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Poke Yoke
Mistake-proofing
POKA-YOKE
to avoid (yokeru) inadvertent errors (poka)
http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
This is not about punishing workers
• Mistake proofing recognizes that every
human will make mistakes and tries to set up
systems that minimize or eliminate those
mistakes.
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.
http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
http://www.assuredquality.com/example_2.htm
Evidence of the Effectiveness

Devices Tend to be Inexpensive...

Frequency of Occurrence

$1000 or more

$250 to $1000

$100 to$250

Cumulative Probability

$25 to $100

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0

$25 or less

Probability

Cost of Poka-Yoke Devices

Cost

http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
…and Very Effective
The “10:1, 100:1, even 1000:1” rates of return referred
to by Bhote above are not unreasonable in practice.
• Dana corporation has reported a $500,000 savings
resulting from a $6 device. (83,000:1)
• AT&T Power Systems (Lucent Technologies)
reported net saving of $2545 per device (3300
devices) [Marchwinsky, 1997]. (25:1*)
• Weber Aircraft reports saving $350,000 during their
first year of implementation of approximately 300
devices. (11:1*)
*Assumes and average devise cost $100
http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
Common Mistake-proofing Devices
•
•
•
•
•
•

Guide Pins
Blinking lights and alarms
Limit switches
Proximity switches
Counters
Checklists

http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
What is Poke-yoke?
A method that uses sensor or other devices for catching
errors that may pass by operators or assemblers.

1. Control Approach
- Shuts down the process when an error
occurs.
- 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.
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.
Contact Method
A contact method functions by detecting whether a sensing
device makes contact with a part or object within the process.
Cylinder present

Missing cylinder;piston fully
extended alarm sounds

An example of a physical contact
method is limit switches that are
pressed when cylinders are driven into
a piston. The switches are connected
to pistons that hold the part in place.
In this example, a cylinder is missing
and the part is not released to the next
process.

Cannot proceed
to next step.
Contact Method using limit
switches identifies missing
cylinder.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Physical Contact Devices

Toggle Switches
Limit Switches

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Energy Contact Devices
Photoelectric switches can
be used with objects that
are translucent or
transparent depending upon
the need.

Light

Transmitter

Receiver

Object

Transmission method: two units,
one to transmit light, the other to
receive.
Reflecting method:PE sensor
responds to light reflected from
object to detect presence.

If object breaks the transmission, the machine is signaled to shut down.
http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Contact Device
An example of a
contact device using a
limit switch. In this
case the switch makes
contact with a metal
barb sensing it’s
presence. If no
contact is made the
process will shut
down.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
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.

In the example to the right a limit switch is
used to detect and count when the required
amount of holes are drilled. The buzzer
sounds alerting the operator that the
appropriate amount of steps have been taken
in the process.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Counting Method
Another approach is to count the number of parts or components required
to complete an operation in advance. If operators finds parts leftover
using this method, they will know that something has been omitted from
the process.
“I have an extra
part. I must have
omitted a step!”

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
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.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Motion-Sequence Method
In order to help operators select the right parts for the right step in a process
the “sequencing” aspect of the motion-step method is used. This is
especially helpful when using multiple parts that are similar in size and
shape.
In this example, each step of the machine cycle is wired to an indicator board
and a timer. If each cycle of the machine is not performed within the required
“time” and “sequence”, the indicator light for that step will be turned on and
the machine will stop.

Machine

Indicator Board

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Types of Sensing Devices
1. Physical contact devices
2. Energy sensing devices
3. Warning Sensors

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Physical Contact Sensors
These devices work by
physically touching
something. This can be a
machine part or an actual
piece being manufactured.
In most cases these
devices send an electronic
signal when they are
touched. Depending on
the process, this signal can
shut down the operation or
give an operator a warning
signal.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Touch Switch
Used to physically detect the presence or absence of an
object or item-prevents missing parts.
Used to physically detect the height of a part or
dimension.

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Energy Sensors
These devices work by
using energy to detect
whether or not an defect
has occurred.

Fiber optic
Vibration
Photoelectric
http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Warning Sensors
Warning sensors signal the
operator that there is a
problem. These sensors use
colors, alarms, lights to get
the workers attention !

Color Code

These sensors may be used
in conjunction with a contact
or energy sensor to get the
operators attention.

