INTEGRATION OF POKA YOKE INTO PROCESS FAILURE MODE AND EFFECT ANALYSIS: A CASE STUDY

The Failure Mode and Effect Analysis (FMEA) is a one of the requirements which was required by the Automotive Industries Action Group (AIAG) to all the automotive suppliers and manufacturers worldwide through the TS16949 Quality System. There were a lot of dicrepencies detected on implementing the FMEA which directly related to the user experinces and knowledge. The descrepencies cause the FMEA not meeting the objectives of it. Conceptually, Poka Yoke is able to fit into the Process FMEA. Failure Mode and Effect Analysis (FMEA) helps predict and prevent problems through proper control or detection methods. Mistake proofing emphasizes detection and correction of mistakes before they become defects. Poka Yoke helps people and processes work correctly the first time. It refers to techniques that make mistakes impossible to commit. These techniques eliminate defects from products and processes as well as substantially improve their quality and reliability. Poka Yoke can be considered an extension of FMEA. The use of simple Poka Yoke ideas and methods in product and process design eliminates both human and mechanical errors. Ultimately, both FMEA and Poka Yoke methodologies result in zero defects and benefit either the end or the next-in-line customer. The first concept of Poka Yoke emphasizes elimination of the cause or occurrence of the error that creates the defects by concentrating on the cause of the error in the process. The defect is prevented by stopping the line or the machine when the root cause of the defect is triggered or detected. The second concept of Poka Yoke focuses on the effectiveness of the detection system. The foolproof detection system eliminates the defect or detects the error that causes defects. The implementation of the Poka Yoke concept in a foolproof detection system eliminates the possibility that error or defects will slip through the process and reach the customer

Spc technigues in the non – manufacturing areas

In order for the company to maintain optimal process stability to make continuous improvements in order to survive and thrive, management needs to know and use certain tools and methods in quality management. Organizations which embrace the TQM concepts should recognize the value of SPC techniques in areas such as sales, purchasing, invoicing, finance, distribution, training, etc., which are outside production or operations – the traditional area for SPC use. A Pareto analysis, a histogram, a flow chart, or a control chart is a vehicle for communication. Statistical Quality Control (SPC) is a term used to describe the set of statistical tools used by quality professionals. Before start a new business (start-up) should be the right study for feasibility and profitability (feasibility study) and business plan for banks or potential investors in order to secure financing. Statistics can be used to come up with a practical business plan with which will be of interest to potential partners or financial institutions. Ways of using statistical data are: control, storage-archiving and retrieval. When using it is necessary to take into account the wide range of needs such as: the need for users, data quality, complete data inventory when entering documents, data protection and security, comparability of data over a period of time, timeliness of final data, financial implication, public understanding and acceptance

Implementing Lean Warehousing model to increase on time and in full of an SME commercial company: a research in Perú

The commercial sector currently has high demands for fast and accurate delivery of orders; however, there is a trend of increasing customer dissatisfaction that directly impacts product returns; this is mainly related to the logistics process of warehouse management. Therefore, a model was developed using the Lean Warehousing methodology and analysis tools, including Poka Yoke, 5S, Standard Work, Multi-criteria ABC, and Kardex. The case study is about an SME footwear importer and trader in Peru. A model was developed to improve the underperformance of correct and on-time delivery orders (OTIF). The research shows the improvement of the On Time index to 80.73%, In Full to 86.46%, and OTIF to 69.80%. The proposed model was implemented through a pilot and simulated through Arena software. This research demonstrates that the application of the Lean methodology together with analysis tools is viable for the improvement of processes in the warehouse area with optimal results, so this research can contribute as a guide to lay the foun- dations for improvement in SME trading companies with similar problems in the quality of delivery of orders, which by the growth they need to improve their level of service continuously

Applying Lean Six Sigma Concepts to Improve Fee Billing Processes

The purpose of this project was to analyze the impact of applying Six Sigma concepts to solve redundancy issues in corporate trust operations. It is an assessment that was performed in the key operational fee processing unit in the Corporate Trust Services (CTS) department in a fortune 500 company. The project focused on the daily administration of fees including: set up, invoicing, collections, supporting comments for fee adjustments, waivers, accurate termination of account fees in key systems of record and business procedures relating to the collection of these fees. The assessment included all Corporate Trust Service business lines and products and the time period in scope was March 1st, 2016 through June 15th, 2016. In this project the DMAIC methodology was used to reduce the number of invoice adjustments and Six Sigma techniques were used to analyze and improve their issues at hand. The results of the project indicate that Six Sigma can positively impact organizational performance by reducing or eliminating redundancies and increasing efficiency. Through the deployment of a poka-yoke system key changes were able to be recommended to facilitate the changes needed

A Study of the Design and Manufacturing of an Elevated Dog Feeder

ABSTRACT The senior capstone which students in the Center for Manufacturing Excellence program partake in was the basis for project. The Dog Box is an elevated dog feeder with an internal food storage compartment. It was designed for medium to large dogs, and can hold over 40 lbs of dog food. The internal storage compartment has drawer access and contains a plastic tote that will hold the food. The purpose of the design was to create an aesthetically pleasing elevated dog feeder that would double as a storage device, and elevated feeding can help prevent health issues in large dog breeds. There were four different design iterations before the fourth and final design was confirmed. The final design featured a wooden exterior with a polyurethane finish, two bowls, a laser engraving, two satin nickel knobs, and a soft close drawer which contained the plastic tote. The manufacturing process utilized a panel saw, radial arm saw, table saw, table saw with a dado blade, finish nailer, brad nailer, impact driver, laser engraver, waterjet cutter, hand sander, and a vacuum. Multiple fixtures and poka yokes were used throughout the process to improve manufacturability, efficiency, and quality. A quality product was created within the scope, cost, and time of the project

A customised lean model for a Chinese aerospace OEM (Original Equipment Manufacturer)

The aim of this research is to introduce Lean Thinking in a systematic and cost effective way; moreover, it is to bring Lean Principles and apply Lean Tools to the new aerospace companies. In particular the research will develop a customised Lean manufacturing model. The following objectives will be achieved during the research. 1); Investigate the principal features of Lean Thinking, and identify state of the art in Lean manufacturing implementation. 2); Identify the current situation of a specific Chinese aerospace company and the requirements needed in becoming Lean. 3); Develop a customised Lean model for applying Lean into a new Chinese aerospace company. 4); Validate the Lean manufacturing model by experts in the company and university. The Chinese traditional thinking is different from lean think. Therefore, to implement Lean in China will face some distinct barriers. The author attempts to resolve these problems through a customised lean model. According to the literature review and researcher‘s knowledge, there is no paper developing a model linking to the barriers of lean implementation in Chinese manufacturing. Therefore, the author will attempt to fill in this gap during the research. The questionnaire and assessment tool will be used to collect information from the company. Best practices will help to establish the structure of the model. However, in China, most companies implement lean through copying examples from the United States, UK and other Western countries without combining their current situation and culture. The contribution of this research is to develop a model to link Chinese barriers and a company‘s situation for lean implementation. Finally, this model will be validated by company and academic experts. The first validation is based on the sponsoring company. Other validations are achieved by academic experts and industrial expert