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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
SENSOR INFORMATION:BASIC TYPES OF SENSORS• Discrete sensors• Analog sensors
TYPES OF PRESENCE SENSORS
• Physical contact• No physical contact
TYPES OF NONCONTACT SENSORS• Ree! relays• In!"cti#e• Capaciti#e
• Photoelectric sensors
AD$ANTA%ES OF T&E $ARIO'S TYPES• F"nctionality• Costs• Areas o( application
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
BASIC TYPES OF SENSORS:
ANA)O% SENSORS• Ans*er the +"estion: ,-here is the part./
or • ,To *hat le#el ha#e *e (ille! the container./
DISCRETE SENSORS
• The part is present or is not present0• Most (re+"ently as1e! +"estion in a 2an"(act"ring
operation0
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF PRESENCE SENSORS:
P&YSICA) CONTACT• e0g0 )i2it s*itches
• A!#antages Can carry 2ore c"rrent %ap 3et*een ter2inals
NO P&YSICA) CONTACT• A!#antages No physical contact
Better (or co"nting sensiti#e s"r(aces4 e0g0 painte! or polishe! s"r(aces
No 2o#ing parts
Faster
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:
REED RE)AYS• Target is 2agnetic• -ill not respon! to non2agnetic targets
*ith relia3ility0
IND'CTI$E• Base! on 2etal targets5 *ill not respon!
to non2etallic targets *ith high relia3ility0
CAPACITI$E
• Cannot !isting"ish 3et*een the real target an! so2ething else in the target region0
M"st control *hat co2es close to the target0
P&OTOE)ECTRIC• Can 3e (oole! 3y a nontarget0
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:
REED RE)AYSTypical range: 'p to 607 in0 8appro90 c2;• Two hermetically sealed metal foil reeds which mae co!tact
with each other to close the circ"it# whe! i! the $ici!ity of a
ma%!et &'erma!e!t or electro-ma%!et(.• The differe!tial is determi!ed )y differe!ci!% the 'oi!t of first
co!tact from the 'oi!t of last co!tact.• *a%!et a''roach m"st )e i! a directio! 'arallel to the directio!
of the li!e co!!ecti!% the tow reeds.
Best applications (or 2agnetically act"ate! s*itches in general:• +ec"rity a!d safety
• to a$oid false tri''i!%• sec"rity door i!terloc for hea$y machi!ery, e!d of tra$el
for ele$ators# cra!es# a!d the lie.• +e!si!% thro"%h walls &!o!-ferro"s# e.%. l"mi!"m a!d
*a%!esi"m(.• Pallet ide!tificatio! i! sy!chro!o"s a"tomated assem)ly li!es.• Relati$e dirty e!$iro!me!ts &e.%. d"st# dirt# sa!d# oil# or coola!t
fl"ids(.• he!e$er hi%h res'o!se s'eeds are re"ired.
Disa!#antages poor longter2 relia3ility 82o#ing parts;
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:
IND'CTI$E SENSORS
• Principle o( Operation:• E!!y c"rrents are in!"ce! in the target 82etallic;
3y the electro2agnetic0• The target reacts *ith the E!!y c"rrents as a
("nction o( the !istance (ro2 the (iel!0• Insi!e the (iel!4 the target atten"ates the 2agnit"!e
o( the E!!y c"rrents0• O"tsi!e the (iel!4 the target !oes not i2pe!e the
E!!y c"rrents0• This type o( oscillator is re(erre! to as a EC<O
8E!!y C"rrent <ille! Oscillator;0
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPTTYPES OF NONCONTACT SENSORS:
CAPACITI$E SENSORS• Principle o( Operation:
• Senses all 2aterials• Contain a high (re+"ency oscillator *ith one o( its
capacitor plates 3"ilt into the sensor0
• Metho! o( Application:• All 2aterials are sense! thro"gh a change on the
!ielectric characteristics0• I!eal applications incl"!e 3"l1 2aterials an! li+"i!s
in containers o( glass an! plastic0
• Characteristics:• Poor choice (or 2etal targets0• Is #ery sensiti#e to en#iron2ental (actors0• Sensing range !epen!s greatly on the 2aterial 3eing
sense!0• Can 3e 2isle! an! there(ore it is i2portant to control
the 2aterial *hich is presente! to the sensor0
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:
P&OTOE)ECTRIC SENSORS
Photoelectric co!trols !eed !o 'hysical co!tact a!d are ideal where se!sed
o)ects m"st remai! "!to"ched. Photoelectric co!trols res'o!d ra'idly to
'arts mo$i!% "icly a!d i! $aryi!% 'ositio!s alo!% a co!$eyor# yet o'erate
de'e!da)ly if act"ated o!ly i!fre"e!tly. There are co!trols for i!door or o"tdoor "se# for $aryi!% am)ie!t li%ht co!ditio!s# for hi%h $i)ratio!# for areas
restricti$e i! s'ace# a!d e$e! for e'losi$e locatio!s.
