BRAKES INDIA’S JOURNEY WITH

POKA YOKE

FOR QUALITY IMPROVEMENT

Presented by:
R. Vasu
Div. Manager,
Brakes India Ltd. Padi.
 AGENDA
1.0 Overview – Brakes India Ltd
2.0 What is pokayoke?
3.0 Why pokayoke is needed?
4.0 Simple but effective mistake proofing in day to day products
5.0 Types of Pokayoke
6.0 Common pokayoke devices
7.0 Pokayoke – To prevent outflow of defects in industries
8.0 Brakes India’s approach towards pokayoke
9.0 Case studies from Brakes India
10.0 Validation of pokayoke
11.0 Sustenance of pokayoke
12.0 Benefits of pokayoke
 Brakes India Limited - Profile

Established 1962
Net Worth 89 m USD
Sales(05-06) 242 m USD
Employees 2997
Engineers 700
Built up Space 1000,000 Sft
Mfg Locations 7
No. Customers 70
Certifications TS16949
ISO 14001
TPM*
Deming**

Largest Brake Manufacturer in India

Largest Brake System Manufacturer in India

* 3 Sites ** Foundry
 2.0 Let’s start with the basic question
What is pokayoke?

Pokayoke is a Japanese term meaning:

Yokeru – To avoid
Poka – inadvertent (unintentional)
errors

Pokayoke stands for ‘Mistake Proofing’ or ‘Fail Safing’

 3.0 Why Pokayoke is needed?

Murphy’s Law says that “Anything that can go wrong will go wrong” !

• Thus, mistakes could happen due to man, machine, method or material.

• We need to modify our design and processes in such a way that it is impossible
to make mistakes in the first place.

• Our prime objective of uncompromising ‘quality’ can be achieved only by

eliminating defects, which occur due to mistakes / errors.
 3.0 Why Pokayoke is needed?
Lets take a look at the 10 different types of errors
ERROR A Simple example
1. Forgetfulness Station master forgetting to lower railway gate

2. Misunderstanding Driver pressing the brake of an auto transmission car

thinking it as a clutch

3. Identification Mistaking an OHP marker for a pen and using it to

write on paper.

4. Amateurishness A new staff in a Departmental Store struggling to

locate a commodity

5. Willfulness Ignoring ‘Red signal’ if there are no vehicles in sight

 3.0 Why Pokayoke is needed?
Lets take a look at the 10 different types of errors
ERROR A Simple example
6. Inadvertent / Unintentional A chef adding excess salt in a dish absent mindedly

7. Slowness A person just learning to drive being slow to step on

the brake

8. Lack of standards Officers raising orders in different formats, without

following one standard format.

9. Occasional Surprises A microwave oven overheating the food item due to

malfunction of the timer

10. Intentional Sabotage due to personal reasons / grudge

 3.0 Why Pokayoke is needed?

We went though the different possible errors that can occur…

Now,

• Are these errors permissible ?

• Are errors of the above kind affordable, be it any field ?

• What would be the consequence of these errors?

 3.0 Why Pokayoke is needed?
QUALITY TARGET IS 100 PERCENT, NOT EVEN 99.99 PERCENT
An Average Quality Level of even 99.9% would mean the
following:

1. At least 1,60,000 wrong prescriptions by doctors every year

(Identification error)

2. More than 1,20,000 new born babies accidentally dropped by doctors every year
(Amateurishness/inadvertent/slowness error)

3. Unsafe drinking water 1 hour every month

(lack of standards error)

4. 2-3 rail accidents every day.

(Forgetfulness/ willfulness error)

5. 2 unsafe plane landings per day at O’Hare Airport in Chicago

(inadvertent/occasional surprise error)
 3.0 Why Pokayoke is needed?

Thus, there is a strong need for a production system based on the principle that:

‘ Errors are inevitable but can always be prevented’

Further, errors increase work at our end and it has to be kept in mind that the
customer is never going to pay us for that additional work.

