you can get your money. This prevents you from forgetting your card in the machine.
- 2/ 8
2 - Examples
PRODUCT poka-yoke: Example: guide pins of different shapes and/or sizes

Without poka-yokes: defect possible (reversed assembly) With poka-yokes: defect cannot be created
PROCESS poka-yoke : Example: poka-yokes are built into the process to check that an operation has been properly performed:
Screw-counter. If a screw is missing or there is insufficient torque, the part is prevented from moving on to the next workstation.
The conveyer stops automatically if the seat is in the wrong position for delivery (headrest too high).
- 3/ 8
3 Identification of Process Poka-Yoke

To improve identification and tracking of process poka-yokes, each one is given a reference number and represented on the plant layout diagram as shown:
PKY 001
PKY 002
PKY ___
FINAL INSPECTION
- 4/ 8
4- Visual Management
This red symbol is PERMANENTLY fixed to the machine Red means the poka-yoke is out of order. The label shows the poka-yoke number and the parameter that must be inspected 100%. The system must be repaired within 8 hours of the breakdown. If necessary, a spare parts stock is created.
PKY002 OUT OF ORDER 100 % INSPECTION REQUIRED

PARAMETER:
Green means properly.
the
poka-yoke
works
Validation must take place before applying this symbol. The label shows the poka-yoke number and the parameter that is under control.
PKY002
WORKING
PARAMETER:
This symbol must be visible and accessible to the operator, who is responsible for visual management
The poka-yoke doesnt work
=
100 % Inspection
PKY002 OUT OF ORDER 100 % INSPECTION REQUIRED

ON PARAMETER :
=
The poka-yoke works No inspection of this characteristic
PKY002 IN ORDER
ON PARAMETER :
- 5/ 8
5- Validation and capitalisation

Validation: Each poka-yoke has a dedicated validation sheet :(FAU-F-PS-0222) specifying: parameter or critical characteristic validation method: master part (correctly identified), description of incorrect operation It is the operator who validates poka-yokes: at each start-up: start of shift or after breakdown (see guide OK 1st part") using validation sheet FAU-F-PS-0222
As soon as the operator sees a poka-yoke malfunction, s/he must immediately notify the Supervisor. The operator logs the time of the malfunction in order to organize an inspection of all the parts produced up to this point. The operator must be trained to conduct 100% inspection of the parameter when the poka yoke fails. Capitalisation: Each poka-yoke has a definition sheet (FAU-F-PS-0221). This document is managed and updated by the UAP Quality correspondent and contains the following information: Detection method Location Explanation of improvements Effects and costs
- 6/ 8
Appendix: suggestions for designing Poka-Yokes
Identify objects by characteristics such as: weight dimensions shape To detect operator deviation or errors, use devices: with physical contact (e.g. contactor, lever) without physical contact: photo-electric cells (transmission, reflection) To detect deviation from set values, use measurement systems: pressure, temperature electricity (voltage,amperage) vibration rpm data transmission
- 7/ 8
General Information
Author : Group QSE Date : 12 January 2004 Aim of the modification: Complete revision of the previous version Cancels and replaces: FAU S PS 0220 Associated documents: FAU S PS 0610 FAU S PS 0620 FAU S PS 0630 FAU S PS 0640 FAU S PS 0660 FAU F PS 0221 FAU F PS 0222
- 8/ 8

Sps0650en Poka Yoke

Uploaded by

Copyright:

Available Formats

Sps0650en Poka Yoke

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sps0650en Poka Yoke

Uploaded by

Copyright:

Available Formats

Faurecia Excellence System

Group Quality Department

Quality System Efficiency

The 6 Quality Basics -> Poka Yoke

Scope: all production sites

Check that this is the latest version of this document.

PRODUCT poka-yoke: Example: guide pins of different shapes and/or sizes

3 Identification of Process Poka-Yoke

PKY002 OUT OF ORDER 100 % INSPECTION REQUIRED

Green means properly.

The poka-yoke doesnt work

PKY002 OUT OF ORDER 100 % INSPECTION REQUIRED

5- Validation and capitalisation

Appendix: suggestions for designing Poka-Yokes

You might also like