MANUFACTURING

SYSTEM
ANALYSIS

Research Report for POKA YOKE (EMP/MCG 5179)

Faraz Ahmad

6851999

Hitesh Sharma

7005135

Robin Malik

6638007

Satwinderpreet Singh Dhaliwal

6689121

WORK DONE BY THE TEAM

Date and Time of the Meetings:
Topic Name: Introduction to Poka-Yoke
Date/Time of meeting: October-1-2012 19:00-21:00

Topic Name: Poka-Yoke in Manufacturing
Date/Time of meeting: October-4-2012 19:00-21:00

Topic Name: Opportunities in Poka-Yoke
Date/Time of meeting: October-7-2012 16:00-19:00

Topic Name: Strengths and weakness in Poka-Yoke
Date/Time of meeting: October-9-2012 19:30-22:00

Topic Name: Case Study & Comparison in Poka-Yoke

Date/Time of meeting: October-11-2012 13:00-17:00

Topic Name: Research & Development in Poka-Yoke

Date/Time of meeting: October-16-2012 18:30-20:00

All members were present in above meetings.

Responsibilities

Hitesh Sharma: Introduction of Poka-Yoke

Faraz Ahmad: Poka- Yoke in manufacturing
Robin Malik: Opportunities in Poka-Yoke
Satwinderpreet Singh Dhaliwal: Strengths and Weakness in Poka-Yoke
The rest of the report was completed in group discussions

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Table Of Contents
1.INTRODUCTION .................................................................................................................... 2
2. MANUFACTURING ............................................................................................................... 3
2.1 Contact Method .................................................................................................................... 3
2.2 Constant Number or Fixed Value Method ........................................................................... 3
2.3 Sequence or Motion Step Method........................................................................................ 3
3. STRENGHTS AND WEAKNESS IN POKA-YOKE .......................................................... 4
3.1 Strengths .............................................................................................................................. 4
3.2 Weakness ............................................................................................................................. 4
4. OPPORTUNITIES OR IMPLEMENTATION OF POKA-YOKE .................................... 5
4.1 Automotive industry ............................................................................................................ 5
4.2 Opportunities in Service Industry ........................................................................................ 5
4.3 Server based Poka-Yoke are divided into: ........................................................................... 5
4.4 Customer based Poka-Yoke are divided into:...................................................................... 6
5. CASE STUDY OF YAMADA ELECTRICAL PLANT 1961 .......................................... 6
6. COMPARISON OF POKA-YOKE WITH OTHER METHODS OF
MANUFACTURING................................................................................................................... 7
7.RESEARCH AND DEVELOPMENT IN POKA-YOKE ..................................................... 8
7.1 Difficulty in Accepting change ............................................................................................ 9
7.2 Low investment Amount...................................................................................................... 9
7.3 Difficulties in continuous processes .................................................................................... 9
7.4 Effect in Time ...................................................................................................................... 9
7.5 Complexity of the process ................................................................................................... 9
8.CONCLUSION: ...................................................................................................................... 10
REFERENCE ............................................................................................................................. 11

1.INTRODUCTION
Defects are the results or effects of mistakes. Errors are the sources or causes of mistakes. In
short Error = Mistake = Defects. Therefore, the removal and control of errors eliminates
mistakes. This is basic principle behind the POKA-YOKE, a Japanese term means FAILSAFING or MISTAKE-PROOFING which was first introduced by Shigeo Shingo (19091990). Poka-Yoke makes sure that every process in an industry is free from defects or errors
at first place. Where this is not possible to find out defects at first place, it performs a
detective function, by eliminating the errors as soon as they are found. So, its a mechanism
that prevents a mistake from being made which is obvious at a glance. In this report, we are
going to discuss SWOT (Strength, Weakness, Opportunities, Threats) analysis on the PokaYoke. This report will enhance our knowledge about Poka-Yoke and also reveal various
aspects which most of us are not aware of.

Fig 1. Three main rules for Poka Yoke

2. MANUFACTURING
Poka yoke can be implemented in any phase of manufacturing from the design of a part to the
assembly. For example a device can count the number of parts that are to be fixed to a body.
This counting will ensure that all the parts are attached to the body not missing any parts. The
Poka Yoke system uses three main methods as follows :

Contact Method

Constant number or Fixed Value method

Sequence or Motion-step method

2.1 Contact Method

This

method

detects

any

deviation

in

shape,

dimensional

characteristics or other specific defects, through mechanisms that are

kept in direct contact with the part. The most common example for
this would be the AC power sockets found in most of the houses in
Canada. The three pin design ensures that the plug is fixed in the
proper way. It is shown in the picture on the side.
Fig 2.1 Plug can be put into
socket only one way

2.2 Constant Number or Fixed Value Method

This type of method is used when a process has a fixed
number of steps or has a fixed number of parts attached to
it. A sensor counts all the parts or the step so that none of
them go missing. If an operator finds the number less he
will know that some step or part is missing. The device on
the right has a screw counting feature.
Fig 2.2 Screw-driver with screw
counting feature

2.3 Sequence or Motion Step Method

This type of method is used to check if a particular step is completed or not with the help of
sensors. If a particular step is not complete the process is shut down. The example of this is
in light indicator boards of machines. If the process is not completed in the given time and
sequence, it will light up the indicator board and shopping the process.

