Who has a safety concern contact or tip Lets band together for S afety Q uality S peed of Execution A ship is safe in harbor but thats not what ships are for Learn more about mistakeproofing at ID: 612015
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Slide1
1
Let’s take a minute for SAFETY:
Who has a safety concern/ contact or tip?
Let’s band together for
S
afety,
Quality, Speed of Execution
A ship is safe in harbor, but that's not what ships are for …
Learn more about mistake-proofing at:
www.freesixsigmasite.com
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SMILE !!
It’s Contagious!
Our objective:
Take away
one mistake proofing idea and go implement it within your process!
And … we’ll ask for one at end of the presentation.Sustain the GainSlide3
Where in the World are Poka-yoke?
They exist in the world around us…
(they’re out there)Slide4
Mistake-Proofing Devices On Your Car
Can’t start the car unless it’s in park or clutched
Can’t fit a diesel nozzle in the gas tank
Doors lock when speed is greater than 5 miles per hour
Bell chimes when headlights left on
Headlights automatically burn & extinguish
Bell chimes when seatbelt not worn
Indicator lights when fuel is low
Gas cap is attached to car by a lanyard
Oil and fuel specs are listed on caps or tanks
Bell chimes when turn signal left on
Light indicates that parking brake is engagedSlide5
What Are Guidelines for Poka-Yoke ?
In general, the approach of Poka-Yoke should meet the following guidelines:
Inexpensive
Based on common sense and obvious to the person involved in the process
It MUST eliminate Occurrence and Detection of the problem
at the root causeSlide6
BTW, Don’t Do “Fake”
Poka-Yoke!aka: “You had one job”
Just for fun!!
Let’s examine a couple …Slide7
Almost !!Slide8
Almost !!Slide9
Almost !!
Do …
Careful pedestrians need to stop??Slide10
Almost !!
There are 2
Partsto this one…Now - notice how far away sign is from hospital bedSlide11
Almost !!
“falls program…”
Really ??!??!!Slide12
Almost !!
So many signs!
Maybe the pit fell in the void after catching fire??Slide13
Almost !!Slide14
Almost !!
At least they had a little fun with this one!Slide15
What is the Purpose of Poka-yoke?
Prevent a foolish action through
3 functions:
SHUT DOWN a process, machine or operationCONTROL a process, machine or operation
WARN that a defect (is about to occur or) has occurredSlide16
Top Causes of Errors
Look for these in your processes…
Processing omissions
: leaving out one or more process steps
Processing errors: process operation not performed according to the standard
Error in setting up
: using wrong tooling or incorrect setting/ adjustmentMissing parts: not all parts are included in assembly/ process
Improper part/ item: wrong part installed in assemblySlide17
Top Causes of Errors (
con’t)
Processing wrong work piece: wrong part machined/ processedOperations errors
: incorrect revision or specification sheetErrors in equipment, maintenance or repair: Defects caused by incorrect repairs or component replacementError in preparation of inspection equipment, fixtures or tools: Damaged inspection tooling; poorly designed fixtures or wrong tools; mis-measurementSlide18
Q) Why a Mistake-proof Hierarchy?
18
A) So you don’t have to “fix” the problem again!
Full Automation
Awareness
Fail-Proof
SimplificationTraining
Behavior typically reverts back
The process is changed to be less
impacted
upon
variation caused by people
Most Desired
Least Desired
No Manual Intervention
Impossible to Fail
Eliminate Activity
Certification and Audits
NotificationSlide19
2
states for Poka-Yoke
Occurrence
–
is the situation
as it happens (occurs)
Detection – the
situation
should alert
at the point of mistake
[“
Shutout
” is best]Slide20
2
states for Poka-Yoke
Occurrence
–
is the situation
as it happens (occurs) (IT HAPPENED!!)
Detection – the
situation
should alert
at the point of mistake
[“
Shutout
” is best]
(STOP IT BEFORE IT HAPPENED!!)Slide21
Example
Why did you “pop open” the trunk to gas up?Slide22
Example
Alert the operator at the point of mistake…
Four xample, when one makes a
misteak, an effective Poko-Yoke system will alert the operotor that a
misteak was made, where it was made, and even how the misteak was madeSlide23
Example
IS GAS CAP SECURE?
Tighten till you hear the “click”Slide24
Example
Computer Start-up Routines
[password/log-in/pin etc]
Computer Shut-down Routines [series of low battery warnings/ actions taken]Slide25
What are the Conditions?
