IRJET- Review Paper on “Productivity Improvement by using Poka-Yoke”

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https://irjet.net/archives/V5/i12/IRJET-V5I12139.pdf

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 761
Pankaj Soni1, Tarun Yadav2
1PG Scholar, Department of Mechanical Engineering, Babulal Tarabai Institute of Research and Technology, Sagar,
Madhya Pradesh, India
2Asst. Professor, Department of Mechanical Engineering, Babulal Tarabai Institute of Research and Technology,
Sagar, Madhya Pradesh, India
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract - Dismissal of made parts at different phases of
assembling can't go on without serious consequences now
days underway situation because of extreme rivalry around
the world. All assembling businesses are moving toward zero
deformity generation. To execute this, the first and most
critical thing which is being finished by the assembling
ventures is to keep the blunder or totally wipe out the mistake
with the utilization of some demonstrated methods. Pokayoke
is one of the techniques and this paper focuses on an
application of this technique on a cutting handling tool of a
liner cutting machine at a cell in liner manufacturing
company. As a study of the application of poka yoke on a liner
cutting machine, possibility of liner mouth misalignment to
prevent the rejection and increase the productivity.
Key Words: Productivity, Poka- yoke, Liner, Zero defects,
Mistake, Improvement.
1. INTRODUCTION
These days, every single organization needs benefit, high
efficiency and esteem in market. There are mottos in many
industrial facilitiesexpressingimperfectiondecreasetargets,
however a definitive point ought to dependably be zero
deformities. "POKA-YOKE" is an indispensable factor in
taking out deformities. Poka-yoke is an idea in absolute
quality administration which is identified with limiting
mistakes at source itself. It manages "trick sealing" or
"oversight sealing".
1.1 Poka-yoke
A poka-yoke is any thought ageorsystemadvancementin an
aggregate gainful administration process that causes
administrator to maintain a strategic distancefrom(yokeru)
botches (poka). Principle point of Poka Yoke idea is to make
entire framework blunder verification that implies nobody
can commit error albeit somebody needs to commit errors
deliberately. It kills the imperfections or shortcomings.
This term was begat by Shigeo Shingo in 1960s for the
piece of Toyota ProductionSystem.ThepointofPoka-yokeis
to structure the procedure with thegoal thatmisstepscan be
identified and remedied promptly, dispensing with
deformities at the source.
1.2 Developing of poka-yoke
An orderly way to deal with develops Poka-Yoke
countermeasures which comprise in a three stage
investigation of the dangers to be overseen:
1. Identification of the need
2. Identification of possible mistakes
3. Management of mistakes before satisfying the need.
These means are contemplated while considering execution
of Poka Yoke framework in any field since this approach
stays same at all the circumstances and conditions. [1]
Example: -
Example: - Side light indicator on dashboard in bikes.
In day time if you are riding your bike so you can’t see that
the indicator is turn on or off. At night it’s as much as simple
as sugar in tea. But now a days you can see a sidelight
indicator on dashboard in each bikes. If the light is turn on it
automatically turn on with it. A buzzer technique is also in
market but some of the bike company not allowing it to use
now. Just because of high battery consumption. This
decreases the accident on ways. If you don’t want to take
turn but your vehicle is showing that you are taking turn so
it can be an accident due to this we can easily see our vehicle
indicator is turn on or not properly. You can see in fig no. 01
that the indicators are properly off and in another fig no. 02
you can see the left indicator is turn on (blinking). Thatisthe
perfect example for poka yoke system. This helpsustoavoid
mistake which we don’t want to create by own.
Fig -1: Indicator off
Review Paper on “Productivity Improvement by using Poka-Yoke”
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 762
Fig -2: Indicator on
2. History
The Poka-Yoke method was introduced by Shigeo Shingo in
1961, when he was one of the engineers Toyota Motor
Corporation. This method, in others Words are used to
prevent original errors and errors in error. [2]
Shigeo Shingo, born in the city of Saga, Japan, Japanese
industrial engineer who distinguished himself as one of the
world's leading expertsinToyota productionandproduction
practices System. Then start in Japanese. Organizations to
implement a Zero Quality Control (ZQC). One of its elements
that implement the ZQC principle is the Poka-Yoke method.
The name Poka-Yoke was founded by ShigeoShingoin1963,
translates as "resistance to errors". Avoid (yoke) errors
deriving from the absence of the mind (Poka). The initial
term was "baka-yoke", which it means "infallible". Thisterm
"baka-yoke" was dishonorable connotation. Therefore, the
term was changed to poka-yoke, whichmeans"error-proof".
