Poka-Yoke

As it seems poka-yoke is a Japanese term, that simply means mistake-proofing .

It was originaly decribed as baka-yoke ,that means fool-proofing ,later it was changed to poka-yoke, may be thinking that there is no fool proof system to completely illuminate human mistakes.

Poka-yoke first introduced by, Mr.Shigeo Shingo as part of Toyota Production system.

Poka-Yoke is system, arrangement or constraint that restrict equipment or operator mistake.This system or arrangement may be in the form of instructions, extra electrical or mechanical device or in the form of some restrictions.

In our day-to-day life we see lots of poka-yoke to make our life safe and convenient.

If your two wheeler is in gear, you cant start it unless you press clutch, that arrangement is poka-yoke. In elevator, you cant open floor door unless elevator comes to your floor, that arrangement is called poka-yoke.

In your organisation if any problem arises, after finding its root cause you can prevent it by implementing a kind of poka-yoke there. The best utilization of poka-yoke is while installing any new machine, equipment or system ,think about the problems related to its operation or functioning ,and think poka-yoke.

Mass Production –  

We found best usefulness and utilization of poka-yoke in mass production, where 100% inspection is not possible, so you have to target on less mistakes.

Any negligence or mistake in mass production will result in total lot rejection, that means a heavy loss by all means.

So that, in mass production (line production) you have to constraint at stages ,operations and movement.All these have to go under surveillance.

For an example we will take ,a  weldshop asembly line of press shop.

In this case the poka-yoke will be for confirmation of,

  • Shape of job
  • Number of operations
  • Number of spots per stage
  • Number of loose parts required to assembled
  • Number of studs to be projected
  • Number of jobs to be filled in a pallet.

KAIZEN

Kaizen

It is Japanese word that means “improvement” or “continuous improvement”.

Kaizen can be done by a single or group of persons, in there work or in machine function .

It has a scope of involvement from ,CEO level to line worker, the moto is to change conventional methodology by a new productive idea ,it may be in the form of some physical change in machine, it may be in the form of mentally change of workmanship, or conceptually change in methodology. You can do kaizen in, the way you read, the way you write, you walk, you talk .You can do kaizen in dustbin utilisation on shopfloor, or in missile launch process. The thing is improvement.

In our life, things we do, in our work place work we do, every where there is always a scope of change or improvement is present. It is like if we want result 5 ,then method will be 3+2, 4+1, 10-5 or 7-2. There are lots of ways for same result , but matter is convenience, what suitable most ,what profitable most. Kaizen demands more ,you achieve result 5 by addition, subtraction or multiplication, but Kaizen is in the source of your operation.That ,what you are using for a result fingers, paper and pencil or calculator. Kaizen demands calculator and even demands more.

Kaizen always challenges a human (or worker in organisation) for creativity, so many organisation offers awards for a good kaizen and maintain kaizen gallaries to motivate others for active participation.

5 S – a basic good habit for an organisation

5 S – a basic good habit for an organisation 

This is a more frequent word we hear in manufacturing industries.

This word not welcome discipline in our industrial life, but also in our personal life.

So, what is 5s.

Basic definition

There are 5 basic Japanese words ,that starts with letter “S”

1S-SEIRI

2S-SEITON

3S-SEISO

4S-SEIKETSU

5S-SHITSUKE

For more convenient in English, we can term it as,

1S-SORTING OUT

2S-SYSTEMATIC ARRANGEMENT

3S-SPIC AND SPAN

4S-STANDARDIZATION

5S-SELF DISCIPLINE

Now I will describe it one by one.

1 S – Seiri or Sorting Out

At our work place categories items nearby you according to your frequency of need.So sort which items you more need, which items you need later and which items you never need.

The items you need more frequently keep into your reach or make it easily accessible.

The items you rarely need or need after some time make a distance space  for them.

The items you identified as useless, scrap or can be convertible (utilize) into other  place ,job or items , place it away from work place .From where it can be scrap or utilize by others.

           2S – Seiton or Systematic Arrangement

After identifying the items you need more frequently place it in proximity from you or workplace.

It reduces time to reach things you need, same time it reduces your effort to find out the items .This will help to fill you work in systematic manner , and more professional. This will increase your output and your performance with less efforts.

Besides your professional life ,it also improves your personal life at your home place .Using it the space can be properly utilizes.

3 S – Spic and Span

After arranging all items in a proper main follow 3s ,that means keep our workplace neat and clean.Make habit , before start your work ,daily clean your equipment,tools and space.

This habit will feel you pleasant while working, it also helps in maintain safe work condition.

We very much know about importance of neat and cleanliness in our personal life.It keeps our home health-wise good, so it keeps us at our work place safety and good.

4 S – Seiketsu or Standardization

It means convert your work place into standard well maintained area. Standardization means make items, easily identified with easily accessible.

For that put labels on items to describe it uses, assembly or required sequence.

This is a best in our home kitchen ,tagging name labels on bins, container.

At work place it reduces our time to search items you need, as if you are new at that place no matter.

5 S – Shitsuke or Self Discipline 

As you come across all above 4s , now make it your habit by self discipline.If you cant force yourself to maintain all, the best practice as generally used by major organisation is a cross audit.

Cross audit is ,allow person from other department to examine your work place according to 1s to 4s. This will help you to find-out your loops and keeps you in discipline.

Organisations puts penalties and rewards for 5S maintenance.That puts organisation in well cultured environment and definitely results in raise productivity.