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Looking For Training That Really Works?

Poka Yoke Methodology(100% M is takes Proof i ng For Zero

Defects )A Quality Workshop From ZenPower International, Your Regional Expert in TPM Quality & Productivity. Singapore Oct 11/12 KL Oct 14/15

Rendezvous Hotel Sheraton Hotel, S. Jaya

MURPHYS LAW IF ANYTHING CAN GO WRONG, IT WILL GO WRONG!!

Do Quality Issues still disrupt your production lines and upset your Customers? Too much is at stake. Take no chances andmake no compromises with Quality. Poke Yoke is at the heart of World-Class TPM and a central tool in the cutting-edgeSix-Sigma program. Learn the complete Poka Yoke methodology Design principles in this 2-Day Intensive Workshop.

THE POKA YOKE METHODOLOGY

What cause defects? Defects are caused by Mistakes. What then are mistakes? A MISTAKE is an ACTION or IN-ACTION by MAN which sets off a chain of events resulting in the defect. Poka Yoke begins by identifying all the possiblemistakes in a process causing defects and implementing mistake-proofing measures to prevent Man from making mistakes.If the Poka Yoke Design is comprehensive, a zero-defect process is not just a theory, but in fact achievable.

PRINCIPLES OF POKA-YOKE DESIGN FOR ZERO DEFECTS

Achieving Zero Defects through Poke Yoke depends on a STRUCTURED APPROACH that singles out every possible MISTAKEfor MISTAKE-PROOFING. Make your factory A Mistake-Free Defect-Free World Class Manufacturer starting with this Workshop.

A Quality Investment.

THERE ARE AT LEAST 11 TYPES OFMISTAKES:

ALL Problems can be traced to MISTAKES due to MANsactions or in-actions.

1. Worker is Forgetful.2. Worker misunderstands.3. Worker misjudges.4. Worker lacks skills.5. Worker is absent-minded, day-dreaming6. Worker willfully breaks work rules.7. Worker is slow.8. Worker deliberately sabotage.9. Method is not suitable.

10. Machine sudden breakdown.11. Material quality inconsistent.

BASED ON CASE STUDIES, LEARN TO DESIGNPOKE-YOKE FOR THE ENTIRE PROCESS.

1. Finding all Mistakes in any Process.2. Finding the most suitable and minimum number

of Poke Yoke devices for 100% Mistake Proofingof any processes.

LEARN THE FIVE GENERIC POKA YOKESOLUTIONS:

1. Guide Pins.2. Error Sensing devices & alarms.3. Limit switches4. Counters and timers.5. Checklists and schedules.

Problems In A Process* Defects* Breakdowns* Administrative Errors.* Accidents.

4Ms Mistakes Analysis.

All Machine, Method, Man,Material Causes of the Problemsare analyzed to find the RootCauses known here as

Generate PokaYoke Solutions For whole Process To PreventMistakes from happening.

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THESE POKA YOKE DESIGN PRINCIPLES ARE APPLICABLE TO ALL TYPES OF MANUFACTURING & SERVICE INDUSTRIES.

Phase 1 Phase 2 Phase 3

WHO SHOULD ATTEND?All Supervisors, Technicians, Engineers, Trainers, ManagersDirectors from various functions including Production,Maintenance, Process, QA, TQM, TPM, HRD Personnel, 6-SigmaBlack Belters responsible for Quality.

SPECIAL TRAINING PACKAGES Customized Corporate Workshops Poke Yoke Train-the-Trainer Package for In-house competency.

Please Call Today For Any Enquiries on above packages

CONTACTS CAN BE MADE AT

Hph Msia: 019-5433188 Mr. Arthur Hph Spore: 02-96916334 Ms. ArleneEnquiries E-mail: zentan@singnet.com.sg

Case: Cylinder does not operate smoothly.Question Answer Short-term

Immediate Actions

1. Why is cylinder operation not smooth?

The oil strainer isclogged.

Clean the strainer.

2. Why is the oilstrainer clogged?

The oil is dirty. Drain oil, c leanand replace.

