Q1) WHAT IS POKE YOKE? EXPLAIN ITS IMPORTANCE WITH EXAMPLES?

Definition Poka Yoke (pronounced Poh-kah YOH-kah) is a concept of mistake proofing processes to result in zero defects. The concept originated at Toyota and is credited to Shigeo Shingo an engineer at Toyota (and author of various books on lean methods using the Toyota production method). Why is Poka Yoke important The concept of Poka Yoke is a fairly simple one mistakes will not turn into defects if worker errors are discovered and eliminated beforehand. Poka Yoke depends on creating simple yet effective visual methods of inspecting the quality of what is being produced and deploying simple efficient systems for highlighting and preventing defects. Often Poka Yoke depends on three different types of inspection (as defined by Shingo) these are: * Judgment inspection sorting the defects out of the acceptable product * Informative inspection Operators inspects their work or the work of the prior operator thus ensuring quick feedback along the production line and the rework of defects at a stage where they are easier to fix. * Source inspection ensuring that the conditions for a quality production environment exist. Prior to deciding where to place mistake proofing systems its important to be able to identify the process step where the defect occurs (often where information inspection is being used this is made easy because it is likely to be the previous step). Poka Yoke represents an easy to implement and rewarding system of mistake proofing and you may be surprised to learn that various examplesexist in day to day life. For example paint that goes on pink then dries white offers a visual tool to check for areas that havent been painted old style floppy disks being designed in such a way that they could only be inserted one way are all forms of Poka Yoke. While Poka Yoke is usually low cost, improvements can be dramatic defining a sensible easy to implement method of removing defects can improve both production runs whilst having a rewarding impact on an organisations bottom line.

EXAMPLES OF POKE YOKE

This pen prevents ruining shirts by retracting the tip automatically when the pen is clipped into your shirt pocket. The catch that keeps the tip out is actually in the pocket clip. When you pullout on the clip to put it on your shirt, the pin that engages the catch is released causing the tip to retract.

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Many Elevators are equipped with an electric eye to prevent doors from shutting on people. They also are equipped with sensors and alarms to prevent operation when overloaded.

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Some brake systems utilize permanent magnets to generate power-off braking force. Current supplied to magnetic coils counter permanent magnetic force to keep the brakes from engaging during normal operation.

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Many smoke detectors are designed so they cannot be mounted on the wall until a battery is installed.

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Retail stores and libraries use "electronic article surveillance" systems to prevent removal of merchandise and books that have not been paid for or checked out.

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This device continuously monitors the water level. If the level is too low, a valve opens to add water to the pool.

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This Stove burner turns off automatically when pot or pan is removed.

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The manufacturer has rigged these wallets to sound an audible beep when a card is absent from the wallet. While this device would clearly be annoying to some users, for others it would be a big help in remember to replace credit cards after use.

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The manufacturer has rigged this drill to stop immediately when the bit contacts any grounded or electrically live materials so you can't drill through hidden pipes or wiring.