Poka-Yoke

by Nikkan Kogyo Shimbun

Author	: Nikkan Kogyo Shimbun
Publisher	: CRC Press
Total Pages	: 310
Release	: 1989-02-01
Genre	: Business & Economics
ISBN	: 9780915299317

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If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole. The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants. The book: Organizes examples according to the broad issue or problem they address. Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes. Provides sample improvement forms for you to sketch out your own ideas. Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)

Zero Quality Control

by Shigeo Shingo

Author	: Shigeo Shingo
Publisher	: Taylor & Francis
Total Pages	: 330
Release	: 2021-12-16
Genre	: Business & Economics
ISBN	: 135140394X

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A combination of source inspection and mistake-proofing devices is the only method to get you to zero defects. Shigeo Shingo shows you how this proven system for reducing errors turns out the highest quality products in the shortest period of time. Shingo provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement. He also discusses inspection systems, quality control circles, and the function of management with regard to inspection.

Applied Problem Solving

by Ivan Fantin

Author	: Ivan Fantin
Publisher	: Ivan Fantin
Total Pages	: 231
Release	: 2014-04-23
Genre	: Business & Economics
ISBN	: 1499122284

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Have you ever solved problems which then recur again and again? Have you ever thought about the benefits you may have from learning a practical approach to clarify complex scenarios? Do you know the rule to build up effective countermeasures? APS is now in its second edition with more content and more examples. Aps is the Methodology of Problem Solving which combines an easy application to real problems and an outstanding effectiveness in finding reliable solutions to avoid the same problems from recurring in the future. The book takes the readers through the methodology by directly working on their own problems, with a lot of real examples and useful check points. Applied Problem Solving collects years of experience of those who have had to use and adapt methods of problem solving in order to achieve operational excellence and management successes. This whole experience has been transformed into a robust mental pathway full of insights, ideas and innovative models useful to apply the art of Problem Solving. The application of Problem Solving needs innovative approaches and methods that this volume aims to present in a clear, concise and effective way, also with the aid of several case studies borrowed from different real every-day life scenarios.

The Quality Toolbox

by Nancy Tague

Author	: Nancy Tague
Publisher	: Quality Press
Total Pages	: 625
Release	: 2004-07-14
Genre	: Business & Economics
ISBN	: 1953079008

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The Quality Toolbox is a comprehensive reference to a variety of methods and techniques: those most commonly used for quality improvement, many less commonly used, and some created by the author and not available elsewhere. The reader will find the widely used seven basic quality control tools (for example, fishbone diagram, and Pareto chart) as well as the newer management and planning tools. Tools are included for generating and organizing ideas, evaluating ideas, analyzing processes, determining root causes, planning, and basic data-handling and statistics. The book is written and organized to be as simple as possible to use so that anyone can find and learn new tools without a teacher. Above all, this is an instruction book. The reader can learn new tools or, for familiar tools, discover new variations or applications. It also is a reference book, organized so that a half-remembered tool can be found and reviewed easily, and the right tool to solve a particular problem or achieve a specific goal can be quickly identified. With this book close at hand, a quality improvement team becomes capable of more efficient and effective work with less assistance from a trained quality consultant. Quality and training professionals also will find it a handy reference and quick way to expand their repertoire of tools, techniques, applications, and tricks. For this second edition, Tague added 34 tools and 18 variations. The "Quality Improvement Stories" chapter has been expanded to include detailed case studies from three Baldrige Award winners. An entirely new chapter, "Mega-Tools: Quality Management Systems," puts the tools into two contexts: the historical evolution of quality improvement and the quality management systems within which the tools are used. This edition liberally uses icons with each tool description to reinforce for the reader what kind of tool it is and where it is used within the improvement process.

Poka-yoke (Spanish)

by H. Hirano

Author	: H. Hirano
Publisher	: Routledge
Total Pages	: 316
Release	: 2017-10-06
Genre	: Business & Economics
ISBN	: 1351423770

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Muchas cosas pueden ir mal en un entorno de trabajo. Cada dia hay oportunidades para cometer errores que resultaran en defectos. Los defectos son despilfarro y, si no se descubren, frustran las espectativas del cliente sobre la calidad. Detras del poka-yoke esta la conviccion de que no es aceptable producir incluso un pequeno numero de articulos defectuosos. Durante mas de 200 visitas a fbricas Japonesas, Productivity ha presenciado el impacto de simples mecanismos poka-yoke instalados por los propios trabajadores para evitar la ocurrencia de defectos. En este libro, 240 ejemplos poka-yoke despertaran su imaginacion para planificar e implantar sistemas de prevencion de errores.Contenido:Errores de proceso Errores de montaje Errores de ensamble Inclusion de items erroneos Errores de insercion Omisiones en montaje Omisiones en proceso Errores de medicion Errores dimensionales Omision de operaciones Errores de operacion Errores de pegado Errores de inspeccion Errores de cableado Errores de pintura Errores de impresion Desalineamientos Errores en preparacion de mquinas Errores de embalaje Desajuste de plantillas y utiles Errores de lavado Problemas miscelaneos

A Study of the Toyota Production System

by Shigeo Shingo

Author	: Shigeo Shingo
Publisher	: CRC Press
Total Pages	: 306
Release	: 1989-10-01
Genre	: Business & Economics
ISBN	: 9780915299171