Hence, we need to establish a reliable system, which can be accomplished by

the concept of

“POKAYOKE”
4.0 Simple but effective mistake proofing in our day to day
products

Before we further open the door on

Pokayoke, types, industrial usage…

lets just glance through some impressive

mistake proofing in a few products that
most of us use .
4.0 Simple but effective mistake proofing in our day to day
products

• Things we use are often mistake proofed

• Many products are mistake proofed for ‘safety’ reasons

• Some products are mistake proofed to make them work properly

as well as to ensure that they are ‘user friendly’
 4.0 Simple but effective mistake proofing

The envelope window serves a dual purpose:

1. It is a labor saving device.
2. It mainly prevents the contents of an envelope intended for one
person being inserted in an envelope address to another.
4.0 Simple but effective mistake proofing

• Hotel rooms are equipped with a room

key holder which turns off the power
when the key is removed

• This ensures no electricity flows to the

room while it is vacant.
4.0 Simple but effective mistake proofing

• This airport luggage cart has brakes

which are applied whenever the yellow
handle is not depressed.

• Carts will not roll unless they are attended

 4.0 Simple but effective mistake proofing

Few instances from computers

• The beveled corner of the diskette pushes a stop in the disk drive out of the way
allowing the diskette to be inserted.

• This feature, along with the fact that the diskette is not square, prohibit incorrect
orientation.
 5.0 Types of Pokayoke

Basic Classification of Pokayoke

PREVENTION / PREDICTION TYPE

- Helps the operator to recognize a defect before it is about to
occur

DETECTION TYPE
- Helps the operator to know about a defect immediately after its
occurrence
 5.0 Types of Pokayoke
A Pokayoke functions in any one of the following 3 ways:
1. ALARM
Signals in the form of buzzers, blinking lights are used to indicate the occurrence
predict any abnormality

2. SHUTDOWN
Machine or process is stopped when defect is either detected / predicted

3. CONTROL
In Prevention type, the Control (Feedback mechanism) automatically prevents errors
from occurring.
In Detection type, the control ensures separation of defectives and stops them from
reaching the next stage of the process.
7.0 POKAYOKE - To prevent the outflow of defects in Industries

In any industry, defects are caused due to at least one of the following factors:

• Processing errors
Incorrect or partially done process due to operator mistake

• Assembly errors
Incorrect assembly done due to operator mistake

• Inspection errors
Rejection components reaching the customer due to monotony & fatigue
faced by the inspector
7.0 POKAYOKE - To prevent the outflow of defects in Industries

• Processing omissions
Caused when the operator misses out a stage / step of the process

• Assembly omissions
Caused when the operator fails to assemble a part & the assembly goes to
next stage

• Apart from the above mentioned factors, defects can also happen due to
packing / labelling / dimensional / misalignment errors.
7.0 POKAYOKE - To prevent the outflow of defects in Industries

We will now go through examples to understand how poka yoke

leads to prevention of defects outflow in industries.
 7.0 POKAYOKE - To prevent the outflow of defects in Industries

Concern: The skip hoist moves Solution: Two ‘Limit switches’ are provided in
even if the safety doors are the safety door sides & the electrical circuit is also
kept open. modified. Now, skip hoist can move up only under
‘safety door closed’ condition.

SHUTDOWN
PREVENTION
CONTROL
DETECTION
ALARM
 7.0 POKAYOKE - To prevent the outflow of defects in Industries

Concern: Possibility of damage to Solution: A ‘ Limit Switch’ is introduced on the

heating coil of the Induction Hardening stopcock.
machine. If the stopcock is not opened, the heating switch
It can happen if the operator fails to turn does not turn on.
the cooling water supply on

SHUTDOWN
PREVENTION
CONTROL
DETECTION
ALARM
 7.0 POKAYOKE - To prevent the outflow of defects in Industries
Solution: The ‘geometrical’ shape of the
component is used to detect the processing omission.
The ‘block’ on the chute will not allow the unmilled part
to pass to the next machine.

Concern: An unmilled part can easily

pass through the chute and cause the PREVENTION
SHUTDOWN
next machine to shut down. CONTROL
DETECTION
ALARM
 7.0 POKAYOKE - To prevent the outflow of defects in Industries
10
9
4 Solution: ‘Micro switches’ were installed under
8 3 each tap drill. The machine would shut down even if
7 one tap drill failed to actuate its switch
5 6
2

10 holes to be tapped

Concern:
Detection of absence of tapping of the
10 holes relied only on the operator.
Defectives, if passed to the next station
SHUTDOWN
resulted in line stoppage. PREVENTION
CONTROL
DETECTION
ALARM
 8.0 Brakes India’s Approach Towards Pokayoke

Low volume
High variety Predominantly
More Child
Parts per Assy Manual assy –
7 To 15 parts high error
possibility
NEED FOR
POKAYOKE
• Proximity Switch • ALARM
• Photo Sensors Prevention • SHUTDOWN
• Limit Switch • CONTROL
• Vision System Detection
• Interlocks – Electrical
• Pins
• Interlocks – Mechanical
• Alarms,
• Counters etc Zero Inprocess Rejection
Zero customer Line Rejections
 8.0 Brakes India’s Approach Towards Pokayoke

MACHINING:

 Processing with reduced tolerance for fitment dimensions.

