“Poka-Yoke”, which means “error prevention” in Japanese, is the process that is used to prevent and solve defaults during the production, which reduces the need of quality inspections aftewards.
The process can be applied in any situation in which error prevention is important in any industry. Some errors that are often reduced or erased from operations can be: (1) Executional; (2) setup; (3) missing parts; (4) measurements, and other potential mistakes that may happen in this environment."
One of the major differentiator factor in Poka-yoke is that is makes the distinction between defects and mistakes. distinguishes between defects and mistakes. Where, a defect is an error that is repeated and that may arrive to the customer, a mistake is a ponctual error. Therefore, the process aims to reduce potential mistakes along the assembly, in order to reduce defects.
The process aims to avoid errors by engaging in preventive measures. It includes the following steps:
Build a multifuncitonal team
Select the process
Map the process
Identify eventual risks (ways and reasons) that may appear
Find the source
Choose the best fitted method
Implement and validate
After the process is concluded, it is important to keep a continuous improvement mindset, in order to ensure that processes are frequently optimized and that results are achieved in the best way possible.
With Glartek’s technology, data is collected from each worker allocated to the process as well as times and steps taken to execute it. The inputs include the conformity or non-conformity of the pieces. The information is furthermore summarized in a table for decision making.
Our technology can provide execution visual support. An error is detected in a dynamic way, and workers are invited to validate if the product is OK or NOK. In addition, visual evidence such as short videos or photos, can be submitted such as videos to guarantee execution.
TThe process becomes easier to execute and more accurate, since it is supported by real-time evidence and contextual data visualization. Digitizes process translate into a an improved mobility for wworkers that can now access more information about the execution of the process, in their workplace, increasing their know-how and productivity. Theplatform also translates into more information for managers, that is transformed into knowledge and becomes a huge support for decision-making.
Workflows are organized to reduce error, to be followed and to be validated. These workflows may include visual evidences one in a while, to guarantee that the standard process is being followed, and that this will translate into a reduced number of mistakes happening in the assembly line. Additionally, as a dynamic process, continuous imrovement methos are higly valued. This is facilitiated with automated reports and visual dashboards that summarizes the process and how it is executed. With this high visibility and control, it will be easier to manage conformity of processes even with big teams.