In the course of repetitive operations that depend in
surveillance or memory, the Poka-yoke can save time and
free the mind of the worker who forms stress. In each one
Product life cycle phase, in every processes in its operations
there is the possibility of errors. In As a result of errors, the
final product has defects and thecustomerisdissatisfiedand
disappointed. The Poka-Yoke method is based on the
practicality of it is not acceptable to produce evenverysmall
Amount of defectiveproducts.Forcompanies,100%product
production without defects. Not just a challenge, but a
necessity. Poka Yoke The method is a simple technique that
allows you to reach this production. [3, 4, 5,]
3. NEED
Defects or production errors are always the key concerns of
any manufacturing industry. Thesuccessofanyorganization
depends on quality of product particularly correct product.
poka-yoke It refers to techniques that make it impossible
Making mistakes When an organization decides implement
lean production then one of the goal is to reduce waste
because nobody is interested in compensating for extra
inventory in scrap account. Toincreasetheprofitpercentage
of the Cost pressures always turn into a headache forthetop
management so as to never accept continued Errors such as
waste, rework, out of tolerance, etc. Instead, they are trying
to reach the value of zero in this segment when customers of
any company buy the product that rightly expects without
flaws products and 100% conventional inspection o
Statistical process control does not guarantee 100%.
Products free from defects. So, we need to Reach the root
cause of any problem and avoid. What gives us product
without defects? [6] Poka-yoke is one of the "good"
presentations kaizen, or continuous improvement Because
of its preventive nature. A poka-yoke Device or solution is a
mechanism or an idea that or avoid the mistake of being
done either makes the error easily detectable at a glance.
The ability to find errors at a glance is important because, as
Shingo says, "the causes of faults lie. In the errors of the
workers, and the defects are the results of neglect these
errors. It follows those errors they will not become faults if
the worker's mistakes are discovered and eliminated in
advance. Even he adds to this that “defects arise because
mistakes are made” both have a cause and effect
relationship. However, errors will not become defects if the
feedback is action in the error phase. Therefore, it is an
effective approach to apply mechanisms to avoid making
mistakes right now occur. [7]
4. Literature review: -
Everyone is working to remove the defect from his
organization. A poka yoke system is invented for a gear
industry. The problem which is eliminated that is the long
hole while doing drilling operation on a part. We know in
every plate there are always 2 sides. So they want to do
drilling only one side but sometimes it’s happening both the
side just because of this the parts gets fail so they fix a
drilling fixture in that tool so the tool gets inside only
according to that we want. First of all theydidresearchon all
the aspect of errors then what is the exact issue then resolve
this by using poka yoke. [8]
An air duct manufacturing company got some points to
eliminate the errors and by using poka yoke system in his
company. The problem was rejection of manufactured duct
after delivered to the customer. The duct is made by
moulding process so some excess material remains on that
the workers will remove that by sharp knifes but some time
it remains same and product delivered to the customer so
they use poka yoke for that. They maintain the defected
piece at initial stage of defect. So that it will never go in
second stage if its defected. It only goes in second process
once it will perfect for the current process. They called it
continues improvement. [9]
5. Reasearch methodology: -
Every organization is working for zero defects as we all
know it’s not possible to eliminate the entire defect at the
same time. So at this time I found some production process
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 763
errors which are responsible for low production.Acompany
is making liner which is used in Flexible intermediate bulk
container (FIBC) or can say in bulk bag. Thisstudyisbeingin
a liner sealing department. The liner is a packetwhichcanbe
hollow and can be one side shield and it’s made up of LLDPE
the full form of this is liner low density polyethylene. They
are of heavy size. So while cutting the film by hand makes
some defect in the liner means the mouth of the liner is not
proper due to it many of the liner get wasted or we need to
do rework on that which consume more time on this as we
all know that if we are doing rework then it’s again using the
time on the product which should be perfect in previous
time. The liner mouth perfection is totally depends on
workers skill. Now they did the work with the use of scissor
by holding the liner in hand. So we are eliminating the
rework and product wastage percentage by usingpoka yoke
method.
5. Expected overcome
The aim of Poka-Yoke method is to eliminate or minimize
human errors in manufacturing processes and management
as a result of mental and physical human imperfections. For
the main part is to eliminate errors independent. The main
idea of this method is preventing causes,whichmayresult in
errors and use relatively cheap control system for
determining compliance of the product with the model.
According to the advantages which we found on the study
we can easily increase the production by 10-20 percentages
by using this technique. The poka yoke is also helping us to
decreasing the wastage percentages. We expect that poka
yoke will help to improve the productivity of the company.
