Poka-yoke Techniques Research Articles

Classification graph of Poka-Yoke techniques for industrial applications: Assembly process case studies effectiveness evaluation

It is widely acknowledged that the expenses associated with substandard quality constitute a significant portion of a company's overall costs. Consequently, organizations adopt quality management systems and implement corrective and preventive measures to reduce these expenses. Within these implementations, Poka-Yoke techniques are notably prominent. Theoretically, these techniques are designed to prevent mistakes that lead to costs, especially quality-related costs associated with nonconforming products. This study proposes a classification of Poka-Yoke techniques and a methodology for evaluating the effectiveness of these techniques. The methodology was applied in the evaluation of selected techniques implemented in various assembly tasks. This assessment relies on objective characteristics of the techniques. The value of this method lies in its ability to easily evaluate techniques to implement in areas where interventions are needed to increase the reliability of the production system. Thus, it serves as a simple tool to help design new and improve existing workplace organizations.

Adverse events in health and safety management in healthcare: meaning and management tools

Highlights. It is necessary to manage adverse events in order to maintain health and safety of patients and medical workers in the process of healthcare. One of the tools that can improve the system of managing such events is the Poka-Yoke technique.Aim. To theoretically justify and analyze the possibility of using lean manufacturing tools in the management of adverse events to ensure the quality and safety of healthcare.Methods. The analysis of domestic and foreign literature, regulatory and legal documentation for the period from 2015 to 2021 was carried out. The following keywords were used as search terms: “adverse events”, “medical error”, “risk management in healthcare organization”, “Poka-Yoke technology”, “adverse events management system”. The Russian Science Citation Index database, “Garant” reference system and Google Scholar search engine were used to find full text publications. The analysis of public reports of government officials on the issues of improving the safety of healthcare was carried out. The methods of system and logical analysis were used for the analysis. The article presents the experience of developing an adverse events management system at the Federal State Budgetary Institution “Research Institute for Complex Issues of Cardiovascular Diseases” (Kemerovo, Russia).Results. The analysis revealed a variety of approaches to management of adverse events. The authors believe that the “Poka-yoke” method, described in the set of national standards and technical specifications maintained by the Russian Federation “GOST R 56407-2015 Lean manufacturing. Basic methods and tools”, can be implemented in the process of managing adverse events. The main advantage of Poka-yoke method is the fact that it is prevention-based; thus, it is possible to introduce the concept of zero defects in healthcare process. The experience of the Federal State Budgetary Institution “Research Institute for Complex Issues of Cardiovascular Diseases” confirms the expediency of using this technique for the development of the adverse events management system.Conclusion. Implementation of the Poka-Yoke technique leads to the improvement in the adverse events management system.

Design and development of ball dispenser Machine through lean manufacturing tool Poka-Yoke technique in automobile industries

In the current scenario manufacturing is the most challenging task with high quality product in minimum time. In automobile assembly industries is lot of small–small part are assembling for make one product. If any small part is missing then the quality and safety of product affected. In this experimental paper discussed about the practical case study in automobile assembly industries. Ball dispenser machine design and developed due to Anything that could make the operator realize that the steel ball has fallen inside the housing if it has fallen. An arrangement that allows person from store to fill the container of balls, but should be out of reach of operator such that the operator could not take-out balls directly.

Influence and Application of Poka-Yoke Technique in Automobile Manufacturing System

Manufacturing defect are most important parameter to improve the quality of product for the all-manufacturing industries. In the manufacturing sector day by day new tool and new techniques are apply for the improve the quality manufacturing at low cost. In this practical study discussed about the most important tool of lean manufacturing is poka-yoke (mistake proofing) technique. In all the manufacturing sector, a lot of small-small problem is affected the product quality and cost. In this paper the 70×90×10 oil seal mixing poka-yoke is solved for the improvement of quality of the product and save the manufacturing cost.

