Lecture # 12

SPC and Poka-Yoke

(Mistake Proofing Devices)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Major tools for
Quality Assurance
1) Statistical Process Control (SPC)
2) Mistake-Proofing (Poka-Yoke)
3) Visual control

Both SPC and mistake-proofing complement each

other. They work together to provide higher quality
than can be achieved by using either tool
independently.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Statistical Process Control
(SPC)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Statistical Process Control (SPC)
•  SPC is a method to track process variability.
•  It is a statistical technique to monitor whether the
process is within the upper and lower control limit.
•  If the process is within the control limits, the process
is said to be stable and predictable.
•  If any of the points go outside the control limits,
then it is advisable to investigate the cause.
•  SPC is used not only to improve the process but also
to monitor the stability, consistency and
predictability of the process.
•  SPC involves taking periodic measurements on the
and recording on the control chart.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
Example of SPC control chart

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Side effects of using SPC
1) Shop floor workers may not understand the statistics
behind SPC and may loose interest.
2) The production managers may leave the quality
improvement effort to QC department and statisticians
who can interpret the results of SPC.
3) There may be too much reliance on charts and graphs
which may prevent other improvements to achieve
perfect quality.
4) If the process is under control, the shop supervisor may
lose the incentive try other improvement ideas.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 The SPC Control Chart caution
•  Sometimes the SPC tool is misapplied, misunderstood and
misinterpreted.
•  The key to the success of SPC is the frequency of sampling or
how often should the sample be taken for measurement &
recording on the control chart.
•  If it is taken very infrequently (rarely) then it increases the
WIP in-between two samples and thereby increases the
quantity of rejects/scrap in case of defects.
•  On the other hand if it is done too frequently then it interferes
with production and increases the cost.
•  QC analyst must select the sample size & frequency to
evaluate benefits and cost trade-off when designing the SPC
scheme.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
Mistake-Proofing
(Poka-Yoke)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Major sources of manufacturing defects
There are three major sources of manufacturing defects:

1) Excessive variance controlled through SPC

2) Mistakes are prevented through mistake-proofing

3) Complexity is addressed through simplification

schemes such as robust design, design for
manufacturability etc.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Type of manufacturing mistakes
•  Omitting a part
•  Performing a process incorrectly
•  Putting a wrong part
•  Setting up the equipment incorrectly
•  Omitting an operation step
•  Installing pat incorrectly

Mistake-proofing is a technique of preventing defects

due to above mistakes.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 What is 1-10-100 Rule?
The 1-10-100 rule states that as a product or service moves
through the production system, the cost of correcting an
error multiplies by 10.
Activity Cost
Order entered correctly $1
Error detected in billing $ 10
Error detected by customer $ 100

Dissatisfied customer shares the experience with others…

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 What is Poka-Yoke?
•  It is a Japanese word for foolproof mechanism
•  Once incorporated into the operation, it eliminates the
probability of defects, safety issues, operator s
mistakes etc.
•  If an operator makes a mistake, poka-yoke will prevent
the defect or stop the machine automatically.
•  It catches the defects at the source and not to deliver a
defective product to the next process.
•  It should significantly reduce inspection time because
the operator is not required to inspect those operations
with poka-yoke mechanism.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 What is Mistake Proofing?
•  The use of process or design features to prevent
errors or their negative impact.
•  Also known as Poka yoke, Japanese slang for
avoiding inadvertent errors which was formalized
by Shigeo Shingo.
•  Inexpensive.
•  Very effective.
•  Based on simplicity and ingenuity.
 Everyday Examples
3.5 inch diskettes cannot be inserted unless diskette is
oriented correctly. This is as far as a disk can be inserted
upside-down. The beveled corner of the diskette along
with the fact that the diskette is not square, prohibit
incorrect orientation.

Fueling area of car has three error-proofing devices:

1. insert keeps leaded-fuel nozzle from being inserted
2. tether does not allow loss of gas cap
3. gas cap has ratchet to signal proper tightness and
prevent overtightening.

New lawn mowers are required to have a safety bar

on the handle that must be pulled back in order to
start the engine. If you let go
of the safety bar, the mower blade stops in 3
seconds or less.
 Mistake-proofing devices
•  They provide 100% inspection of the operation.
•  They detect the defects quickly and prevent their being
processed further.
•  They identify the conditions that allow mistakes to occur
so that it can be prevented quickly.
•  They provide timely information about the process.
•  Merely installing mistake-proofing devices will improve
quality but major advantage is realized when the
problem is addressed immediately.
•  They promote the discovery of root causes by providing
instant feedback about the process.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
 Approaches to developing mistake-
proofing devices

1) Item characteristics for product such as correct

shape, size, weight, dimension and color.
2) Required operations approach for the process to
ensure that all operation steps have been performed.
3) Performance approach for the process ensures that
the operation is being performed properly.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Examples of mistake-proofing devices
•  Guides (pins, slots & rails) to orient the work piece properly.
•  Templates (paper, plastic, wood or metal) to ensure that the part is
positioned properly.
•  Limit switches (positive stops) to ensure proper positioning
location.
•  Counters or timers to identify proper quantity, amount and time
duration.
•  Gates to stop & prevent the operation to proceed unless certain
conditions are met.
•  Sensors such as light curtains, weight sensors, vibration sensors,
force gages, pressure transducers to increase the reliability of the
operation.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
 Foolproof system of stopping the pallet at a
specific location on the assembly line