3. STRENGHTS AND WEAKNESS IN POKA-YOKE

3.1 Strengths

1. Poka-Yoke make use of those techniques to identify the errors in which mistakes are
impossible to make.
2. The keen strength of Poka-Yoke is that it can eliminate both human and mechanical
errors in each step of the process.
3. In manufacturing industry its main concern is to reduce the waste and associated
machining, by inspecting each stage for the excess material and machining rather than
after several stages.
4. Poka-Yoke also contributes to reduce the inventory holdings.
5. It yields more customer satisfaction because they are served with a best quality
product.
6. Poka-Yoke encourages better employee relationships by involving them in support
teams who identifies the processes which are causing problems.
7. It always tends to enhance the productivity of plant, it is its prime concern to increase
the productivity by decreasing the number of errors.
8. It lowers the quality cost because numbers of errors in a process are decreased.
Moreover, it tends to lower the quality cost by minimizing the waste produced during
the process. Poka-Yoke is a part of quality and continual effort such as KAIZEN.

3.2 Weakness

1. Poka-Yoke increases the operators inspecting time as compared to the time taken by
operation in usual process.
2. It sharply increases the scrap material for a short period of time.
3. It sometimes gives an error in indentifying any type of error.
4. Usually it responds very fast in some cases and relatively very slow in some cases.
5. Poka-Yoke does not give full information sometimes.
It does not process completely in some cases or we can say incorrect processing

4. OPPORTUNITIES OR IMPLEMENTATION OF POKA-YOKE

Manufacturing is a business where one small error in a system can lead to thousands of
dollars in damaged goods, twisted machine parts, and even endanger human lives. Poka-Yoke
can be implemented at any step where the possibility of error is there or something can go
wrong. Poka-Yoke is mainly used to improve the quality of the process by taking out the
defects or prevent causes which can cause errors.

4.1 Automotive industry

Purpose is to manufacture the elements of high quality which
meet the quality standard in accordance with the principle
process of continuous improvement (Kaizen).

Example: car seat belt indicator. If one forgets to put the seat
belt, then you will get an indicator sign as warning that you
forgot to wear seat belt.

4.2 Opportunities in Service Industry

In manufacturing errors made by producers are considered, whereas service industry
considers errors made by both server and the customer.
In call centres Poka-Yoke is used to deal issues with compliances. Poor training, fatigue and
limits of human consistency can lead to agent skipping key steps in process.

In software designing there are very compelling reasons to use Poka-Yoke for the benefits of
end user and creating high quality software in sorter frame of time. Eg: Gmail attachment
checks and password indicators.

4.3 Server based Poka-Yoke are divided into:

Task Poka-Yoke: focus on common mistake that server makes while performing task
for the customer.
Treatment Poka-Yoke: puts stress on interaction between customer and the server.

Example: Burger king utilizes warning-oriented by placing cue cards at the service
Tangible Poka-Yoke: improves the physical impression and experience for the
customer. Example: Motorola uses control oriented pok yoke in the legal department
by having a second lawyer inspect all legal work for spelling, presentation, and
arithmetic.

4.4 Customer based Poka-Yoke are divided into:

Preparation Poka-Yoke:

helps in preparing the customer before entering the

service. Example: usually Universities send emails to students prior for registration to
next semester.
Resolution Poka-Yoke: basically reminds the customers of the value of their input to
continuous improvement of the service. Exapmle: Hotels use automated check-out
system through the television in each room.
Encounter Poka-Yoke: attempt to fail-safe a customer at a service who may
misunderstand, ignore, or forget the nature of the service or their role in it. Example:
selection system used in used in gas and oil station to direct customer so that they
do not pull wrong thing in the station.