Failure mode and effect analysis (FMEA) of radiotherapy

Learning outcomes Learning outcomes are as follows: students will discover the importance of process orientation in management; students will determine the root cause of the problem by applying root cause analysis technique; students will identify the failure modes, analyze their effect, score them on a scale and prioritize the corrective action to prevent the failures; students will analyze the processes and propose error-proof system/s; and students will analyze organizational culture and ethical issues. Case overview/synopsis Purpose: This case study is intended as a class-exercise, for students to discover the importance of process-orientation in management, analyze the ethical dilemma in health care and to apply quality management techniques, such as five-why, root cause analysis, failure mode and effect analysis (FMEA) and error-proofing, in the management of the health-care and service industry. Design/methodology/approach: A voluntary reporting of a case of “radiation overdose” in a hospital’s radio therapy treatment unit, which led to an ethical dilemma. Consequently, a study was conducted to establish the causes of the incident and to develop a fail-proof system, to avoid recurrence. Findings: After careful analysis of the process-flow and the root causes, 25 potential failure modes were detected and the team had assigned a risk priority number (RPN) for each potential incident, selected the top ten RPNs and developed an error-proofing system to prevent recurrence. Subsequently, the improvement process was carried out for all the 25 potential incidents and a new control mechanism was implemented. The question of ethical dilemma remained unresolved. Research limitations/implications: Ishikawa diagram, FMEA and Poka-Yoke techniques require a multi-disciplinary team with process knowledge in identifying the possible root causes for errors, potential risks and also the possible error-proofing method/s. Besides, these techniques need frank discussions and agreement among team members on the efforts for the development of action plan, implementation and control of the new processes. Practical implications: Students can take the case data to identify root cause analysis and the RPN (RPN = possibility of detection × probability of occurrence × severity), to redesign the protocols, through systematic identification of the deficiencies of the existing protocols. Further, they can recommend quality improvement projects. Faculty can navigate the case session orientation, emphasizing quality management or ethical practices, depending on the course for which the case is selected. Complexity academic level MBA or PG Diploma in Management – health-care management, hospital administration, operations management, services operations, total quality management (TQM) and ethics. Supplementary materials Teaching Notes are available for educators only. Subject code CSS 9: Operations and Logistics.

Process improvement through Lean-Kaizen using value stream map: a case study in India

Lean-Kaizen is composed of two words lean and Kaizen; lean means elimination of non-value added activities (waste) and Kaizen means continuous improvement. Hence, Lean-Kaizen means continuous elimination of wastes through small-small improvements. This paper presents implementation of Lean-Kaizen concept in a small- and medium-scale enterprise (SME) at a non-capital region in India. The existing situation of the shop floor of selected SME was recorded, and current state map was prepared. The takt time was calculated, and bottlenecks were identified. Finally, a future state map was developed and gap areas were identified that served as a guide for determining the future lean activities. The “5-why” method was employed for identifying root causes in order to bridge the identified gap, and Kaizen events were proposed as solutions. In this study, two Kaizen events were proposed. In the first Kaizen event, the poka-yoke technique was used to control the variation caused by the slide of cylindrical grinding machine which eliminated wheel touch mark problem on the selected product. In the second Kaizen event, the brainstorming technique was applied to clamp the workpiece on the serration side rather than the slot side which eliminated the roughness on outer diameter. After the implementation of Kaizen events, reduced inventory level, reduced lead time and reduced cycle time, rework elimination, improved productivity, and improved product quality were achieved. It is concluded that Lean-Kaizen is an effective and reliable improvement technique which helps to tackle all types of inefficiencies hidden in the organizations.

Failure Analysis and Prevention of High-Voltage Failure of FHP Motor

This paper describes a systematic approach adopted to identify the possible causes of fractional horsepower AC motor failure and subsequent fault-proofing procedures developed using Poka-yoke concept. Seven quality control tools and Why–Why analysis are employed to determine the root cause of problem, and poka-yoke technique is used for process redesign. As a result human errors are eliminated, and improved process design led to negligible failures from the initial failure rate (4500 ppm). The whole approach is generic in nature and can be adopted to solve wide variety of industrial problems.