(ripe for poka-yoke)
Adjustments
Unclear or no instructionsUndefined
processMany
units/mixed unitsMultiple
stepsInfrequent productionIneffective or lack of standardsMultiple handoffsHand processing
Rapid repetitionHigh volume demand or deadline pressures Environmental conditionsSlide26
Try It !
Mistake-Proof This: A local countertop company makes and then loads the countertop pieces on to a truck and goes to the customer’s home and installs the countertop.
More than 15% of all installation jobs have to be done with more than one trip to the customer’s home because one or more pieces of the countertop was not loaded on the truck. Propose a change that will ensure all the material is loaded on the installation truck.Slide27
Try It !
Mistake-Proof This: The far-sighted instructor in a rush to get to work on time often forgot and left his glasses at home.
Propose a change that will ensure the instructor does not forget his glasses.Slide28
Try It !
Mistake-Proof This:
Mechanics in the instrument lab have to calibrate instruments in accordance with a procedure that has several steps.
They sometimes inadvertently skip a step in the procedure. Propose a change that will ensure no steps are skipped.Slide29
Go Forth
Identify what your impediments to improvement are
Work on those and you will be on the right track
In particular, what are barriers tohigher equipment uptimehigher process capabilitysafer environments or equipmenthigher capital and labor productivity without adding cost or more highly trained personnel
I call this building better process stabilitySlide30
Surfin’ for Ideas?
Better Practice Sharing
Your goal: Implement
One
Idea
Slide31
A Better Practice …
Use CAPS: (Action Verb) then, the event …
In your Outlook CalendarSlide32
A Better Practice …
Label, Label, Label
Color code …Slide33
A Better Practice …
Which side is gas cap on?…
Points to left side
(see white arrow)Slide34
A Better Practice …
Sign (Warning)
Metal tabs (Shut-out)Slide35
A Better Practice …
This rental truck has a door latch that will not allow the loading ramp to slide out while the latch is in the closed position.Slide36
Countdown to Takeoff –
Get on the plane, people !!
A Better Practice …Slide37
A Better Practice …
Green tag for “Carry On” bags that had to be checked.Slide38
A Better Practice …
Slotted metal guard (“stand-off”) to prevent accidently stopping luggage conveyor at the airport.Slide39
A Better Practice …
Place sign above (or below) the Fire ExtinguisherSlide40
A Better Practice …
P.P.E. REQUIREMENTS to enter into the operation.
Steel toe shoes, reflective vest, hard hat, etc.Slide41
A Better Practice …
COFFEE/ SINK AREA (signage) for galley operations.
Considerate but firm…Slide42
A Better Practice …
TIME ALERT (signage) for coffee operations.
Denotes type and how long coffee has been sitting…Slide43
What Did We Cover Today?
In general, ‘Poka-Yoke’ (mistake-proofing) should ultimately be
to prevent a foolish action:
Common Guidelines for Poka-yoke (inexpensive, common sense, attack the root cause)BTW: Don’t do “Fake”
Poka-Yoke (You had one job…)
Purpose of Poka-yoke (S, C, W)
States – (Occurrence/ Detection)Examined Operating ‘Conditions’ in which they breed …(multiple handoffs, undefined processes, adjustments, etc)Better Practice Sharing (they’re out there… share them!)Slide44
Oops !!
[Mistakes, - some are obvious]Slide45
[…
some recover well!]Story on back of each bag of chips…Slide46
[And
… some, not so much!]Slide47
Lot’s O’ Reasons… to address
Focus your analysis on those causes…Slide48
And, NOW
- What is your Poka-Yoke?
An idea you can put into practice…Slide49
Look for these Conditions:
Adjustments
Unclear
or no instructions
Undefined process
Many units/mixed units
Multiple stepsInfrequent productionIneffective or lack of standardsMultiple handoffs
Hand processingRapid repetitionHigh volume demand or deadline pressures Environmental conditionsS
HUT DOWN a process, machine or operation
C
ONTROL a process, machine or operation
W
ARN that a defect (is about to) or has happened
Key Points about Mistake ProofingSlide50
Mistake Proof This!
A great idea you can put into everyday practice …Process / Step: _________________________
Describe the Error: ______________________Mistake-proofing Measure: _________________ _____________________________________
What foolish action does it prevent?
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