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      • Six Sigma: Measure : 1 Identify Measurement and Variation
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      • Six Sigma Analyze : 1 Measuring and modeling the relationship between Variables
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      • Six Sigma: Improve Phase : 5 Poke Yoke
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Six Sigma: Improve Phase : 5 Poke Yoke

mistake proof Judgment Inspection  Informative Inspection Successive Check Self Check Source Inspection Poke Yoke Systems Control Warning Mistake proof
5. Poka-YokeShigeo Shingo is widely associated with a Japanese concept called Poka-Voke(pronounced poker-yolk-eh) which means to mistake proof the process. Mr. Shingo recognized that human error does happen but it can be corrected before creating defects.
Human errors can occur in many ways. Any operation that relies on the human element will run into the problem of errors. The notion of concentrating 100% of the time on a task will not guarantee zerodefects in the product. Poka-yoke is the Japanese term for “mistake-proofing” or “fail-safing” a task. Poka-yoke devices can be installed at low costs.
Inspection and Quality (S. Shingo)
Types of Inspections
1.Judgment Inspection: Discover defects after the facts, Sort out bad products
Disadvantage:
•Costly
•Difficult to eliminate all defects if human inspection is used
•No feedback to process
2. Informative Inspection: Taking data from process, when defects/abnormal condition occurs, the information is feedback to the process, and corrective actions will be taken.
Statistical Process Control / Successive Check / Self Check
-The Pitfalls of SPC (Shingo) •It is a sample inspection, so if the process is not capable, it cannot catch All the defects
-The feedback is usually slow
Successive Check
Successive check is to let the immediate down stream process To check the output of the immediate upstream process. Basic Principles of successive check method
•Always 100% inspection
•Judgment about defect is done objectively
•When a defect occurs, the information will be immediately feed back to immediate Upstream, root cause will be immediately investigated
•Eliminate hidden root cause one at a time, until they are all gone.
Self Check
Successive check is to let current process to check itself and Trouble shoot the process immediate if defect occurs. Basic Principles of self check method
•Always 100% inspection
•When a defect occurs, the root cause analysis will follow instantly and corrective
action will be taken immediately
•Eliminate hidden root cause one at a time, until they are all gone.
•Inspection should be done at low cost and automatically
3. Source Inspection:
Source Inspection is based on the idea of discovering and correcting errors before errors become a defect
Basic Principles of self check method
•Always 100% inspection
•When a defect occurs, the source of errors will be traced in upstream and/or adjacent/related process elements and be identified
•Real time check mechanism will be implemented and whenever an error shows up, it will Be immediately identified and eliminated
Poke Yoke Systems
There are three types of regulatory mechanisms for Poke Yoke
1.Control: When abnormalities occur, the Poke Yoke system will halt the operations
2. Warning: When abnormalities occur, the Poke Yoke system will send warning
3. Mistake proof: When abnormalities occur, the Poke Yoke system Will make mistake impossible to happen
Poke Yoke device should be cheap, able to perform 100% inspection, and gives results instantly Poke Yoke system can detect abnormalities by detection technology and/or process procedures.
Other design improvements to “error proof’ the process include: .
Elimination of error-prone components
. Amplification of human senses
. Redundancy in design (back-up systems)
. Simplification by using fewer components
. Consideration of functional and physical environmental factors.
