100-Metodos-de-Qualidade-Total

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MANAGEMENT METHODS 43 Method 12 Error proofing (pokayoke) Purpose To design an operation in such a way that specific errors are prevented from causing major problems to the customer. When to use It can be used when defects occur and require 100 per cent inspection, immediate feedback and action at the: • source of raw materials and components • start of the production process • production points where an error may occur How to use In a pokayoke system, carry out automatic continuous inspection and, if abnormalities occur, then provide feedback and take action. However, before processing can begin, one has to halt the process, obtain feedback and execute necessary action. Benefits Unlike statistical quality control systems, in which a fairly long time elapses between the 'check' stage and the execution of feedback and action, pokayoke minimizes defects by carrying out feedback and action immediately at a low cost. Examples A large steel press is automatically monitored for wear. If the thickness becomes less than a specified amount, an alarm sounds and action has to be taken to rectify the error. A second example involves a car manufacturer which was concerned to prevent omission of car door pockets in production . The operation in which pockets were mounted on the door trim involved three specifications, and workers occasionally neglected to mount the pockets, or mounted them incorrectly, according to their attention to work in progress. To improve the process, door trims were exposed to a detector which recognized whether pockets were missing. If right and left pockets had been reversed or if a pocket had not been mounted, a buzzer sounded, air stopped flowing to the screw-tightening lock and the operation could not proceed. In this way, instances of pocket omission were eliminated.
44 100 METHODS FOR TOTAL QUALITY MANAGEMENT Method 13 Force analysis Purpose To identify external and internal forces at work when developing a contingency plan. When to use Use this method before developing a list of potential problems for your problem prevention plan. How to use 1 Draw a circle. 2 Write down the external forces trying to keep the plan from occurring (outside the circle). T eamwork E o> Q) C :0 :; e 0 a.. (/l Figure 1 Force analysis
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REFERENCES Akao, Y. (1991) Hoshin K
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INDEX acceptable quality level (AQL
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100-Metodos-de-Qualidade-Total

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