Poka-Yoke |
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This concept is all about taking preventative measures to stop errors entering the production cycle. The logic is to get products manufactured ‘right first time’. Underlying Poka-Yoke characteristics:
Poka-Yoke is particularly used in the motor industry where car parts must be placed in a certain sequence, for example car badges which have insertions in certain areas which mean operators must insert the part in a set manner. Benefits of Poka-Yoke include a reduction in waste and associated machining costs as non-conforming material is identified at each stage rather than a inspection stage between several stages. By reducing the waste in the system, there should be an associated reduction in inventory holdings, improvements in customer satisfaction levels as a better quality product is delivered to them. Poka-Yoke should also lend itself to improvements in employee relationships as it encourages more involvement and getting support teams involved to improve processes which keep causing problems. Dis-advantages of Poka-Yoke include the increased times that operators would have to spend inspecting their work, however this does mean a reduction in scrap costs over the long-term. In the short-term your business may experience a sharp increase in scrap materials, but the resulting improvements which arise from identification means less non-conformance in the long-term. Back to Lean Manufacturing Methods Main Menu |
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