Providing fail safe cut-off mechanisms
. Enhancing product producibility and maintainability
. Selecting components and circuits that are proven
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  • Home
  • Six Sigma Wiki
    • History of Six Sigma : The Guru’s
    • Lean vs Six Sigma
    • What is Six Sigma ? Objectives Fundamental Beliefs Benefits
    • Six Sigma Project Overview >
      • Six Sigma Process Performance Metrics
      • Project Execution : Selection , Flowchart , Management , Evaluation
      • Voice of the Customer (VOC) >
        • CTX (Critical to X) Quality
        • Kano Model
        • Different type of Quality Cost
      • Risk Analysis SWOT (Strength, Weakness, Opportunity, Threat)
    • Six Sigma Team Management : Types, Roles, Size, Stages & Life cycle >
      • Six Sigma Organizational Infrastructure Team Leadership >
        • Six Sigma Roles and owners process
        • 3 levels of business management process
        • Six Sigma Training: Black vs Green Belt
        • Overview of DMAIC : Key points
      • Six Sigma Team Tool: Facilitation & Groupthink
      • Nominal Group Techniques Multivoting Force Field Analysis Brainstorming
      • Diagrams : Affinity Tree PDPC Matrix Interrelationship Prioritization matrices Activity network diagram
      • The 4 Stages of Team Growth & Human factor: Forming, Storming, Norming, and Performing
    • Six Sigma: Define Phase : Outcomes & 6 Element >
      • Six Sigma Define: 1Define Problem & 2 Identify Customer
      • Six Sigma : Define : 3 : Identify CTQs ( VOC Kano Model )
      • Six Sigma : Define : 4 : Map Process 5 Refine Project Scope
      • Six Sigma : Define : 6 Update Project Charter ( PERT CPM Gantt Bar WBS)
    • Six Sigma: Measure Phase : Outcomes & 5 Element >
      • Six Sigma: Measure : 1 Identify Measurement and Variation
      • Six Sigma: Measure : 2 Determine Data Type
      • Six Sigma: Measure : 3 Develop Data Collection Plan
      • Six Sigma: Measure : 4 Measurement System Analysis & Data Collection
      • Six Sigma: Measure : 5 Perform Capability Analysis
    • Six Sigma: Analyze Phase : Outcomes & 4 Element >
      • Six Sigma Analyze : 1 Measuring and modeling the relationship between Variables
      • Six Sigma Analyze : 2 Hypothesis Testing
      • Six Sigma Analyze : 3 Failure mode and effects analysis (FMEA)
      • Six Sigma Analyze : 4 Analysis of Variance (ANOVA)
    • Six Sigma: Improve Phase : Overview & 6 Element >
      • Six Sigma: Improve Phase : 1 About Design of experiments (DOE)
      • Six Sigma: Improve Phase : 2 DOE Process variables & Analysis
      • Six Sigma: Improve Phase : 3 Design Selection Guideline
      • Six Sigma: Improve Phase : 4 : Lean 5S
      • Six Sigma: Improve Phase : 5 Poke Yoke
      • Six Sigma: Improve Phase : 6 Standard Work & Kaizen
    • Six Sigma: Control Phase : Overview & 3 Element >
      • Six Sigma: Control Phase : 1. Statistical Process Control
      • Six Sigma: Control Phase : 2. Control Chart
      • Six Sigma: Control Phase : 3. Other: Pre-control Technique, TPM & Visual Management
  • Lean Wiki
    • History of Lean & Guru’s >
      • Birth of Lean
    • About Lean, Value, Waste, Muda, Mura & Muri >
      • Overview Lean Tools, Techniques & House of Lean
      • Lean Excellence, Tools & Framework
      • Lean Framework 6 points, metric & Stability
    • Lean Team Setup : Structure, Meeting & Project >
      • Self Directed Work Teams (SDWT) , ACHIEVE TEAM SYNERGY , SQDCM, Teamwork Principles, Team Structure & Team Leader
      • The 4 Stages of Team Growth & Human factor: Forming, Storming, Norming, and Performing
    • Lean Process Mapping: Generic & Type >
      • SIPOC: Suppliers, Input, Process, Output & Customers
      • Lean Process Management , Excellence , Identification , Design & Mapping
      • Lean Process Mapping Symbols
      • How to Create a Simple Process Flow Diagram
      • Lean Value Stream Mapping, current, future & 3 type of work
      • Value Stream Mapping (VSM): About & 17 steps
      • Other Types of Process Maps & Pitfalls: Resources: iDef0, Document Map, Work Diagrams, Rendered Process Map
    • Lean Process Optimization , Andon System , Error Proofing ( Poka Yoke ) & Defect vs Errors >
      • Lean 5S System
      • Kanban : Benefits, Shapes of Inventory, Type, Operation & Sizing
      • Cellular Manufacturing: About, Benefits & 4 Dimensions of Cells
      • Heijunka, A 3 Thinking, Hoshin planning, Jidoka, Poka‐yoke , Kanban, Takt , Kaizen
      • Lean Kaizen (continuous improvement), Systems Thinking & Process Variability
      • Lean Visual Management & Visual Control
      • Lean Waste Detail: Eight Types of Waste
      • Line Balancing, Cycle Time, Takt Time, Assembly / Workload Balance & Man – Machine – Setup – Time
      • Single Piece Flow, Continuous Flow & Standardized Work
      • SMED Single Minute Exchange of Dies
      • Total Productive Maintenance (TPM): Preventive Maintenance Corrective Maintenance Inbuilt Maintenance
  • Blog
  • Contact