5. CASE STUDY OF YAMADA ELECTRICAL PLANT 1961

Shigeo Shingo was visiting the Yamada electric plant in 1961. Where, management told him
about a problem which the company was facing from several years. This problem was in a small
switch with two push buttons. To work properly, this switch should be supported by two
springs. But sometimes, workers assembling these switches forget to put the second spring.
Occasionally, this defect was not discovered during the testing of the switches in the plant. But,
when the customers start using the product they send the complaints to the company that their
switches are not working properly. This was very embarrassing to the company. Because, due to
this, company was affected in two ways:
6.1 Cost Wise: Company has to send an engineer at the site to repair or change the
switch, which adds more expenses in products manufacturing cost.
6.2 Reputation Wise: Because, Now in the market, people are talking about the
companies defines switches. Which ruined the companies several years of reputation
in a very awful way.

Fig 5: Start Stop Button

Management was trying its best to overcome this problem by warning its employees and
workers, but results werent so impressive. So, Shigeo Shingo suggested the management a very
simple solution.
In the old assembly method of switches, a worker has to pick two springs from a box containing
springs. But, what he suggested that, every worker should have a dish containing two springs
instead of a box containing springs. If any of the dish, contains the spring then that will remind
the worker that he has not installed the second spring.
By implementing this technique, company has solved its problem of missing springs.

6. COMPARISON OF POKA-YOKE WITH OTHER METHODS OF

MANUFACTURING
TQM
TQM is both a
Philosophy
and set of
guiding
principles
that represent
the
foundation of
a
continuously
improving
organization.

5S
5S is a
technique that
results in a
well
organized
workplace
complete with
visual
controls and
order.

Kaizen
Kaizen is a
Japanese
word for
philosophy
that define
managements
role in
continuously
encouraging
and
implementing
small
improvement
involving
everyone.

JIT
JIT is a
manufacturing
philosophy
that produces
necessary
units, with the
required
quality, in the
necessary
quantities, at
the last safe
movement.

Kanban
The Kanban
card is A
message that
signals
depletion of
products,
parts or
inventory that
when received
will trigger
replenishment
of that
product, part
or inventory.

Poka Yoke
Poka Yoke is
a technique
that help
operators
avoid
mistakes in
their work
caused by
choosing the
wrong part,
leaving out a
part,
installing a
part
backwards,
etc.

TQM Stands
for :
Total-Made
up of whole
Quality-
Degree of
excellence
Management-
Act of
handling,
controlling,
directing an
organization.

Maximum
user
satisfaction at
minimum
cost.

Benefits:
Customer
focused,
First to
service and
cost,
Long term

5S refers to:
SEIRI- clear
unnecessary
items from
work area
SEITON-
organize work
area in an
orderly
manner
SEISO- clean
work area
SEIKESTU-
maintain
work area
cleanliness
SHITSUKE-
maintain self
discipline in
work area.
Increase the
storing place,
preserve
standards,
reduce
unproductive
times.

In KAIZEN :
JIT refers to
KAI refers
Just In Time
Change,
production.
ZEN refers
Better i.e
changes for
better or
continuous
improvement.

In KANBAN:
KAN refers to
Card ,
BAN refers to
signal. It is a
Japanese term
for Visual
record.

In POKA
YOKE:
POKA refers
to Mistake,
YOKE refers
to Proofing.

Kaizen makes
the process
more efficient
, effective and
adaptable.

Eliminates
waste of time,
labour and
storage space.

Benefits:
Reduce idle
time and
fatigue to
workers,
Reduce
wastage,
Improvement
in quality and
productivity.

Benefits:
Work
improvement,
Environment
improvement,
Process
improvement,
Quality
improvement.

Benefits:
Reduction in
storage space,
Less working
capital,
Less
likelihood of
stock
perishing.

Kanban main
goal is to
make a highly
efficient and
effective
factory
production
system.
Benefits:
Processes
scans,
generates
purchase,
Suppliers
acknowledge
orders,
Inventory
delivered to
point of use.

Poka Yoke
goal is to
eliminate
defects in a
product by
preventing or
correcting
mistakes.
Benefits:
Creates a
system that
prevents
defects from
occurring,
Can be use to
catch defects,
Helps people
and
processes
work right
the first time.

7.RESEARCH AND DEVELOPMENT IN POKA-YOKE

There are a lot of barriers in implementing Poka-Yoke in industries, research and development
has to be carried out in these areas so as they become easy to be implemented in the system.
Following are some areas in which there could be development.

7.1 Difficulty in Accepting change

When there is a complete change in the manufacturing process in order to implement error
saving methods, there is a lot of training that will be required to be given to the workers, for
them to accept the change. Some of them will find this very difficult to adapt. Thus maximum
research should be carried out so that there is least amount of change in the system. And
training should be carried out at regular intervals so that the workers are updated with the latest
trends.