Step by step approach.
1- Indentify the error.
2- Finding the root cause.
3- Find the resolutions
4- Find the best way to resolve it.
5- Implement the invented poka yoke technique.
6- See the result and check the perfections.
REFERENCES
[1] Aishwarya J. Kurhade “REVIEW ON POKA-YOKE:
TECHNIQUE TO PREVENT DEFECTS” INTERNATIONAL
JOURNAL OF ENGINEERING SCIENCES & RESEARCH
TECHNOLOGY ISSN: 2277-9655 November, 2015.
[2] M. Dudek-Burlikowska, D. Szewieczek “The Poka-Yoke
method as an improving quality tool of operationsinthe
process”
[3] J. Ketola, K. Roberts, Demystifing ISO 9001:2000 – part
2, „Quality Progress”, 34/10 (2001).
[4] H. àachajczyk, M. Dudek-Burlikowska, Quality
continuous improvement of company with usage the
Poka-Yoke methods, PSKN 7/2006, 57-64, (in Polish).
[5] Shinto S., Zero Quality Control: Source Inspection and
the Poka– Yoke System, Cambridge, MA: Productivity
Press, 1986.
[6] Patel Parikshit K, Vidya Nair, Patel Nikunj S “A Review
on use of Mistake Proofing (Poka Yoke) Tool in Blow
Molding Process”
[7] Mr. Parikshit S. Patil; Mr. Sangappa P. Parit; Mr. Y.N.
Burali “Poka Yoke: The Revolutionary Idea In Total
Productive Management”
[8] Yash Dave, Dr. Nagendra Sohani“IMPLEMENTATION OF
POKA-YOKE TECHNIQUE IN A GEAR INDUSTRY”.
International Journal of Latest Research in Science and
Technology Volume 4, Issue 3: Page No.32-33,May-June
2015.
[9] Mr. Sujay Biswas, Dr. Abhijit Chakraborty “Using Poka -
Yoke for the Development of SMEs” American Journal of
Engineering Research (AJER) e-ISSN:2320-0847p-ISSN
: 2320-0936 Volume-5, Issue-9, pp-15-18
BIOGRAPHIES
Mr. PANKAJ SONI
Pursuing Master Of Engineering in
Industrial Engineering &
Management from Babulal Tarabai
Institute of Research and
Technology, Sagar, India
Mr. TARUN KUMAR YADAV
Currently working as an Assistant
Professor at Babulal Tarabai
Institute of Research and
Technology, Sagar (M.P). He
Completed Master Of Engineering
in Industrial Engineering &
Management (IET), Indore, India.
His research area includes
Operation Management, total
quality Management, Supply Chain
Management

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IRJET- Review Paper on “Productivity Improvement by using Poka-Yoke”

  • 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 761 Pankaj Soni1, Tarun Yadav2 1PG Scholar, Department of Mechanical Engineering, Babulal Tarabai Institute of Research and Technology, Sagar, Madhya Pradesh, India 2Asst. Professor, Department of Mechanical Engineering, Babulal Tarabai Institute of Research and Technology, Sagar, Madhya Pradesh, India ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - Dismissal of made parts at different phases of assembling can't go on without serious consequences now days underway situation because of extreme rivalry around the world. All assembling businesses are moving toward zero deformity generation. To execute this, the first and most critical thing which is being finished by the assembling ventures is to keep the blunder or totally wipe out the mistake with the utilization of some demonstrated methods. Pokayoke is one of the techniques and this paper focuses on an application of this technique on a cutting handling tool of a liner cutting machine at a cell in liner manufacturing company. As a study of the application of poka yoke on a liner cutting machine, possibility of liner mouth misalignment to prevent the rejection and increase the productivity. Key Words: Productivity, Poka- yoke, Liner, Zero defects, Mistake, Improvement. 1. INTRODUCTION These days, every single organization needs benefit, high efficiency and esteem in market. There are mottos in many industrial facilitiesexpressingimperfectiondecreasetargets, however a definitive point ought to dependably be zero deformities. "POKA-YOKE" is an indispensable factor in taking out deformities. Poka-yoke is an idea in absolute quality administration which is identified with limiting mistakes at source itself. It manages "trick sealing" or "oversight sealing". 1.1 Poka-yoke A poka-yoke is any thought ageorsystemadvancementin an aggregate gainful administration process that causes administrator to maintain a strategic distancefrom(yokeru) botches (poka). Principle point of Poka Yoke idea is to make entire framework blunder verification that implies nobody can commit error albeit somebody needs to commit errors deliberately. It kills the imperfections or shortcomings. This term was begat by Shigeo Shingo in 1960s for the piece of Toyota ProductionSystem.ThepointofPoka-yokeis to structure the procedure with thegoal thatmisstepscan be identified and remedied promptly, dispensing with deformities at the source. 