Typical applications incl"!e:• o"!ti!%• 6a)eli!%• o!$eyor co!trol• 7i! le$el co!trol• Parts i!s'ectio!• Feed a!d/or fill co!trol• Paca%e ha!dli!%• Thread )rea detectio!
• Ed%e %"ide• e) )rea detectio!• Re%ristratio! co!trol• Food 'rocessi!%• Parts mo!itori!% a!d sorti!%• 7atch co"!ti!%• Ro)otics• Parts ha!dli!%
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPTTYPES OF NONCONTACT SENSORS:
P&OTOE)ECTRIC SENSORS
Con#eyor ControlThis a''licatio! i!$ol$es sorti!% )row! card)oard )oes which are coded with "' to fo"r )lac mars 'er
)o. The a''licatio! is to se!se the !"m)er of mars o! each )o.
Pac1age &an!ling diff"se sca! 'hotoelectric co!trol is "sed to detect the li%ht reflected from the o)ect i! this a''licatio!.
The co!trol detects the li%ht reflected off the )o# t"r!i!% 9: a!d 9FF the %l"i!% machi!e.
)a3elingThis a''licatio! is desi%!ed to detect the leadi!% ed%e of a )lac )ar code o! a read a!d write la)el. The
la)els are ed%e to ed%e o! a s'ool. he! the )ar code is detected the se!sor o"t'"t tri%%ers a laser )ar
code reader which reads the )ar code.
Foo! ProcessingThis a''licatio! mo!itors the le$el of a! acc"m"lator i! a meat 'rocessi!% facility. 'hotoelectric co!trol
detects a fill le$el of hot-do%s i! the acc"m"lator the! t"r!s o! the co!$eyor for a 'reset time 'eriod. +idewalls of the acc"m"lator are 'olished stai!less steel. The e"i'me!t is s")ect to daily washdow!.
Fill )e#el ControlThis a''licatio! i!s'ects the fill le$el of $ario"s ars of food 'rod"cts. The 'hotoelectric system 'rod"ces
a! o"t'"t whe! either a! "!der or o$er fill co!ditio! is detected.
Parts &an!lingFi)er o'tics are ideal for areas too small for a sta!dard 'hotoelectric co!trol. The fi)er o'tic ca)les direct
the li%ht from the )ase to where the se!si!% is !eeded.
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Target
Thru:
•Light source (emitter) andreceiver are placed oppositeeach other.
•The object to be detected passesbetween the two.
Advantages:
1. Most reliable when target is opaque
2. Long range scanning, most excess gain
3. Use in high contamination areas, dirt, mist,condensation, oil film, etc.
4. Precise positioning or edge-guiding of opaquematerial
5. Parts counting
Types of Non-Contact Sensors
Photoelectric Sensors
Emitter Receiver
THRU
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Diffuse:
• Light beam is directed at theobject to be detected.
• Light will be reflected off theobject in many directions.
• Some of the light reflected fromthe object will be sensed by the
receiver.
Advantages:
1. No reflector required.2. Convenient for installation.
3. One sided scanning.
4. Senses clear materials whendistance is not fixed.
5. Ease of alignment
Types of Non-Contact Sensors
Photoelectric Sensors
Target
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:
P&OTOE)ECTRIC SENSORS
Pro9i2ity 8!i(("se; Bac1gro"n! S"ppression
7ac%ro"!d s"''ressio! "tili;es 2 recei$ers )ehi!d the recei$i!% le!s. They areaimed at a 'recise 'oi!t i! fro!t of the "!it a!d se!se the 'rese!ce of a tar%et
*hen the o"tp"t o( 3oth recei#es are e+"al.
