““Those who are not dissatisfied Those who are not dissatisfied will never make any progress.” - will never make any progress.” - ShingoShingo
(1909 – 1990)
Dr. Shigeo ShingoDr. Shigeo Shingo
Industrial engineerIndustrial engineer Born January 8, 1909 in Saga City, JapanBorn January 8, 1909 in Saga City, Japan In 1955 he took charge of industrial In 1955 he took charge of industrial
engineering and factory improvement engineering and factory improvement training at the Toyota Motor Company training at the Toyota Motor Company
He was a leading proponent of statistical He was a leading proponent of statistical process control in the 1950s, but became process control in the 1950s, but became frustrated with the statistical approach as he frustrated with the statistical approach as he realized that it would never reduce product realized that it would never reduce product defects to zerodefects to zero
Died November 14, 1990 at the age of 81Died November 14, 1990 at the age of 81
Zero Quality Control Zero Quality Control (ZQC)(ZQC)
An approach to quality An approach to quality management that relies heavily management that relies heavily on the use of Poka Yoke deviceson the use of Poka Yoke devices
Successive checksSuccessive checks Self-checksSelf-checks
– Each method relies on 100% Each method relies on 100% inspection whereas traditional SPC inspection whereas traditional SPC rely on random checksrely on random checks
Poka YokePoka Yoke Japanese for mistake-Japanese for mistake-
proofingproofingPoka - inadvertent mistakePoka - inadvertent mistakeYoke – preventYoke – prevent
– Developed in the 1960sDeveloped in the 1960s Either prevents a mistake Either prevents a mistake
from being made or makes from being made or makes the mistake obvious at a the mistake obvious at a glanceglance
““The cause of defects lie in The cause of defects lie in worker errors, and defects worker errors, and defects are a result of neglecting are a result of neglecting those errors – mistakes will those errors – mistakes will not turn into defects if not turn into defects if worker errors are worker errors are discovered and eliminated discovered and eliminated beforehandbeforehand” - Shingo” - Shingo
What would Dr. Deming have to say about that?
Three types of Three types of inspectioninspection
Judgment inspectionJudgment inspection Informative inspectionInformative inspectionSource inspectionSource inspection
–Often Poka Yoke devices Often Poka Yoke devices ensure the proper ensure the proper operating conditions exist operating conditions exist prior to actual productionprior to actual production
PokaYoke Device PokaYoke Device CategoriesCategories
Prevention device - make Prevention device - make errors impossibleerrors impossible
Detection device - Make Detection device - Make errors visible to the operatorerrors visible to the operator
Characteristics of Good Poka Yoke Characteristics of Good Poka Yoke DevicesDevices
tthey are simple and hey are simple and cheapcheap
they are part of the they are part of the process process
they are placed close to they are placed close to where the mistakes where the mistakes occuroccur
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