Duration
2 days
Overview
This course intends to explore the most effective method in ensuring quality. As defects always created from
manufacturing or operation errors, preventing errors is the best mean and approach to eliminate defect. In fact,
Poka Yoke is one of the most effective and efficient method to achieve “Zero Defect” manufacturing and quality.
We will conduct this workshop with examples from the production lines and real life application.
Objectives
After the training session, the participants should be able to:
- Understand what is Poka Yoke.
- Apply Poka Yoke concepts where applicable.
- Apply source inspection techniques in manufacturing processes.
- Differentiate the various types of quality control systems such as SPC, Inspection, Poka Yoke.
- Understand and expose to different function of Poka Yoke such as orientation etc.
Contents
- 1. Challenges for today's company.
* Competition for survival.
* Quality, Productivity and Profits.
* Quality Control methods.
# Inspection.
# Process Control.
# Quality Systems.
- 2. Introduction to Poka-Yoke.
* Definition of Poka-Yoke.
* Effect and characteristics of Poka-Yoke.
* Types of manufacturing errors.
* Types of Human Error in Loading and Handling Processes.
** Examples of mishandling
** Examples of Negligence
** Examples of Difficult Loading Process
** Examples of Process Created Problems resulting Human Mistakes and Rejects
*** Workshop : Your Examples.
- 3. Zero Quality Control System.
* Components of a zero quality control system.
* Poka-Yoke techniques application.
- 4. Improvement process.
* Fundamentals of improvement process.
* Application of statistics in improvement process.
* Stratification and classification of defects.
* Deriving improvement action items.
- 5. Types of validation.
* Self validation.
* Successive validation.
* Source validation.
- 6. Poka-Yoke functions and techniques.
* The orientation method.
* The fixed value method.
* The contact method.
* Locking Mechanism.
* Sensory method.
* The motion step method.
- 7. Setting up a Poka-Yoke method.
* Methods to overcome human errors based on Loading, Unloading and Transportation
** Case studies and solutions.
* Choosing a validation method.
* Setting up the validation method.
* Incorporating the Poka-Yoke techniques in the production process.
- 8. Effect of Poka-Yoke techniques.
* Reduce inventory.
* Relationship of Product defects and equipment failures (Causes and effects)
- 9. Cases Study.
* IC Marking Process.
* Shearing Operation.
* Frame forming operation.
- 10. Exercises, Discussion and closing.
Training Methodology
This session will be conducted in workshop manner. Real examples from the industries and also the
participant lines will be use as case study and applied as an working examples. Apart from the workshop,
the course also will have some lectures and a lot of group study.
Who Should Attend
The target audiences include ALL Technical Executives, Engineers and Managers from Process, Quality, Planning and Production who are interested to know or need to apply Maintenance & Improvement Techniques.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.