1.2 Developing of poka-yoke An orderly way to deal with develops Poka-Yoke countermeasures which comprise in a three stage investigation of the dangers to be overseen: 1. Identification of the need 2. Identification of possible mistakes 3. Management of mistakes before satisfying the need. These means are contemplated while considering execution of Poka Yoke framework in any field since this approach stays same at all the circumstances and conditions. [1] Example: - Example: - Side light indicator on dashboard in bikes. In day time if you are riding your bike so you can’t see that the indicator is turn on or off. At night it’s as much as simple as sugar in tea. But now a days you can see a sidelight indicator on dashboard in each bikes. If the light is turn on it automatically turn on with it. A buzzer technique is also in market but some of the bike company not allowing it to use now. Just because of high battery consumption. This decreases the accident on ways. If you don’t want to take turn but your vehicle is showing that you are taking turn so it can be an accident due to this we can easily see our vehicle indicator is turn on or not properly. You can see in fig no. 01 that the indicators are properly off and in another fig no. 02 you can see the left indicator is turn on (blinking). Thatisthe perfect example for poka yoke system. This helpsustoavoid mistake which we don’t want to create by own. Fig -1: Indicator off Review Paper on “Productivity Improvement by using Poka-Yoke”
  • 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 762 Fig -2: Indicator on 2. History The Poka-Yoke method was introduced by Shigeo Shingo in 1961, when he was one of the engineers Toyota Motor Corporation. This method, in others Words are used to prevent original errors and errors in error. [2] Shigeo Shingo, born in the city of Saga, Japan, Japanese industrial engineer who distinguished himself as one of the world's leading expertsinToyota productionandproduction practices System. Then start in Japanese. Organizations to implement a Zero Quality Control (ZQC). One of its elements that implement the ZQC principle is the Poka-Yoke method. The name Poka-Yoke was founded by ShigeoShingoin1963, translates as "resistance to errors". Avoid (yoke) errors deriving from the absence of the mind (Poka). The initial term was "baka-yoke", which it means "infallible". Thisterm "baka-yoke" was dishonorable connotation. Therefore, the term was changed to poka-yoke, whichmeans"error-proof". In the course of repetitive operations that depend in surveillance or memory, the Poka-yoke can save time and free the mind of the worker who forms stress. In each one Product life cycle phase, in every processes in its operations there is the possibility of errors. In As a result of errors, the final product has defects and thecustomerisdissatisfiedand disappointed. The Poka-Yoke method is based on the practicality of it is not acceptable to produce evenverysmall Amount of defectiveproducts.Forcompanies,100%product production without defects. Not just a challenge, but a necessity. Poka Yoke The method is a simple technique that allows you to reach this production. [3, 4, 5,] 3. NEED Defects or production errors are always the key concerns of any manufacturing industry. Thesuccessofanyorganization depends on quality of product particularly correct product. poka-yoke It refers to techniques that make it impossible Making mistakes When an organization decides implement lean production then one of the goal is to reduce waste because nobody is interested in compensating for extra inventory in scrap account. Toincreasetheprofitpercentage of the Cost pressures always turn into a headache forthetop management so as to never accept continued Errors such as waste, rework, out of tolerance, etc. Instead, they are trying to reach the value of zero in this segment when customers of any company buy the product that rightly expects without flaws products and 100% conventional inspection o Statistical process control does not guarantee 100%. Products free from defects. So, we need to Reach the root cause of any problem and avoid. What gives us product without defects? [6] Poka-yoke is one of the "good" presentations kaizen, or continuous improvement Because of its preventive nature. A poka-yoke Device or solution is a mechanism or an idea that or avoid the mistake of being done either makes the error easily detectable at a glance. The ability to find errors at a glance is important because, as Shingo says, "the causes of faults lie. In the errors of the workers, and the defects are the results of neglect these errors. It follows those errors they will not become faults if the worker's mistakes are discovered and eliminated in advance. Even he adds to this that “defects arise because mistakes are made” both have a cause and effect relationship. However, errors will not become defects if the feedback is action in the error phase. Therefore, it is an effective approach to apply mechanisms to avoid making mistakes right now occur. [7] 4. Literature review: - Everyone is working to remove the defect from his organization. A poka yoke system is invented for a gear industry. The problem which is eliminated that is the long hole while doing drilling operation on a part. We know in every plate there are always 2 sides. So they want to do drilling only one side