3. Why is the oil dirty? Dirt has enteredthe tank.

Prevent surroundingdirt from scattering.

4. Why did dirt getinto the tank?

Upper plate of tank has a hole.

Plug the hole

5. Why is the hole there? Standardize future

repairs.

Example: FISHBONE ANALYSIS to identifythe 4Ms Causes of the End Crack Defect.

WHY-WHY ANALYSIS for each 4MCauses to Pin-Point the MISTAKES

Repair error by Maintenance.

TheMISTAKEFOUND!!

EndCrack

NoProcedures

MC

Material

Method

Cylinder. jerky

HoleOilStrainer

Man

Careless

Dusty

Dirtyoil

Poke Yoke Design Methodology For A 100% Mistake-Free Process

Plant QualityAssurance Matrix:All defects in the factory areidentified to the processeswhere they originate andappraised for further actions.

4Ms Analysis:

*Each Process defects areanalyzed for their 4Ms causes inthe sequence of Machine,Method, Man and Material.

*Fishbone & Why-Why Tools.*P-M Analysis Tool specifically

for chronic problems.

Machine-Quality Matrix:Set equipment conditions that precludequality defects, by maintaining perfectequipment for perfect quality of

processed goods and products. The precision conditions are checked thatmeasured values are within standardvalues for early countermeasures.

4Ms Mistake Analysis :

For each Process perform Why-Why Analysis of all4Ms for the Root Causes whichare Man-Mistakes.

Poke Yoke Process Design forZero Defects.

- Process/Mistakes Attribution- Defects prioritization and

Critical Value EvaluationBase-lining for before / after comparison.

Poke-Yoke Application- Types, design and

function of Poke-Yokedevices.

- Appropriate choice of Poke-Yoke devices-Verifying Poke Yoke

solutions and revisit PlantQA Matrix

mailto:zentan@singnet.com.sgmailto:zentan@singnet.com.sgmailto:zentan@singnet.com.sg

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Poke-Yoke Methodology Workshop Registration form.Tick one: [ ] Singapore Seminar 11/12 Oct 2004 [ ] KL Seminar 14/15 Oct 2004

Name : ______________________Position:________________ Contact Tel ______ext____ Name : ______________________Position:________________ Contact Tel ______ext____ Name : ______________________Position:________________ Contact Tel ______ ext____ Contact Person : ____________________________________ Payment PlanTel:____________ Fax:________________ Check Mailed ( ) Yes Check # _____________ Position_______________________ Dept:_______________ Date of Mailing : ____________ Company:_________________________________________ Total Amount = ________ Address :__________________________________________ (Check Payable To ZenPower International) Please tick if Hotel reservation is required ( ) If Yes, indicate the number of rooms. ( ) Dates ( to )

PLEASE FAX YOUR REGISTRATION EARLY TO AVOID DISSAPOINTMENTZenPower International Fax: 02-64545402 E-mail: zentan@singnet.com.sg

Mailing Address For Checks : ZenPower Intl., No.5 Tagore Avenue, Singapore 787645(ZenPower International is a company registered in Singapore since 1995)

Note: We reserve the right to postpone or cancel the Workshop in which case a full refund will be made. We can assist your HRDF applications.

DAY - 1

A) Evolution of Poke Yoke in Ultimate Quality Control. - Judgment Inspection most common and un-productive.- Informative Inspection its practices and limitations.- Source Inspection checks for mistakes, not defects.- Definitions of Mistakes & Poke-Yoke.- The 11 Types of generic mistakes leading to defects.- The Five Generic Poke Yoke devices and their Applications.

B) Poke Yoke Process Step:1 - Process Selection.- Poke Yoke Implementation: Ad-Hoc or Company-wide strategy?- Establish the Factory QA (Quality Assurance) Matrix.- Establish the likelihood of defects occurrence.- Establish the Mistake-Proofing level for each defect-type.- Perform Critical Value Evaluation for each defect-type

(Application 1: Group Exercise & Shared Learning) Participants will be grouped and asked to establish a partial QAMatrix under guidance based on their actual work-place experiences.C) Poke Yoke Process Step:2 Defects 4Ms Cause Analysis - How to extract list of defects in Process from QA Matrix..- Nature of and Guidelines to separate between the sporadic

and chronic defects.- Pre-requisite of Effective Problem Solving depends on

thorough hands-on and on-site Investigation of the 3 Actuals.- Identifying the 4Ms for each chronic defect through Fishbone Analysis and Why-Why Analysis.