Six Sigma through Poka-Yoke: a navigation through literature arena

From the middle of 1980s, Six Sigma concept emerged in Motorola. Because Six Sigma implementation facilitated the companies to achieve profitability, it was implemented subsequently in many parts of the world. Six Sigma is implemented by majority of the companies situated in the world by applying DMAIC (stands for define, measure, analyse, improve and control) phases. Meanwhile, there have been reports of the failures of implementing Six Sigma programmes presumably due to the failure to consider and apply the appropriate tools and techniques. In this regard, it is to be noticed that Poka-Yoke, which is a tool that can be used to achieve zero-defect manufacturing, has the potential to support the implementation of DMAIC phases of Six Sigma. On deriving this observation, the literature navigation reported in this paper was carried out to understand the essence of Six Sigma and Poka-Yoke as well as the trend of applying Poka-Yoke in DMAIC phases. In the literature survey conducted to carry out this literature navigation, the researches on applying Poka-Yoke concept in DMAIC phases were studied by referring to the relevant research papers. It has been pointed out that the Poka-Yoke solutions suggested in these research papers were not actually implemented in real-time scenario. Hence, this article ends with a suggestion that future researchers can make efforts to actually implement Poka-Yoke technique in DMAIC phases for achieving the goals of Six Sigma.

Design Modification in Special Purpose Machine by Introducing Poka-Yoke Techniques

This paper mainly comprises of design and fabrication of torque value check by using pneumatics as a base concept. The machines which detect the play of the wheel end which is placed in the steering column for converting the rotational motion to angular motion of the tyres. The torque meter which displays the play of the wheel end through a digital output. Since the customers prefer their own specification there is a chance of misplacement in the batch production. The steering column manufacturing unit faces a serious crisis. In order to overcome this Japanese technique called Poka Yoke (error proof) has been infused with this design. The Programmable Logical Circuits (PLC) controlled unit which plays the vital role in the sequencing the pneumatic cylinders according to operations planned. The sensors placed in the proper orientation helps the worker to detect the error in the work piece. With this an additional printer device is installed which automatically prints the label code for the product. The sensor allows the operator to paste the label in the correct position. If the label is positioned in the wrong place the led emits red light to glow or the green light glows which indicates the part is correct.

Proposition of pick & work system for application in manual assembly

Many assembly processes in mechanical production systems have high share of manual operations. These manual operations can have big influence on final time and quality of production. Because the work is realized by human it is very important to take in account human properties and design the operation in way which will eliminate – mistakes and errors. To achieve this it is possible to use PokaYoke techniques and Pick-by systems. The paper describes the possibility of the use of these tools in assembly and proposes own Pick & Work system concept for application in the assembly operations.

Implementation of poka-yoke to achieve zero defects in an assembly line of a limited company

This paper aims at achieving zero defects in a starter assembly line by the implementation of poka-yoke technique. The study of the operations of starter assembly line with the help of cause and effect diagram revealed that there was a problem in stop ring and retainer assembly station. Then poka-yoke is implemented for correct sequence and complete pressing operation of stop ring and retainer assembly. With the implementation of poka-yoke, no defects were produced in the starter assembly line. No manual intervention was needed in the assembly. A good process quality was achieved. A check for effectiveness was done for a sample of 500 pieces and in all the samples complete pressing of the retainer and stop ring assembly was achieved. All the components were found to be good in the performance test. Finally, after implementation manpower was saved of 50% and cost was saved up-to 25%.

Critical incidents during prehospital cardiopulmonary resuscitation

We wanted to identify incidents that led or could have led to patient harm during prehospital cardiopulmonary resuscitation. A nationwide anonymous and Internet-based critical incident reporting system gave the data. During a 4-year period we received 548 reports of which 74 occurred during cardiopulmonary resuscitation. Human error was responsible for 85% of the incidents, whereas equipment failure contributed to 15% of the reports. Equipment failure was considered to be preventable in 61% of all the cases, whereas incidents because of human error could have been prevented in almost all the cases. In most cases, prevention can be accomplished by simple strategies with the Poka-Yoke technique. Insufficient training of emergency medical service physicians in Germany requires special attention. The critical incident reports raise concerns regarding the level of expertize provided by emergency medical service doctors.