but sometimes it’s happening both the side just because of this the parts gets fail so they fix a drilling fixture in that tool so the tool gets inside only according to that we want. First of all theydidresearchon all the aspect of errors then what is the exact issue then resolve this by using poka yoke. [8] An air duct manufacturing company got some points to eliminate the errors and by using poka yoke system in his company. The problem was rejection of manufactured duct after delivered to the customer. The duct is made by moulding process so some excess material remains on that the workers will remove that by sharp knifes but some time it remains same and product delivered to the customer so they use poka yoke for that. They maintain the defected piece at initial stage of defect. So that it will never go in second stage if its defected. It only goes in second process once it will perfect for the current process. They called it continues improvement. [9] 5. Reasearch methodology: - Every organization is working for zero defects as we all know it’s not possible to eliminate the entire defect at the same time. So at this time I found some production process
  • 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 12 | Dec 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 763 errors which are responsible for low production.Acompany is making liner which is used in Flexible intermediate bulk container (FIBC) or can say in bulk bag. Thisstudyisbeingin a liner sealing department. The liner is a packetwhichcanbe hollow and can be one side shield and it’s made up of LLDPE the full form of this is liner low density polyethylene. They are of heavy size. So while cutting the film by hand makes some defect in the liner means the mouth of the liner is not proper due to it many of the liner get wasted or we need to do rework on that which consume more time on this as we all know that if we are doing rework then it’s again using the time on the product which should be perfect in previous time. The liner mouth perfection is totally depends on workers skill. Now they did the work with the use of scissor by holding the liner in hand. So we are eliminating the rework and product wastage percentage by usingpoka yoke method. 5. Expected overcome The aim of Poka-Yoke method is to eliminate or minimize human errors in manufacturing processes and management as a result of mental and physical human imperfections. For the main part is to eliminate errors independent. The main idea of this method is preventing causes,whichmayresult in errors and use relatively cheap control system for determining compliance of the product with the model. According to the advantages which we found on the study we can easily increase the production by 10-20 percentages by using this technique. The poka yoke is also helping us to decreasing the wastage percentages. We expect that poka yoke will help to improve the productivity of the company. Step by step approach. 1- Indentify the error. 2- Finding the root cause. 3- Find the resolutions 4- Find the best way to resolve it. 5- Implement the invented poka yoke technique. 6- See the result and check the perfections. REFERENCES [1] Aishwarya J. Kurhade “REVIEW ON POKA-YOKE: TECHNIQUE TO PREVENT DEFECTS” INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY ISSN: 2277-9655 November, 2015. [2] M. Dudek-Burlikowska, D. Szewieczek “The Poka-Yoke method as an improving quality tool of operationsinthe process” [3] J. Ketola, K. Roberts, Demystifing ISO 9001:2000 – part 2, „Quality Progress”, 34/10 (2001). [4] H. àachajczyk, M. Dudek-Burlikowska, Quality continuous improvement of company with usage the Poka-Yoke methods, PSKN 7/2006, 57-64, (in Polish). [5] Shinto S., Zero Quality Control: Source Inspection and the Poka– Yoke System, Cambridge, MA: Productivity Press, 1986. [6] Patel Parikshit K, Vidya Nair, Patel Nikunj S “A Review on use of Mistake Proofing (Poka Yoke) Tool in Blow Molding Process” [7] Mr. Parikshit S. Patil; Mr. Sangappa P. Parit; Mr. Y.N. Burali “Poka Yoke: The Revolutionary Idea In Total Productive Management” [8] Yash Dave, Dr. Nagendra Sohani“IMPLEMENTATION OF POKA-YOKE TECHNIQUE IN A GEAR INDUSTRY”. International Journal of Latest Research in Science and Technology Volume 4, Issue 3: Page No.32-33,May-June 2015. [9] Mr. Sujay Biswas, Dr. Abhijit Chakraborty “Using Poka - Yoke for the Development of SMEs” American Journal of Engineering Research (AJER) e-ISSN:2320-0847p-ISSN : 2320-0936 Volume-5, Issue-9, pp-15-18 BIOGRAPHIES Mr. PANKAJ SONI Pursuing Master Of Engineering in Industrial Engineering & Management from Babulal Tarabai Institute of Research and Technology, Sagar, India Mr. TARUN KUMAR YADAV Currently working as an Assistant Professor at Babulal Tarabai Institute of Research and Technology, Sagar (M.P). He Completed Master Of Engineering in Industrial Engineering & Management (IET), Indore, India. His research area includes Operation Management, total quality Management, Supply Chain Management