Applications:
• *aterial ha!dli!% - co!$eyi!% systems
• ollisio! detectio! for <=>s &"tomatic <"ided =ehicles(• ar / tr"c wash• 6e$el se!si!%
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Retroreflective:
•Light beam is directed at a reflective target(reflector, tape or other reflective object) -one which returns light along the samepath it was sent.
•The object to be detected passes betweenphotoelectric control and reflective target.
Advantages:
1. One-sided scanning
2. Ease of alignment
3. Immune to vibration
Types of Non-Contact Sensors
Photoelectric Sensors
Target
Retroreflective
Reflector
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
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Convergent:
• Light beam is directed at object to bedetected (ignores backgroundsurfaces)
• Object must be at a given distance inrelationship to photoelectric controlbefore light will be reflected to receiver
Advantages:
1. First choice for detecting clearmaterials
2. Ignores unwanted backgroundsurface reflection
3. Detects objects with low reflectivity
4. Detects height differential
Types of Non-Contact Sensors
Photoelectric Sensors
Target
Convergent Beam
FixedDistance
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NONCONTACT SENSORS:P&OTOE)ECTRIC SENSORS
Fi3er Optic Sensors
hat do yo" do whe! the 'hysical co!strai!ts of the a''licatio! do!>t allow for
i!stalli!% re%"lar# self-co!tai!ed se!sors? *ay)e the tar%et is i! a hi%h tem'erat"re
or chemically a%%ressi$e e!$iro!me!t. Perha's the tar%et is small or $ery fast-mo$i!%.
Fi)er-o'tics# a''lied to 'hotoelectric sca!!i!%# sol$es these 'ro)lems.Fi3er Optics an! Sensing
ll fi)er o'tic se!si!% mode are im'leme!ted "si!% o!e ty'e of am'lifier which co!tai!s
)oth emitter a!d recei$er i! o!e ho"si!%.
Fi3er Optic Thr"3ea2 Scanning
@si!% two o''osed# i!di$id"al fi)er o'tic ca)les# the o)ect to )e detected )reas the
)eam. The tar%et m"st )e at least the same dime!sio! as the effecti$e )eam# which i!
this case# is the )"!dle diameter. 7eca"se the )eam is $ery small# the detectio! ca! )e$ery 'recise. ty'ical a''licatio! mi%ht )e ed%e detectio! for a we) 'ri!ti!% 'ress.
:eedle ti's red"ce the )eam dime!sio! for "se with etremely small tar%ets# ty'ical for
a''licatio! i! semico!d"ctors a!d 'harmace"tical i!d"stries.
Typical application:• +mall 'arts detectio!• Ed%e detectio!• Ai%h tem'erat"re e!$iro!me!t &00 de%rees FB(
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Fiber Optic:
• Not a scanning technique but rather another way of transmitting light beam.
Advantages:
1. High temperature applications 4. Corrosive areas
2. Where space is limited 5. Noise immunity
3. Size and flexibility of fiber leads 6. Color sensing
Types of Non-Contact Sensors
Photoelectric Sensors
Target orReflector
Thru
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
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Polarized:
• Will work only with comercubereflector or special polarizedreflective tape.
• Will not false trigger whensensing shiny object.
Advantages:
1. One-sided sensing
2. Does not false trigger offhighly reflective object
3. Senses clear materials
4. Ease of alignment
5. Immune to vibration
Types of Non-Contact Sensors
Photoelectric Sensors
Target
Polarized
SpecialReflector
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
APP)ICATION SCAN TEC&NI='E
+mall 'arts detectio! Fi)er o'tics or Thr" sca! with a'erat"res
6o!% dista!ce sca!!i!% Thr" sca!
Ai%h tem'erat"re se!si!% Fi)er o'tic
+hi!y o)ect or film detectio! Polari;ed sca!
+e$ere e!$iro!me!t &Etreme d"st or dirt( Thr" sca!
6imited mo"!ti!% s'ace Fi)er o'tic
E'losi$e e!$iro!me!t Thr" sca! or Retro
ashdow! e!$iro!me!t Thr"# Retro-reflecti$e or Ciff"se
!alo% 'ositio! se!si!% Ciff"se or Fi)er 9'tic
o!$eyor *o!itor
- Dam detectio!
- Part co"!t
- Part 'ositio!
Polari;ed# Ciff"se or Retro
=i)ratory Feeder Fi)er o'tic
6id or a' detectio! o!$er%e!t )eam or Fi)er 9'tic
lear )ottle detectio! Polari;ed or Fi)er 9'tic
Tra!s'are!t material Polari;ed sca!