(Application 2: Group Exercise & Shared Learning)Groups will select one of their Processes to identify the 4Ms of defectsin their chosen Process under guidance.

D) Poke Yoke Process Step:3- Analyze 1 st M Machine Causes

- Identifying machine Q-components affecting quality throughapplying Why-Why Analysis.

- Identifying optimal conditions of these machine part. Methods of measurements for parts with function-loss and function reduction.

- Monitoring these parts through Inspection & Precisionchecks. Merge items into SPC and PM Checklists.

(Application 3: Group Exercise & Shared Learning)Groups will identify Machine components affecting quality. They will apply the above tools under guidance.

DAY - 2

E) Poke Yoke Process Step:4 Process Mistakes Analysis- Reasons for addressing 1 st M-Machine before the other 3Ms

(Method, Man, Materials)- Definition of Mistake Versus 4Ms causes of Defects.- Detailed technique of Why-Why Analysis in find Man-Mistake.

(Application 4: Group Exercise & Shared Learning)Groups will use Why-Why Analysis to discover the underlyingMistakes of the 4Ms of defects identified in Application 2.

- Treatment of Chronic Defects for Mistake-Proofing.- Brief Introduction to the P-M Analysis methodology for solving of

Chronic defects to identify the 4Ms causes.- Case Study and example of a chronic defect resolution using P-M Analysis.

- Chronic defects with both independent and overlapping causes.F) Poke Yoke Process Step:5 Process/Mistake Analysis- Criteria for identifying the Auto and Manual Process sub-steps.- Use of the Poke Yoke Process/Mistake Worksheet to match where

and when Mistakes can happen.- Critical Value Evaluation for prioritizing defects.- Defining the requirements for a Mistake-Free Quality Process.

(Application 5: Group Exercise & Shared Learning)Groups will use Mistakes identified in Application 4 to design therequirements of a Mistake-Free zero defects process. G) Poke Yoke Process Step:6 Poke Yoke Applications- Some common daily examples of Mistake-Proofing.- The PDCA Cycle and the Source Inspection Principle of Poke-Yoke.- The three Levels of Mistake-Proofing.- Common Mistake-Proofing Poke Yoke devices.

- Formulating suitable Mistake-Proofing measures from Mistakesidentified from Step-5.- The Mistake-Proofing Poke Yoke Worksheet.

(Application 5: Group Exercise & Shared Learning)Groups will use the Mistake-Free process specifications designed inApplication 5 to conceptually come up with various Mistake-Proofingmeasures using different Poke-Yoke devices.)

H) Final Q&A.

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Professional Bio-data of Workshop Leader

Career Brief.

Moses Tan (MSc, BIT, Dip Electronics, Cert-Tech Ed.) an Industry TPM Consultant, started his career as a Technical Sales Training Instructor at SingaporeElectronics & Engineering Ltd in 1981. In this position, he compiles training manuals and conducts on-site training of Radar & CommunicationsEquipment for its Clients from the aerospace industry. Subsequently, he moved into the Electronics and Semiconductor Industry. He last spent 10 years atSilicon Systems, a Semiconductor manufacturer with full capabilities from design, foundry, assembly and testing. During this time, he was assignedvarious roles in HRD, Production and TPM (Total Productive Maintenance). His last position was 6 years as TPM Training Manager under the directsupervision of TDK advisory staff located on-site in Singapore. He also worked with TPM counterparts in the United States.

Academic Credentials.

His academic credentials are a balance of the hard and soft skills MSc (TQM Major) from Leicester University; BIT (University of S Queensland), Dip.In Electronics (Singapore Polytechnic) and Cert-Ed (Technical Training) from the Institute of Education, Singapore. He is also a certified ISO CertifiedLead Assessor,

Professional Experiences & Services Summary.

