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- 2. Why do people make inadvertent mistakes? How does poka-yoke help prevent such mistakes • Inadvertent mistakes are the ones we didn’t know about until it was too late. • We didn’t follow a procedure because we didn’t know about it. We daydreamed while we should have been completing a task and got things wrong. • We didn’t mean to make a mistake, it just happened.
- 3. Poka Yoke Technique • One of the most potent strategies for standardizing work, it may be used in any industrial or service business. • Poka-Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes. • To avoid faults from developing, Poka-Yoke checks that the appropriate circumstances exist before a process step is completed. • Instead, Poka-Yoke serves a detective role, identifying flaws in the process as early as feasible.
- 4. List and explain the three levels of mistake- proofing • Level 1: 1. At Level 1, the goal is to prevent the faulty product from reaching the next process, or even to reach its intended consumer. 2. Cannot pass or accept. 3. Checklists or inspection sheets testing at the end of a product lifecycle can be the examples
- 5. Level 2 • Cannot process • Commonly referred to as the "warning" level.
- 6. Level 3: • Cannot produce. • All measures applied to prevent the fault from happening are included in Mistake Proofing Level 3. • Parts that do not comply with the law cannot be produced.
- 7. Why is brainstorming an important tool in the Improvement phase of DMAIC • In the DMAIC process, the fourth phase is the Improve phase. • Brainstorming: • Generating Many Radical, Creative Ideas • Using brainstorming, you may solve problems in a casual, informal manner while also using lateral thinking. • When individuals are "jolted" out of their regular patterns of thinking, it helps them to become unstuck.
- 8. Brainstorming Method 1. You can use this tool to find solutions to difficulties that are interfering with your present workflow. 2. All viable options should be considered in order to motivate team members to participate.
Notas del editor
- The person "is human" and "simply made a mistake", therefore there's nothing we can do about it. This, however, is incorrect. We have the power to prevent these mistakes from happening again. Customers are more satisfied, quality is better, and profits are higher for companies that spend in understanding the reasons behind human mistakes
- This technique prevents, corrects, or draws attention to human errors as they happen.
- Examples: Red or green lights indicate if the correct torque has been obtained using a DC Torque Tool Counting devices that stop the component from moving forward until the right number of screws have been tightened.
- Examples:USB slots that only allow connection in one position Assembly fixtures that prevent parts from being inserted incorrectly
- During the Improve phase, we can discuss solutions to discover the best ones, then apply them to address the problem. As a result, individuals are encouraged to come up with strange ideas and concepts. A few can be fashioned into original, innovative answers to a problem, while others can serve as a catalyst for more.