6a)el detectio! Ciff"se or Fi)er 9'tic
7i! or ho''er le$el Thr" whe! "si!% wi!dow Ciff"se from a)o$e
*old or die clear to close Thr" sca! or Fi)er 9'tic &hi%h tem'(
*a hei%ht mo!itor &i.e. For tr"cs( Thr" sca!
9'a"e material o! semitra!s'are!t carrier Thr" sca!
*otio! detectio! ll sca! ty'e
APP)ICATIONS FOR P&OTOE)ECTRIC SENSORS
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPTAD$ANTA%ES DISAD$ANTA%ES APP)ICATIONS
*a%!et 9'erated - !e'e!si$e - *a%!et re"ired - +ec"rity a!d safety
&reed relay( - =ery selecti$e tar%et - +e!siti$e to weldi!% i!terloci!% ide!tificatio! fields - +e!si!% thr" metal
Aall Effect - om'lete switchi!% - *a%!etic tar%et o!ly - ey)oard
f"!ctio! is i! a si!%le - Etremely se!sit i$e to
i!te%rated circ"it i!d"strial e!$iro!me!t
- 9'erates "' to 150h;
- Ai%h tem'erat"re
&150 de%rees (
- <ood resol"tio!
@ltraso!ic - +e!ses all materials - Resol"tio! - !ti-collisio! o! <=
- Re'eata)ility Coors
- +e!siti$e to )ac%ro"!d
a!d e!$iro!me!t cha!%es
- Cista!ce limitatio! to
0mm
!d"cti$e - Resista!t to harsh - Prese!ce detectio! o! all
e!$iro!me!ts i!ds of machi!es
- Easy to i!stall - =ery 'o'"lar
- =ery 'redicta)le
a'aciti$e - +e!ses all materials - =ery se!siti$e to - 6e$el se!si!% with li"ids
- Cetects thro"%h walls e!$iro!me!t cha!%es a!d !o!-metall ic 'arts
Photoelectric - +e!ses all materials - +")ect to co!tami!atio! - Parts detectio!
- *aterial ha!dli!%
- Paca%i!%
- =ery 'o'"lar
Pie;o-electric - Tor"e &a"tomated or
ma!"al(
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
NE- APP)ICATIONS:
• Press"re sensing
• Shape sensing
• -eight sensing
• Presence sensing
• Color sensing 8!ar1 #s light;
• Tor+"e sensing 8Pie>oelectric;
• Position sensing
• C"sto2 ? a!apti#e si>e parts
• $ac""2 sensing
• Flo* sensing 8e0g0 gallon ? 2in"te;
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
PO<AYO<E Sensors at a De2ing Pri>e -inner 60 Mechanical @0 &eat Sensor
0 Magnetic 60 %as Sensor
0 Bea2 C"t 660 Force Sensor
0 S"per Sonic 60 Tor+"e Sensor
70 I2age Sensor 60 Meter Relay
0 Co"nter 60 $i3ration Sensor
0 Bea2 Re(lector 670 A"to2atic Meas"re2ent
0 Press"re Sensor
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
T&E MOST EFFECTI$E TYPES OF ERROR NOTIFICATION MEANS
%etting the OperatorGs Attention:
• $is"al Signal 8(lashing light is 3est;• A"!io Signal 8lo"! an! persistent4 e0g0 3"rglar alar2;• Protecti#e Barrier 8to pre#ent !e(ect or operator inH"ry;• -hen "se!: lo* !e(ect occ"rrence rate an! *hen
repairs can 3e 2a!e0
Sh"tting Do*n the Operation:
• 'pon !etecting a ,noncon(or2ance/ the operation
is si2ply sh"t !o*n4 i0e0 the ne9t part *ill not 3e processe!0• -hen "se!: relati#ely higher occ"rrence rates an!
*hen repairs are not possi3le0
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Pro3le2 TypeError Proo(ing
Installe!
Type o(
Sensor 'se!
Type o(
Inter#ention 'se!
*issi!% 5om'o!e!ts o"!ter to $erify *icro-switch *achi!e i!terloc
correct !"m)er of
com'o!e!ts
Pre-co"!ti!% the :o!e :o!e
!"m)er of com'o!e!ts
Fit"re at the o'eratio! Proimity switch *achi!e i!terloc
to detect the 'rese!ce
of com'o!e!t from the
're$io"s o'eratio!