Lights

Lights connected
to Micro switches
& timers

http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
Poke yoke

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Poke yoke

  • 2. POKA-YOKE to avoid (yokeru) inadvertent errors (poka) http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
  • 3. This is not about punishing workers • Mistake proofing recognizes that every human will make mistakes and tries to set up systems that minimize or eliminate those mistakes.
  • 4. 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. http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
  • 6. Evidence of the Effectiveness Devices Tend to be Inexpensive... Frequency of Occurrence $1000 or more $250 to $1000 $100 to$250 Cumulative Probability $25 to $100 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 $25 or less Probability Cost of Poka-Yoke Devices Cost http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
  • 7. …and Very Effective The “10:1, 100:1, even 1000:1” rates of return referred to by Bhote above are not unreasonable in practice. • Dana corporation has reported a $500,000 savings resulting from a $6 device. (83,000:1) • AT&T Power Systems (Lucent Technologies) reported net saving of $2545 per device (3300 devices) [Marchwinsky, 1997]. (25:1*) • Weber Aircraft reports saving $350,000 during their first year of implementation of approximately 300 devices. (11:1*) *Assumes and average devise cost $100 http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
  • 8. Common Mistake-proofing Devices • • • • • • Guide Pins Blinking lights and alarms Limit switches Proximity switches Counters Checklists http://www.campbell.berry.edu/faculty/jgrout/mistakeproofing667.ppt
  • 9. What is Poke-yoke? A method that uses sensor or other devices for catching errors that may pass by operators or assemblers. 1. Control Approach - Shuts down the process when an error occurs. - 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.
  • 10. 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.
  • 11. Contact Method A contact method functions by detecting whether a sensing device makes contact with a part or object within the process. Cylinder present Missing cylinder;piston fully extended alarm sounds An example of a physical contact method is limit switches that are pressed when cylinders are driven into a piston. The switches are connected to pistons that hold the part in place. In this example, a cylinder is missing and the part is not released to the next process. Cannot proceed to next step. Contact Method using limit switches identifies missing cylinder. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 12. Physical Contact Devices Toggle Switches Limit Switches http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 13. Energy Contact Devices Photoelectric switches can be used with objects that are translucent or transparent depending upon the need. Light Transmitter Receiver Object Transmission method: two units, one to transmit light, the other to receive. Reflecting method:PE sensor responds to light reflected from object to detect presence. If object breaks the transmission, the machine is signaled to shut down. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 14. Contact Device An example of a contact device using a limit switch. In this case the switch makes contact with a metal barb sensing it’s presence. If no contact is made the process will shut down. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 15. 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. In the example to the right a limit switch is used to detect and count when the required amount of holes are drilled. The buzzer sounds alerting the operator that the appropriate amount of steps have been taken in the process. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 16. Counting Method Another approach is to count the number of parts or components required to complete an operation in advance. If operators finds parts leftover using this method, they will know that something has been omitted from the process. “I have an extra part. I must have omitted a step!” http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 17. 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. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 18. Motion-Sequence Method In order to help operators select the right parts for the right step in a process the “sequencing” aspect of the motion-step method is used. This is especially helpful when using multiple parts that are similar in size and shape. In this example, each step of the machine cycle is wired to an indicator board and a timer. If each cycle of the machine is not performed within the required “time” and “sequence”, the indicator light for that step will be turned on and the machine will stop. Machine Indicator Board http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 19. Types of Sensing Devices 1. Physical contact devices 2. Energy sensing devices 3. Warning Sensors http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 20. Physical Contact Sensors These devices work by physically touching something. This can be a machine part or an actual piece being manufactured. In most cases these devices send an electronic signal when they are touched. Depending on the process, this signal can shut down the operation or give an operator a warning signal. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 21. Touch Switch Used to physically detect the presence or absence of an object or item-prevents missing parts. Used to physically detect the height of a part or dimension. http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 22. Energy Sensors These devices work by using energy to detect whether or not an defect has occurred. Fiber optic Vibration Photoelectric http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt
  • 23. Warning Sensors Warning sensors signal the operator that there is a problem. These sensors use colors, alarms, lights to get the workers attention ! Color Code These sensors may be used in conjunction with a contact or energy sensor to get the operators attention. Lights Lights connected to Micro switches & timers http://www.landp.com.au/special/presentation_demos/mproof_smpl_1.ppt

Editor's Notes

  1. (READ SLIDE TEXT) A caveat about this definition: We do not use errors and mistakes as synonyms. However, in this presentation we draw on the work of many people, and some authors will use the word mistake as a synonym with error. Where one of these is quoted, we have not changed their words. We do indicate their less precise use of the word mistake by italicizing it on the slide.
  2. PARAPHRASE SLIDE ask for more car examples.
  3. Sensing devices are the actual mechanism used to make contact, count, or identify the motion sequence of a work piece. They are the third tier of a poka-yoke system ( tires: approaches-methods-sensing devices).
  4. Various examples