RICOH manufacturing DX Practical Lab
Countermeasures for human errors
~ Introducing Poka-Yoke case studies ~
Human errors can pose a threat to operational safety in manufacturing facilities. Floor managers are heavily focusing on implementing "Poka-Yoke," to create a mistake proof factory.
Effective implement of Poka-Yoke can prevent outflows of defective products caused by human errors. To enhance productivity and gain a healthier work environment, we recommend introducing a Poka-Yoke system suited for your workplace.
Here are some specific benefits of incorporating Poka-Yoke into manufacturing facilities.
Since the two benefits listed above may eliminate risks from manufacturing sites greatly, we may say that Poka-yoke has a significant effect on a factory’s environment and production.
Human errors, which are mistakes caused by workers, can also result in machine malfunctions and work-related accidents. By implementing Poka-Yoke, it is likely to reduce the risks of putting onsite employees in such danger.
Comprehensive safety measures may promote worker’s safety and enhance work morale. Taking thorough poka-yoke shall protect the company’s trust within the industry.
In order to choose the correct poka-yoke, we shall highlight the goals the company wants to achieve through the implement of poka-yoke.
Poka-yoke is crucial for timely detection and elimination of defective products. Effectively identifying defective products through Poka-Yoke will not only preventing the release of flawed items but will also increase the output of quality goods and increase the company’s trustworthiness.
The type of poka-yoke that should be implemented depends on the goal you want to achieve.
There are five main factors that may induce Human errors.
Misinterpreting the current situation and required actions may result in inadequate confirmation and improper machine operation, ultimately leading to work errors.
Incorrect methods and procedures for executing tasks may lead to errors while operating machinery or proceeding safety checks.
Failing to recall necessary instructions can lead to inappropriate actions. Memory lapses may cause important tasks or checks to be overlooked, resulting in flawed products.
Human errors can result from missing, mishearing, misreading, or misinterpreting information in the inspecting process. Cognitive mistakes may also induce incorrect judgement and perception, leading to cases where defective products are passed on without being recognized.
Neglecting established rules may prevent jobs from being performed in the correct manner, resulting in mistakes. Failure to follow safety rules may result in insufficient execution of necessary tasks, resulting in defective products, accidents, and so on.
There are mainly three types of Poka-Yokes.
Creating a system or environment that prevents the occurrence of mistakes is one way to implement poka-yoke. For example, we may hedge risks at the designing stage by devising the shapes and materials of parts so that defects and assembly operation errors are unlikely to occur. Foolproof designs,” which ensures safety by designing the product so that it will not operate normally in the event of a malfunction, is also attracting attention as an effective measure.
Thorough implementation of pre-occurrence measures can reduce the risk of defective products.
This term refers to measures to minimize the impact of defective products. It refers to a system to detect defective products as soon as they pass through the line where they were generated and are transferred to the next process, and to exclude them from shipment. Even if defective products are not detected at the site where they are generated, if measures are thoroughly implemented after the occurrence, the risk of their eventual shipment or outflow can be prevented.
This term refers to measures to minimize the impact of defective products. It may include systems to detect any defective products produced in line before they get shipped to store. Even if defective products are not detected at the site where they are generated, if measures are thoroughly implemented in the inspection step, the risk of their eventual shipment or outflow can be prevented.
The following are specific examples of Poka-yoke cases that have been adopted by companies engaged in the manufacturing industry. In all of these cases, equipment and systems were introduced in response to the improvement of issues and have achieved significant results.
Fujifilm Techno Products, a medical equipment manufacturer, has integrated the RICOH SC-10A work support camera system into their unit manufacturing process for blood testing equipment. The system identifies and addresses issues like incorrect screw order or insufficient torque, minimizing potential work error occurrences.
The introduction of the system enables inexperienced workers to work at the site, reducing the need for skilled labor and securing personnel. The camera's automatic judgment history is now stored on a server, eliminating the need for filling out paper sheets during checks.
Ono Sokki, a manufacturer of measuring instruments for automobile development and research, also introduced the RICOH SC-10A for the assembly of new product systems. The system not only identifies missing installments but also saves work outcomes as images.
By introducing SC-10A as a measurement to ensure product traceability and reduce defects, Ono Sokki have improved overall product quality. In addition, standardization of process control has enabled interchangeability of personnel, leading to increased business efficiency.
Ricoh Industries, a manufacturer of small lot high value-added large-size printers, is now introducing jigs made via 3D printing technology to simplify their intricate assembly process involving numerous numbers of parts. Adopting jigs with part-specific shapes has reduced errors and has improved the assembly process's clarity. These 3D-printed jigs are manufactured using lighter resin material, enabling faster acquisition.
In addition, the production line at the site was reviewed by consolidating multiple jigs and tools and making the workbench mobile, which simplified the workflow and saved space. As a result, the number of monthly defects was reduced to zero, production efficiency was improved by more than 20%, and tool management costs were significantly reduced.
The following points will be effective in incorporating Poka-Yoke
As mentioned above, there are many different types of poka-yoke. We recommend that you keep the above points in mind when considering specific tools and improving the functionality of your poka-yoke.
First, it is important to find out why Poka-Yoke is necessary and what the issues are at the work site. There may be several factors behind the need for Poka-Yoke, such as “the manuals are difficult to understand and the work seems complicated,” “the work environment makes it difficult to concentrate on the work,” and “a culture to ensure compliance with the rules has not been sufficiently fostered. It is important to determine the key points such as “Where are the problems in your company?” and then take more effective types of poka-yokes to deal with the identified problems.
Placing the appropriate Poka-Yoke tools at the right on-site locations is crucial. Tools used for Poka-Yoke comprise of specific jigs designed to prevent errors in part installation or assembly. Based on the work site conditions, it's important to determine the optimal placement of various tools.
Careful consideration should be given to the types and placement methods of tools and equipment to ensure the work site's environment is improved.
It is also important to conduct training for employees daily and to have a system in place so that they can always respond calmly in the event of an emergency problem. Even if workers are careful about their work, human troubles may still occur, so each employee needs to have a high level of crisis management ability to quickly respond when a problem occurs. It can be said that poka-yoke is more likely to be adopted in workplaces with workers that hold strong crisis management skills and staffs who can calmly respond to emergencies.
By referring to examples of successful poka-yoke in other companies, identifying points where mistakes are likely to occur in your own company and searching for optimal countermeasures will lead to improved quality and productivity. There are a variety of systems and devices that are effective for poka-yoke, such as work inspection cameras that can digitalize quality inspections and jigs and tools that are designed to prevent mistakes, so choose the method that is most suitable for your site.
Please explore the best type of poka-yoke based on feedback from the field and use it to strengthen your competitiveness.
