2014-08-02

Pokayoke

Pokayoke is Japanese word.
Poka : Inadvertent error

Yoke : To Avoid

Pokayoke stands for : Mistake Proofing, Fool Proofing

Where to use Pokayoke ?

Highly repetitive situation. High productivity area

When to use Pokayoke?

Safety issue and quality problems
Right at First Time

Why Pokayoke is needed? 

Safe working, Builds quality in product, Waste elimination

Mistake can happen because of Man, Machine, Material, Method. Mistake Leads to Defect. Due to that accident, customer complaints, loss of tome, loss of money etc reduced.


Kinds of Human Mistakes?

Forgetfulness, Identification, Misunderstanding, Amateur, Sudden/ Surprise, Slowness, Lacks of Standard, Inadvertent, Intentional.

Defect caused because of human mistake?

Process error : Incorrect or partially done
Inspection error : Monotony or fatigue faced by operator 
Assemble error : Improper assembly
Assemble Omission : Fails to assemble a part
Process omission : Missing of step
Some other errors are 
Labeling error / Packing error / dimensional error / Misalignment error

 “ Mistakes are inevitable but can always be prevented”



By establishing Pokayoke

How to Prevent Mistakes ?

By use of,
Photo Sensors        
Temperature controller  
Humidity sensor
Pressure switches
Limit switches
Mechanical stoppers
Proximity switches
Flow switches
Float switches
Temperature controller