E!correct Processi!% Process se"e!ce :o!e &all fit"res :o!e
fit"ri!% s'ecially desi%!ed(
.ro!% 5om'o!e!ts =erifyi!% com'o!e!t 6i%ht tra!smissio! =ideo or a"dio alarms
sha'e# wei%ht# or
dime!sio! switches
EAMP)ES OF PO<AYO<EGS
FOR T&E T&REE MOST COMMON PROB)EMS
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ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
-hat is the 3est 2etho! (or sensing (l"i! le#els
(or a 2achine.
-hat is the 3est 2etho! (or sensing 2agnets (or
electric 2otors.
-hat are three possi3le 2etho!s (or sensing 3"rs
on a cylin!er 3ore.
-hat is the 3est 2etho! (or !etecting the presence
o( an Oring.
BEST SENSIN% IDEAS
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EPREFER.PPT - 025
2/13/00
Fo"r Categories o( Errors ="estions to As1....
Missing Parts s there a model mi s"ch that some models re"ire a 'art
while others re"ire !othi!% at all i! that locatio!?
s the 'art assem)led as a small 'art after some mai!
acti$ity?
s the 'art diffic"lt to see after )ei!% assem)led?
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EPREFER.PPT - 02
2/13/00
Missing PartsMissing Parts
s the 'art G
@!see! or "!to"ched i!
s")se"e!t 'rocess ste's? Ciffic"lt to see d"ri!% assem)ly?
Ciffic"lt to assem)le?
Ciffic"lt to see after assem)ly?
Ciffic"lt to differe!tiate )etwee! 're
a!d 'ost assem)ly?
s the 'art G
@!see! or "!to"ched i!
s")se"e!t 'rocess ste's? Ciffic"lt to see d"ri!% assem)ly?
Ciffic"lt to assem)le?
Ciffic"lt to see after assem)ly?
Ciffic"lt to differe!tiate )etwee! 're
a!d 'ost assem)ly?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
a! the 'art )e com)i!ed with
a!other 'art?
a! the 'art )e elimi!ated?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
a! the 'art )e com)i!ed witha!other 'art?
a! the 'art )e elimi!ated?
hat ca! )e do!e to detect whether
the 'art has )ee! assem)led?
Detection device - tor"e
co"!ter# 'hotoelectric eye o$er
co!tai!er# limit switch atdis'e!ser#....
hat ca! )e do!e to detect whether
the 'art has )ee! assem)led?
Detection device - tor"e
co"!ter# 'hotoelectric eye o$er
co!tai!er# limit switch at
dis'e!ser#....
6oc o"t s")se"e!t o'eratio! if 'art
is missi!%.
Lock out device - limit switch#
co!d"cti$ity se!sor...
6oc o"t s")se"e!t o'eratio! if 'art
is missi!%.
Lock out device - limit switch#
co!d"cti$ity se!sor...
m'leme!t o'erator i!str"ctio!s#$is"al aids a!d trai!i!% as mi!im"m
re"ireme!t
HE+
:9
:9
Implement Error Proofing
(process/design change and/or
detect/lock out device)
Verify results
HE+
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EPREFER.PPT - 02
2/13/00
Brainstor2 Error Proo(ing Mechanis2
*ae $isi)le/o)$io"s if missi!%
olor co!trast
=isi)le at !"mero"s o'eratio!s a!d 'ac
@se mirrors
Positio! of 'art as mo$es dow! li!e
=is"al aid/'ict"re 'osted with 'art 'rese!t a!d hi%hli%hted
Redefi!e 'rocess ssem)le early i! 'rocess
+"ccessi$e chec
Rearra!%e m"lti'le write-"' to elimi!ate Isometimes do/sometimes do!>tJ
*o!itor 'art s"''ly
9!ly s"''ly 'arts !eeded for that model &!o "estio!s-if there are 'arts 'rese!t#
"se them(
6ot co!trol# co"!t 'arts-m"st e"al K 'ieces 'rod"ced
+e!sors
Photoelectric eyes to detect# loc o"t "!til corrected
6imit switch to detect# loc o"t "!til corrected
*odify desi%!
Elimi!ate 'art
Missing Parts - Thought Starters
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EPREFER.PPT - 02
2/13/00
Misasse23le! Parts s the o'eratio! diffic"lt for the o'erator to see as they
'erform the o)?
s there a! assem)ly or 'ositio!i!% o'eratio! that ca! )e
com'leted i!correctly?