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This is the "green book" that started it all -- the first book in English on JIT, written from the engineer's viewpoint. When Omark Industries bought 500 copies and studied it companywide, Omark became the American pioneer in JIT. Here is Dr. Shingo's classic industrial engineering rationale for the priority of process-based over operational improvements in manufacturing. He explains the basic mechanisms of the Toyota production system, examines production as a functional network of processes and operations, and then discusses the mechanism necessary to make JIT possible in any manufacturing plant. Provides original source material on Just-ln-Time Demonstrates new ways to think about profit, inventory, waste, and productivity Explains the principles of leveling, standard work procedures, multi-machine handling, supplier relations, and much more If you are a serious student of manufacturing, you will benefit greatly from reading this primary resource on the powerful fundamentals of JIT.

Improving Production with Lean Thinking

by Javier Santos

Author	: Javier Santos
Publisher	: John Wiley & Sons
Total Pages	: 260
Release	: 2015-03-24
Genre	: Technology & Engineering
ISBN	: 1119120268

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Unique coverage of manufacturing management techniques--complete with cases and real-world examples. Improving Production with Lean Thinking picks up where other references on production processes leave off. It is increasingly important to integrate and systematize lean thinking throughout production/manufacturing and the supply chain because the market is becoming more competitive, products are becoming more complex, and product life is getting shorter and shorter. With a practical focus, this book encompasses the science and analytical background for improving manufacturing, control, and design. It covers specific methodologies and tools for: * Material flow and facilities layout, including a six step layout design process * The design of cellular layouts * Analyzing and improving equipment efficiency, including Poka-Yoke, motion study, maintenance, SMED, and more * Environmental improvements, including 5S implementation With real-life case studies of successful European and American approaches to lean manufacturing, this reference is ideal for engineers, managers, and researchers in manufacturing and production facilities as well as students. It bridges the gap between production/manufacturing and supply chain techniques and provides a detailed roadmap to improved factory performance.

Make No Mistake!

by C. Martin Hinckley

Author	: C. Martin Hinckley
Publisher	: CRC Press
Total Pages	: 424
Release	: 2001-09-30
Genre	: Business & Economics
ISBN	: 9781563272271

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With C. Martin Hinckley's new book Make No Mistake! An Outcome Based Approach to Mistake-Proofing, that vision can become a reality. If you work for a company that emphasizes traditional quality control methods, it's unlikely that you've seen defects eliminated despite your substantial efforts. Make No Mistake! clarifies the reasons why such traditional methods fail and shows how world-class quality can be achieved at a minimal cost through mistake-proofing — the practice of controlling virtually every source of potential errors. As the author states, "The great value of mistake-proofing is that, independent of the cause, psychological factor, production stage, or potential consequences, it blocks or warns about an undesired outcome at a point in the process when the consequences can be minimized." Truly the first of its kind, Make No Mistake! is a compendium of the best methods for reducing complexity, variation, confusion and the other root causes of defects — but the centerpiece of this powerful mistake-proofing tool is an outcome-based classification system that focuses on preventing rather than detecting defects. Even more importantly, Hinckley's mistake-proofing documentation forms will help you adapt this methodology to your own defect prevention efforts. Make No Mistake! is an amazing compilation of mistake-proofing tools that is encyclopedic in scope. Because mistake-proofing is a skill that improves through familiarity with previous solutions, Hinckley's new classification systems is the key to rapidly finding outstanding solutions to current problems on the shop floor. Make No Mistake! is one book that will be invaluable in your company's quest for quality. Make No Mistake! includes: Over 200 mistake-proofing examples from varied industries Easy-to-use mistake-proofing documentation forms you can use on the job Introduction to principles of mistake-proofing and design for assembly A quick, step-by-step methodology for developing superior mistake-proofing concepts Listing of select suppliers of mistake-proofing devices

Lean Lexicon

by John Shook

Author	: John Shook
Publisher	: Lean Enterprise Institute
Total Pages	: 184
Release	: 2014-01-21
Genre	: Business & Economics
ISBN	: 1934109460

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With 14 new definitions touching on management, healthcare, startups, manufacturing, and service, the 5th edition of the Lean Lexicon, is the most comprehensive edition yet of the handy and practical glossary for lean thinkers. The latest Lexicon, updated in 2014, contains 60+ graphics and 207 terms from A3 Report to Yokoten. The Lexicon covers such key lean terms as andon, jidoka, kaizen, lean consumption, lean logistics, pull, plan-for- every-part, standardized work, takt time, value-stream mapping, and many more. The new terms are: • Basic Stability • Coaching • Gemba Walk • Huddle • Kamishibai Board • Kata • Leader Standard Work • Lean Management • Lean Management Accounting • Lean Startup • Problem Solving • Service Level Agreement • Training Within Industry (TWI) • Value-stream Improvement Unlike most other business glossaries in print or online, the Lexicon, introduced in January 2003, is focused exclusively on lean thinking and practice. Like the past four, the fifth edition of the Lean Lexicon incorporates terms and improvement ideas from our customers. We continue to welcome suggestions from the growing lean community in its traditional industries and beyond.