The limit switches detects side to side position of the part while pair of electric
eyes checks its position from front to rear. The stopper prevents the pallet from
continuing along the line if it is positioned incorrectly.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
 Foolproof system of ensuring that all the required
parts and instruction sheets are put in the shipping box

Electric eye is installed in front of each parts bin so that the workers hand is interrupted when he
removes a part or instruction sheet from its bin. Unless all the beams have been interrupted, the stopper
will not release the box & allow it leave the workstation.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
 Steps to implement mistake-proofing devices
1) Define the objective of mistake-proofing device.
2) Identify the defect to be eliminated.
3) Look for similar solutions in the past.
4) Determine the location where the defect could happen & where it
should be discovered.
5) Understand current operation & procedure.
6) Identify the root cause or conditions which can cause the defect.
7) Decide the purpose of the device: detect the defect, detect the
mistake or prevent the mistake.
8) Determine the appropriate mistake-proofing device which could
meet the objective.
9) Create the device and test for its effectiveness.
10) Install the device and measure the results.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
 Examples of
Poka-yoke mechanism

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Fixture used as Poka-yoke

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Limit switch used as Poka-yoke

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Use of a plastic template to prevent misloading
of electronic components
(Arrow indicates the proper direction of installing the components)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Poka-yoke (fail safe)
(Examples of Error-proof devices)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Poka Yoke Systems
Two Poka Yoke System approaches are utilized in manufacturing
which lead to successful zero defect systems:
1. Control Approach
a) Shuts down the process when an error occurs.
b) Keeps the suspect part in place when an operation is
incomplete.
2. Warning Approach
Signals the operator to stop the process and correct the
problem.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Common Mistake proofing Devices
•  Guide Pins
•  Blinking lights and alarms
•  Limit switches
•  Proximity switches
•  Counters
•  Checklists

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Methods for Using Poka yoke
Poka yoke systems consist of three primary methods:
1. Contact
2. Counting
3. Motion-Sequence
Each method can be used in a control system or a warning
system.
Each method uses a different process prevention approach for
dealing with irregularities.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Contact Methods
1) Do not have to be high tech!
Passive devices are sometimes the best method. These can be as
simple as guide pins or blocks that do not allow parts to be seated in
the wrong position prior to processing.

2) Take advantage of parts designed with an uneven shape!

A work piece with a hole a bump or an uneven end is a perfect
candidate for a passive jig. This method signals to the operator right
away that the part is not in proper position.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Counting Method

Used when a fixed number of operations are required

within a process, or when a product has a fixed number
of parts that are attached to it.
A sensor counts the number of times a part is used or a
process is completed and releases the part only when
the right count is reached.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Motion-Sequence Method
The third poka yoke method uses sensors to determine if a motion or a step
in a process has occurred. If the step has not occurred or has occurred out of
sequence, the the sensor signals a timer or other device to stop the machine
and signal the operator.

This method uses sensors and photo-electric

devices connected to a timer. If movement
does not occur when required, the switch
signals to stop the process or warn the
operator.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Types of Sensing Devices

Sensing devices that are traditionally used in poka yoke systems can be
divided into three categories:
1. Physical contact devices
2. Energy sensing devices
3. Warning Sensors

Each category of sensors includes a broad range of devices that can be

used depending on the process.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

3 Rules of POKA YOKE
•  Don t wait for the perfect POKA
YOKE. Do it now!
•  If your POKA YOKE idea has
better than 50% chance to
succeed…Do it!
•  Do it now….improve later!

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Evolution towards Jidoka (Autonomation)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Application of Jidoka (autonomation) in a Shearing operation

1) A limit switch is installed to check when the coil is finished & needs replacement. When the coil is about to run out, a
light panel lights up and a speaker sounds so that the operator can prepare for the next coil.
2) A counter is installed in the machine to monitor the number of strokes and the quantity produced. When the required
quantity is completed, the machine stops and the buzzer signals the operator.
3) A limit switch & a timer were installed to monitor that the storage cart needs replacement. If the limit switch is on for
more than a specified time (indicating that the storage cart is getting filled), the machine stops automatically & the
buzzer gives the signal to the operator.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
Application of Jidoka for inventory control
(Limit switches control the inventory level between processes)

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Visual control

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Visual controls using lights

Visual controls using lights is called Andon or trouble lights .

Production problems are communicated through lights, buzzers and
video cameras. Same as lights at checkout counters in a grocery store.

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Visual production control board

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Visual production control board at the workstation

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Examples of visual production board

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Example of visual control to prevent errors

•  Pressure gage can be color coded to indicate normal condition.

•  Valve can tagged with a card indicating normal position

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Example of visual control applied to
Workplace Organization

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Visual organization for hand tools

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

 Example of visual control applied to Material Handling

•  Visual control using maximum height indicator in parts storage area.

•  Using same color of the cart and the kanban card for parts transfer
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
Example of visual control applied to convey information

Lights and sound are used to inform people of the status of the
production line.
Copyright 2006 © by Dr. Govind Bharwani, Wright State University
Machine-maintenance communication
through visual light system

Copyright 2006 © by Dr. Govind Bharwani, Wright State University

Examples of visual information on a display board
•  Machine layout
•  Job rotation plan
•  Attendance list
•  Vacation plan
•  Control charts
•  Standard work sheet
•  Safety check points
•  Awards for suggestions
•  Housekeeping evaluation sheet
•  Status of improvement activity
•  Productivity & quality charts
Copyright 2006 © by Dr. Govind Bharwani, Wright State University