Fo"r Categories o( Errors="estions to As1....
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EPREFER.PPT - 028
2/13/00
Misasse23le! PartsMisasse23le! Parts
s the 'art G
Ciffic"lt to see d"ri!% assem)ly?
Ciffic"lt to assem)le? Ciffic"lt to see after assem)ly?
Ciffic"lt to differe!tiate )etwee! 're
a!d 'ost assem)ly?
6aci!% %"ides or fit"res for 'ro'er
assem)ly or 'ro'er ali%!me!t?
s the 'art G
Ciffic"lt to see d"ri!% assem)ly?
Ciffic"lt to assem)le? Ciffic"lt to see after assem)ly?
Ciffic"lt to differe!tiate )etwee! 're
a!d 'ost assem)ly?
6aci!% %"ides or fit"res for 'ro'er
assem)ly or 'ro'er ali%!me!t?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&%"ides# fit"res# a"tomatio!(
a! the 'art )e com)i!ed with
a!other 'art?
a! the 'art )e elimi!ated?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&%"ides# fit"res# a"tomatio!(a! the 'art )e com)i!ed with
a!other 'art?
a! the 'art )e elimi!ated?
hat ca! )e do!e to detect whether
the 'art has )ee! misassem)led?
Detection device - tor"e co"!ter#
'hotoelectric eye# limit switch
hat ca! )e do!e to detect whether
the 'art has )ee! misassem)led?
Detection device - tor"e co"!ter#
'hotoelectric eye# limit switch
6oc o"t s")se"e!t o'eratio! if 'art
is misassem)led.
Lock out device - limit switch#
co!d"cti$ity se!sor...
6oc o"t s")se"e!t o'eratio! if 'art
is misassem)led.
Lock out device - limit switch#
co!d"cti$ity se!sor...
m'leme!t o'erator i!str"ctio!s#$is"al aids a!d trai!i!% as mi!im"m
re"ireme!t
HE+
:9
:9
Implement Error Proofing
(process/design change and/or
detect/lock out device)
Verify results
HE+
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EPREFER.PPT - 030
2/13/00
Brainstor2 Error Proo(ing Mechanis2
=is"al aids
=is"al aid/'ict"re 'osted with correct 'ositio! hi%hli%hted
Redefi!e 'rocess
ssem)le early i! 'rocess
+"ccessi$e chec or'lace or%a!i;atio!
9r%a!i;e for maim"m ease a!d $isi)ility
+e!sors
Photoelectric eyes to detect# loc o"t "!til corrected
6imit switch to detect# loc o"t "!til corrected
*odify/desi%! fit"re @!a)le to assem)le i!correctly
*odify desi%!
Elimi!ate 'art
Pre$e!t misassem)ly - e.%. two si;es of st"ds
Pro$ide %"ides or refere!ces
Misassembled Parts- Thought Starters
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EPREFER.PPT - 031
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Incorrect Processing s there a! o'eratio! that re"ires a reco%!itio! of some
characteristic to determi!e what to do with the 'art !et?
REJECTSGOOD
Fo"r Categories o( Errors="estions to As1....
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EPREFER.PPT - 032
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Incorrect ProcessingIncorrect Processing
Coes the o'eratio! re"ire reco%!itio!
of some characteristic to determi!e
what to do with the 'art?
(e.g. ed light indicates place in re!ect
pile" visual inspection #or pre-de#ined
de#ects)
Coes the o'eratio! re"ire reco%!itio!
of some characteristic to determi!e
what to do with the 'art?
(e.g. ed light indicates place in re!ect
pile" visual inspection #or pre-de#ined
de#ects)
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&fit"res# a"tomatio!(
a! the 'art )e com)i!ed with
a!other 'art?
a! the 'art )e elimi!ated?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&fit"res# a"tomatio!(
a! the 'art )e com)i!ed witha!other 'art?
a! the 'art )e elimi!ated?
hat ca! )e do!e to detect whether
the 'art has )ee! i!correctly
'rocessed?
Detection device - reset )"tto!#
'hotoelectric eye# limit switch
hat ca! )e do!e to detect whether
the 'art has )ee! i!correctly
'rocessed?
Detection device - reset )"tto!#
'hotoelectric eye# limit switch
6oc o"t s")se"e!t o'eratio! if 'art
is i!correctly 'rocessed.