After 20 years in employment, he left the TDK Company in 1995 and founded his own Consultancy business, ZenPower International. His goal was tofully focus on specializing as the Best Regional provider of customized Industry TPM expertise and generic TPM training provider.

Full TPM Implementation Services :In the area of providing Industry TPM expertise, Moses has undertaken many various types of long and short-term on-site Industry TPM projects both inSingapore and Malaysia. Some long-term on-site TPM Projects involves intensive hand-holding of the full TPM implementation according to the JIPMStandards. Four such notable multi-year TPM projects involve *Companies in the Building-materials and Electronics, PCB and Semi-conductor Sub-contracting business. Testimonies from their Clients and Suppliers were extremely positive. Bottom line results were gratifying and consistent withexpectations. Companies planning TPM Implementation will find in us a fully committed partner.

Specific TPM Implementation Projects:A typical medium term on-site TPM projects involve a partly Japanese-owned Automobile Company which was then preparing for the official JIPM TPMAudit by Japanese Expert Auditors. Moses prepared them over a final period of more than 9 months and the Company was able to host the JIPM TPMAudit successfully. Companies already with an on-going TPM Program are invited to contact us for specific assistance with special requirements .

Specific Trouble-Shooting of Serious Chronic Problems:

Probably, the most challenging projects that prove his expertise were on-site facilitation of actual and serious Chronic Problems in terms of quality defectsand equipment failure by using P-M Analysis to help his Clients resolve. To date, he has personally under-taken on-site facilitation of more than 17Chronic Problems at various Clients factories with 100% **success rate. Many of these are Industry-wide type of chronic problems in the Paper Mill,SMT, Semi-conductor Assembly and Test and Automobile Industry, which he successfully undertook with the Clients technical staff. He enjoys suchchallenges best. All Process, Assembly or fabrication Companies facing persistent and crippling Chronic Problems are invited to contact us for a fast problem-resolution proposal without obligations.

Public and In-House TPM Methodology & Tools Training:He also provides short-term TPM Service such as in the areas of TPM training. The training topics include TPM Introduction, Why-Why Analysis, P-MAnalysis, Poka Yoke, Office & Administrative TPM or 5S, OEE Equipment Improvements, Quality Maintenance, Planned Maintenance, SMED, LeanManufacturing, JIT, SMWT (Self-Managing Work Teams) , MTBA, MTBF, MTTR projects, Kaizen Employee Suggestion Program, 360 Degrees Peer Appraisal FB System Development, etc He has a steady and growing Clientele base of Asian, Japanese and Western MNCs for potential Clientsreference on request. Please enquire for details.

Notes: *Names of clients can be released for reference purposes on request.

**Success Rate is measured from both the results and facilitation perspectives. There are cases where the clients have been able to fullyunderstand their chronic problems as well as implement full counter-measures to eliminate them. In some other cases, full counter-measureswere not able to be implemented due to technical, cost or other considerations. These were also deemed as successful where the Client haveexpressed satisfaction from insights gained from the project facilitation.

Consultation, Projects and Customized Training TPM Clients List since 1996 May 2004

SCI Manufacturing Singapore Pte Ltd; Mitshiboshi Belting Pte Ltd, Singapore; Carsem Semiconductor Sdn Bhd. Malaysia; Carsem Malaysia Sdn Bhd, NEC Semiconductor Spore Pte Ltd.; SonyDisplay Device (Spore) Pte Ltd.; Showa Denko HD; Sumitomo Bakelite Pte Ltd; Singapore. Siemens Component Pte Ltd; Singapore. Malaysia Newsprint Industries Sdn Bhd; Guocera Tile Industries(Kluang) Sdn Bhd; Johore ; Yamaha Motors Hong Leong Sdn Bhd.; Hitachi-Nippon Steel Pte Ltd, Singapore.Taiko Denki Sdn Bhd, Senai.; Malaysia Newsprint Sdn Bhd. { And many other Companies who had sent delegates to our Public Seminars}

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