7.2 Low investment Amount

The amount that has to be invested in implementing error-proofing methods should be justified.
If the amount is very large and increases the overall cost of manufacturing, that will intern
increase the cost of the final product. This will increase their competition in the market and will
affect the number of people buying the product. Thus development should be carried out in a
way that minimum amount is spent and better Poka-Yoke is implemented.

7.3 Difficulties in continuous processes

If manufacturing of a product involves a number of processes, a change in any process would
affect the other processes also, which would add to the cost, training of the workers, time, etc.
We should strive to achieve that the change made in a particular process does not affect the
other process.

7.4 Effect in Time

Poka-Yoke should be implemented in a way that the time used for manufacturing a product
does not increase. If the time used for manufacturing increases the number of products produced
will decrease, which will intern increase the price of the final goods. The best option will be that
the poka-yoke is implemented and the time for manufacturing is decreased. This will bring
more profit to the company.

7.5 Complexity of the process

Poka-Yoke should not add to the complexity of the process, the optimum implication should be
that the process becomes easy to manufacture and reduces error in manufacturing.

8.CONCLUSION:
Poka-Yoke is simple but quality assurance method which prevents errors. To implement PokeYoke, we need to understand as to why people make errors and we have to analyze the process
to know where errors are likely to occur and what root causes contribute to them. But by taking
broader view point of failure, we can use Poka-Yoke during the design phases of products and
services to find where we can incorporate low cost features that improve the customers
experience.

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REFERENCE

Dvorak, Paul. "Poka-Yoke Designs Make Assemblies Mistake-proof." Machine Design

Kejuruteraan Sistem Pembuatan, Manufacturing system engineering,

http://putra-design.blogspot.ca/2008/12/poka-yoke.html

Article on The Managing Mentor

http://www.themanagementor.com/enlightenmentorareas/mfg/QM/pokayoke.htm

Article on A Techies Notebook

http://techie-notebook.blogspot.ca/2012/07/poka-

yoke-applying-mistake-proofing-to.html

http://www.google.ca/imgres?imgurl=http%3A%2F%2F4.bp.blogspot.com%2F-
gLNHmr7wCro%2FTWmcYa2HOFI%2FAAAAAAAAAdI%2FAE9avqgaKfY%2Fs1600%2Fpokayok
e1.jpg&imgrefurl=http%3A%2F%2Falanavegas89.blogspot.com%2F2011_02_01_archive.htm
l&h=324&w=432&sz=22&tbnid=XBjxPac7uDSzKM%3A&tbnh=109&tbnw=145&prev=%2Fsea
rch%3Fq%3Dpoka%2Byoke%2Bimages%26tbm%3Disch%26tbo%3Du&zoom=1&q=poka+yok
e+images&usg=__V7GNRglNZuZgJZPvA89ocywdAas%3D&docid=9uKKVlyz3mn_bM&sa=X&ei
=lHB4UJm6CoWNygH13oD4Cg&ved=0CCwQ9QEwAw

http://www.themanagementor.com/enlightenmentorareas/mfg/QM/pokayoke.htm

http://www.school-for-champions.com/tqm/poka-yoke.htm

http://news.directindustry.com/press/fiam-utensili-pneumatici-spa/ihe-hydraulic-impact-

wrenches-with-air-shut-off-now-also-with-screw-counting-device-poka-yoke-17524-
365443.html

http://thequalityportal.com/pokayoke.htm

http://www.ieor.iitb.ac.in/files/Sundar-Webs/PokaYoke.pdf

http://www.bukisa.com/articles/140095_introduction-to-poka-yoke-error-proofing-

principles

http://it.toolbox.com/wiki/index.php/Poka_Yoke

http://facultyweb.berry.edu/jgrout/pokasoft.htm

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http://www.google.ca/imgres?q=push+button+start+stop+switch&hl=en&rlz=1C1AS
UT_enCA469CA469&biw=1366&bih=632&tbm=isch&tbnid=6HSU8ACkFblomM:&imgr
efurl=http://www.aliexpress.com/item/Control-Station-Switch-XAL-
B213/343800135.html&docid=sAHUXviqUC3N2M&imgurl=http://img.alibaba.com/i
mg/pb/567/879/272/272879567_998.jpg&w=502&h=311&ei=dcd9UPPPB4KxywGO
oYHACg&zoom=1&iact=hc&vpx=702&vpy=98&dur=428&hovh=138&hovw=245&tx=
138&ty=137&sig=117122063332363997749&page=1&tbnh=132&tbnw=239&start=
0&ndsp=19&ved=1t:429,r:3,s:0,i:75

http://www.slideshare.net/akanshajha1/final-ppt-12655421

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