The ‘Poka Yoke’ or project quality made
Poka yoke means literally Failsafe, and is a fundamental tool of Lean.
In the ‘Poka Yoke’ each piece can only fit into a hole.
Since babies, we are educated to make the minimum possible errors, and indeed many will ring them this toy whose ultimate goal is the baby as little as possible wrong fitting the pieces into its slot.
Each piece can only fit in a hole. It is easy to go wrong. In fact sure until we complete our baby will make mistakes, but the cost of such errors is minimal, and the error final, which reaches our client is IMPOSSIBLE.
That’s the ‘poka yoke’. No more, but as yet there is room on this page, we’ll decorate it with an example, which I guess is why they have come to the floor 131 of this article.
Scenario 1: Picking Product
All boxes of all products are labeled with an alphanumeric code of 11 characters. But not all references included in the boxes barcode EAN 13, DUN 14, EAN 128 or to put it another way, readable by our SGA.
There are errors in picking, because when the product bar code is scanned and it is not legible, there is a possibility that the product ‘chopped’ from the shelf than the waiting customer.
Solution poka yoke 1
When the bar code is not readable, the system opens the field screen alphanumeric code stock of 11 characters, where the operator must fill in for the last three digits hollow.
You must read them in the box and include them on the screen. If you do not succeeds, the SGA does not allow you to continue with the task of picking. Possibility of errors = 0.
Scenario 2: Location of product from the beach facilities
The task manager assigns the operator must perform a gap where the location. The store is divided into aisles in alphabetical order. The system can direct the operator to a hollow passageway AE, say at the level of the column 20 and at a height of 8 meters.
It is impossible to confirm the location in the barcode on the shelf, because the height of the location. The possibility of error is that the operator can go into the hallway BE instead of AE and confirm by hand on the screen the wrong location.
When you skip a task of picking against the intended location, the operator who performs the task of picking communicates not find a product. The incidence is very difficult to solve. Who can imagine that the operator has placed the product so far from the correct location ?.
Solution poka yoke 2
The operator at the time of placing the goods, you should confirm with the scanner against the barcode right column hall, located a few feet away and only add height hand.
Thus, if an error occurs in the location, we are confident that the right product is in the hallway and in that column, but on another level, easily solving the problem.
There are two simple examples … Or not so simple ?.
I can tell you that the first solution with the number of errors was reduced shipments in the Distribution Center 50%, from more than 400 errors per million lines sent only 200. Impressive is not it ?.
The poka yokes help us significantly to improve the quality of our processes. Let us use them and also if we propose our operators as Teian … hunky-dory.
Congratulations on reaching the end of this article. They are demonstrating interest in improving.
I encourage you to continue with our next chapter that discuss the power of 5S audits and the importance of the ‘s’ Sustain or maintain the acquired improvement.
some poke yoke examples