Lock out device - limit switch#
co!d"cti$ity se!sor...
6oc o"t s")se"e!t o'eratio! if 'art
is i!correctly 'rocessed.
Lock out device - limit switch#
co!d"cti$ity se!sor...
m'leme!t o'erator i!str"ctio!s#$is"al aids a!d trai!i!% as mi!im"m
re"ireme!t
HE+
:9
:9
Implement Error Proofing
(process/design change and/or
detect/lock out device)
Verify results
HE+
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EPREFER.PPT - 033
2/13/00
Brainstor2 Error Proo(ing Mechanis2
=is"al aids
L"ality alert i!dicati!% hi%h 'ote!tial for error
Fit"re or tem'late o"tli!i!% 're-defi!ed defects
7o%ey or sam'le )oards for $is"al i!s'ectio!
Redefi!e 'rocess
Reset or ac!owled%e )"t at the a''ro'riate !et o'eratio!
"tomate
or'lace or%a!i;atio!
+e'arate a!d clearly la)el reect locatio!s/co!tai!ers
+e!sors
Photoelectric eyes to detect# loc o"t "!til corrected
6imit switch to detect# loc o"t "!til corrected
$ncorrect Processing- Thought Starters
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EPREFER.PPT - 034
2/13/00
Incorrect Parts s there a selectio! of 'arts i! fro!t of the o'erator that
wo"ld allow for the wro!% 'art to )e chose! a!d assem)led?
Fo"r Categories o( Errors="estions to As1....
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EPREFER.PPT - 035
2/13/00
Incorrect PartsIncorrect Parts
s there a selectio! of 'arts a$aila)le
at the worstatio!?
re similar 'arts assem)led o!to the'rod"ct at the same locatio!?
s there a selectio! of 'arts a$aila)le
at the worstatio!?
re similar 'arts assem)led o!to the'rod"ct at the same locatio!?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&o!solidatio!# se'arate o'eratio!s(
a! the 'art )e com)i!ed with
a!other 'art?
a! the 'art )e elimi!ated?
a! a!ythi!% )e do!e to resol$e this
i! desi%! of 'rod"ct/'rocess?
&o!solidatio!# se'arate o'eratio!s(
a! the 'art )e com)i!ed witha!other 'art?
a! the 'art )e elimi!ated?
hat ca! )e do!e to detect whether
the i!correct 'art has )ee!
assem)led?
Detection device - )ar code#
'hotoelectric eye# limit switch
hat ca! )e do!e to detect whether
the i!correct 'art has )ee!
assem)led?
Detection device - )ar code#
'hotoelectric eye# limit switch
6oc o"t s")se"e!t o'eratio! if the
i!correct 'art is detected
Lock out device - limit switch#
co!d"cti$ity se!sor...
6oc o"t s")se"e!t o'eratio! if the
i!correct 'art is detected
Lock out device - limit switch#
co!d"cti$ity se!sor...
m'leme!t o'erator i!str"ctio!s#$is"al aids a!d trai!i!% as mi!im"m
re"ireme!t
HE+
:9
:9
Implement Error Proofing
(process/design change and/or
detect/lock out device)
Verify results
HE+
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EPREFER.PPT - 03
2/13/00
Brainstor2 Error Proo(ing Mechanis2
*ae $isi)le/o)$io"s if i!correct 'art
olor code - match 'art to 'rod"ct
=isi)le at !"mero"s o'eratio!s a!d 'ac
Positio! of 'art as mo$es dow! li!e
=is"al aid/'ict"re 'osted with correct 'art 'rese!t a!d hi%hli%hted
Redefi!e 'rocess
ssem)le early i! 'rocess
+"ccessi$e chec
Rearra!%e m"lti'le write-"' to se'arate assem)ly of lie 'arts
*o!itor 'art s"''ly
9!ly s"''ly 'arts !eeded for that model
+e!sors
Photoelectric eyes to detect# loc o"t "!til corrected
6imit switch to detect# loc o"t "!til corrected
*odify/desi%! fit"re
@!a)le to assem)le i!correct 'art
*odify desi%!