Poka - Yoke in Welding

Integral Coach Factory is the Premier Coach (ICF) building Industry in Indian Railways. This factory has so far produced more than 30000 coaches in about 170 designs. It was the first among the Indian Railway production units to get ISO 9001 certification. Quality of the coach is being ensured from the raw material to end product. In ICF. fabrication of coaches are being carried out by welding process. Though welding is a reliable metal joining process, the soundness of the weldment largely depends on Men, Machine, Material and Method. The quality of the weldment is ensured by implementation of various quality tools. Even then it is quite difficult to achieve 100% defect free product in manufacturing. Even if 100% inspection is resorted to at every stage of manufacturing defects are inevitable since the inspection is being carried out by human and human errors are inadvertent and inevitable. Poka-Yoke is a tool which achieves 100% defect free product at low cost with the aid of low cost equipments. These low cost equipments aids the employee to manufacture defect free product. The aim of this study is to develop Poka-Yoke methods in a welding application. Few parameters which affect the quality of the weld are identified, and various methods are developed to control these parameters and eliminate defects. The parameters identified are shielding gas flow rate, pre and post heat temperature, welding sequence and electricity. These parameters are recorded in a standard format. Poka-Yoke Techniques were applied to control the above said parameters and ensure error free welding in ICF.

Poka-Yoke Process Controller: Designed for Individuals with Cognitive Impairments

Poka-yoke is a Japanese term meaning “error proofing.” Poka-yoke techniques were developed to achieve zero defects in manufacturing and assembly processes. The application of these techniques tends to reduce both the physical and cognitive demands of tasks and thereby make them more accessible. Poka-yoke interventions create a dialogue between the worker and the process, and this dialogue provides the feedback necessary for workers to prevent errors. For individuals with cognitive impairments, weighing and counting tasks can be difficult or impossible. Interventions that provide sufficient feedback to workers without disabilities tend to be too subtle for workers with cognitive impairments; hence, the feedback must be enhanced. The Poka-Yoke Controller (PYC) was designed to assist individuals with counting and weighing tasks. The PYC interfaces to an Ohaus™ CT6000 digital scale for weighing parts and for counting parts by weight. It also interfaces to sensors and switches for object counting tasks. The PYC interfaces to a variety of programmable voice output devices so that voice feedback or prompting can be provided at specific points in the weighing or counting process. The PYC can also be interfaced to conveyor systems, indexed turntables, and other material handling systems for coordinated counting and material handling operations. In all of our applications to date, we have observed improved worker performance, improved process quality, and greater worker independence. These observed benefits have also significantly reduced the need for staff intervention. The process controller is described and three applications are presented: a weighing task and two counting applications.

Impact of a poka-yoke device on job performance of individuals with cognitive impairments.

Job performance and production related issues are important not only to successful vocational training and ultimate job placement for individuals with cognitive disabilities, but also for their ability to have expanded vocational options. This study hypothesized that the application of Kaizen philosophy, and poka-yoke techniques in particular, could create job opportunities and improve productivity of individuals with cognitive disabilities. Poka-yoke or error-proofing techniques are part of the collection of Kaizen techniques. Kaizen refers to continuous improvement in performance, cost/effectiveness, and quality. Kaizen strives to empower the worker, increase worker satisfaction, facilitate a sense of accomplishment, and thereby create pride-of-work. These techniques typically reduce the physical and cognitive demands of a task and thereby render the task more accessible. The job was a fuel clamp assembly. A redesigned assembly fixture was the poka-yoke intervention. Consistent with poka-yoke principles, the intervention improved the productivity of everyone attempting the assembly. In particular, the workers in this study showed an 80% increase in productivity and an average percent error drop from 52% to about 1% after the process redesign. Furthermore, the workers showed improved morale, self-esteem, and pride-of-work. Prior to the process redesign, only the higher functioning workers could successfully perform the assembly. After the redesign a greater number of workers could successfully perform the assembly. These results not only validated the study hypothesis, but demonstrated that the success facilitated by applying Kaizen techniques had similar results with individuals with cognitive disabilities as with nondisabled workers.