 Ongoing process capability for critical and significant product characteristics.
 Provision in fixtures to check for customer mounting conditions.
 Pokayoke to prevent wrong loading in fixtures with interlocks.

SUB-ASSEMBLY AND SPECIAL PROCESS :

 Automatic monitoring of critical process parameters .

 Qualification of special process through DOE .
 Weld monitors for weld cycle monitoring.

FINAL ASSEMBLY :

 Assembly fixtures to check customer fitment conditions.

 Pokayoke for prevention and detection of wrong assembly with rejection bin interlock.
 Vision system for detecting presence and orientation of Parts .
 Automated 100 % testing of Product performance characteristic with certification Mark
10.0 Now, the BIG CHALLENGE
facing us is…

• How do we validate the pokayoke?

• How do we ensure the sustenance

of the pokayoke ?
 10.0 Validation of PokaYoke

Validation is required to check the adequacy of the pokayoke.

Validation is carried out by means of simulation.

A NG component is deliberately tried out to verify whether the pokayoke in the system
works or not.
For instance: As discussed in the previous slides, if one of the retainers is reversibly
loaded or not loaded at all, the cycle should not start as the sensors fail to sense the
retainer presence.

• The frequency of validation is usually once per shift, done at the start of the shift.
• The frequency is determined by the unit Quality Module.
• Sometimes, pokayoke functioning is validated through the ‘First Off’ report. In case
of ‘guide pins’, ‘interference pins’, the wrong loading prevention is mentioned in the
report.
• Thus validation would have to take place at a regular basis to check the adequacy of
the pokayoke.
 11.0 Sustenance of PokaYoke

A pokayoke can be successful in preventing outflow of defects, only

when it displays consistency.

•In other words, sustenance of the pokayoke is a must to contain & control
defects.

•Sustenance can be ensured by carrying out ‘ Pokayoke Audits’ at regular

intervals.

•These audits not only help sustain the pokayoke but also indirectly
validate the pokayoke once again.

•The audit is for an entire line/cell which may contain more than one poka
yoke.
 11.0 Sustenance of PokaYoke

Important checkpoints in BI’s Pokayoke check list:

1. Address of poka yoke in both the FMEA & the Control Plan

2. Contingency plan for poka yoke non functioning situation

3. List of poka yoke in the line / cell

4. Validation method & its frequency

5. Operator awareness of poka yoke presence & then on poka yoke non functioning

6. Presence of poka yoke samples

 12.0 Benefits of Pokayoke

1. The first & foremost benefit of any pokayoke is ‘improved productivity’:

Elimination of traditional inspection,and substantial reduction the delay between
production steps
Operators also spend less time examining their work to make sure it is correct.
Interruptions for handling scrap, rework, and repair are eliminated in case of
prevention type of poka yoke.

2. Highest level of quality can be achieved :

Only mistake-proofing can produce and sustain defect rates below 100 parts per
million (ppm), which leads to World Class Manufacturing.
Shigeo Shingo, the quality guru that lead the quality revolution at Toyota, stated:
"This (mistake-proofing), I think, is the quickest road leading to
attainment of zero defects."
With efficient poka yoke systems, it is possible to prove Shingo again & again!
 12.0 Benefits of Pokayoke

3. Pokayoke enables ‘efficient manufacturing’ :

As production efficiency improves, manufacturers become increasingly aware of the
fact that a single defect in the process shuts down the production flow

The desire to eliminate undesirable production shutdowns is the strongest incentive

for eliminating defects and implementing mistake-proofing.

4. Low cost of quality control & minimized inventory :

Mistake proofing devices eliminate most of the inspection time & man power .
When every part is virtually defect free, there is no need for piles of parts between
work stations.

5. Last but not least – Customer Loyalty :

When customers receive defect free products, they’re happy.
Experience shows that customers of the companies with the highest quality are
loyal. Retaining an existing customer is always more important than
getting a new customer.
Poka yoke helps us achieve it!
THANK YOU

Queries please…