Elimi!ate 'art
Pre$e!t assem)ly of i!correct 'art
$ncorrect Parts- Thought Starters
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EPREFER.PPT - 03
2/13/00
The Error Proofng Process:– Utilizes a multi-unctional aroach
–!s "ri#en $% Customer Satisaction an"allo&s or 'uic( resonse an"imlementation o solutions
– !s use" to )*ill+ ro$lems– !s "ocumente" in the ,Pro$lem Sol#ing
Document .PSD/– Suorts Continuous !mro#ement
0etho"olog%– !s the ,Contain ste in the 1 Ste Pro$lem
Sol#ing Process
People&
Teamwork
12 E#aluate 32 !"enti%
42 5nal%ze
62 Plan
72 !mlement
Prevent Select
ContainCorrect
Error-Proofing Process“Quick Response / Quick Implementation”
!nstitutionalize
the Solutionan" the Ongoing
Control
InstitutionalizeContinuousImprovement
Opportunity
Pro$lem Sol#ing Documentation
8irst Time
'ualit%
.82T2'2/
at
Oeration
Deartmental
Containment
Station
9et&or(
!nternal
Plant
5u"it
Customer
Reects
.PP0/
S%stematic
Pro$lem
Sol#ing
Process
Candidates for Error Proofing
;arrant%
!normation
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EPREFER.PPT - 03
2/13/00
6J DEFECT RATE 899% YIELD;
OF A)) STATIONS
RES')TS IN J
CONFORMIN% PROD'CTS
ell 1
ell 3
ell 2
ell 4
1M
Cefect
Rate1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1MCefect
Rate
1M
Cefect
Rate1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
1M
Cefect
Rate
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EPREFER.PPT - 038
2/13/00
PROCESS FA))O'T TAB)E
%entered Process
Process capa3ility ratio Parts per 2illion !e(ecti#e
0.50 133#00.00
0.5 24#400.00
1.00 2#00.001.10 8.00
1.20 31.00
1.30 8.00
1.40 2.00
1.50 .0
1.0 1.01.0 0.34
1.0 0.0
2.00 0.001
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EPREFER.PPT - 040
2/13/00
DIDN’T WASHDIDN’T WASH
HANDSHANDS
DIDN’T WASHDIDN’T WASHHANDSHANDS
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EPREFER.PPT - 041
2/13/00
Implementation Procedure:
• Product Tooling Design Phase
N Predict Potential &ualit' De#ects during
Product Tooling Design Stage.se DM to modi#' Tooling Design to
Prevent Potential De#ects #rom *ccurring inProduction based on Potential De#ects$denti#ied.
+uild Poka-,oke Devices into the Processhere Design ies0 can not be$ncorporated.
ERROR PROOFIN%
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EPREFER.PPT - 042
2/13/00
• Production Phase
N etro-#it Poka-,oke Devices into 1isting
Tooling se &ualit' 2istor' to Target Potential 1rror
Proo#ing 3pplication Sites
*btain Set-p *perator $nput as to 4here to
3ppl' 1rror Proo#ing0 Devices as ell as the T'pe o# Devices to se.
Implementation Procedure (ontinued!:
ERROR PROOFIN%
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EPREFER.PPT - 043
2/13/00
"ome Error Proofing #uidelines:• Standardi5e Press Shut 2eights
• tili5e Digital Process Parameter 6ages
• 3ppl' Locating Devices to Dies" itures" 1tc.
• 6ages Pre-calibrated prior to Start o# Set-p
• tili5e %ommon/0&uick %onnect ittings and%lamping 2ardare
• *ne 4a'0 Loading • 7889 %omponent Presence %heck
• :eri#' Machine %'cle %ompleted0
• Detected 1rror0 Stops Process
ERROR PROOFIN%
CAS'A) CONNECTIONS BET-EEN
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CAS'A) CONNECTIONS BET-EENDEFECTS AND &'MAN ERRORS
Ca"ses
o( De(ects
Omitted Processing
Processing ErrorsErrors Setting Up Workpieces
Missing Parts
Wrong Parts
Processing Wrong Workpiece
Misoperation
Adjustment Error
Improper Equipment Setup
Improper Tools and Jigs
&"2an
Errors
I n t e r n a t i o n a l
M i s u n d e r s t a n d i n g
F o r g e u l
M i s i d e n t i i c a t i o n
A m a t e u r s
W i l l u l
I n a d ! e r t e n t
S l o " n e s s
# o n $ S u p e r ! i s i o n
S u r p r i s e
Strongly Connecte! Connecte!
SOURCE: NKS/Factory Magazine “Poka-Yoke”