How do you ensure quality and customer satisfaction using lean methods such as poka-yoke and jidoka?

The Bluetooth Torque Meter: A Poka-Yoke Revolution Traditionally, the manufacturing process relied on popular torque meters to determine the correct level of tightness for fastening and fixing components. However, the team saw an opportunity to introduce a new approach by integrating Bluetooth technology into a state-of-the-art torque meter. The Bluetooth torque meter was designed to be a poka-yoke device, capable of preventing errors and defects during the fastening process. It was equipped with sensors and alarms that would alert operators in real-time if any deviation from the desired torque occurred.This innovative solution aimed to eliminate the risk of under-tightening or over-tightening, ensuring the utmost precision and reliability.

Poka-yoke in assembly operations. During my career in manufacturing I have seen some good examples of “mistake proofing” in assembly operations, it takes design work for it be effective. In Computer assembly I have seen where connections have been designed that cables or other components will only fit one way, this means a mistake cannot go to the next stage of assembly.

The jidoka system not only served as a safety net but also fostered a culture of continuous improvement. Regular kaizen events were held, where workers and supervisors came together to analyze the root causes of defects and identify areas for enhancement. Here are some additional examples of visual controls that can be used in a jidoka system: 1-Color-coded indicators: Different colors can be used to represent specific statuses or conditions in the assembly process. For instance, green may signify that a step has been completed successfully, while red may indicate a problem or defect that requires attention. 2-Error-proofing labels 3-Visual work instructions

Judoka - Good use of Intelligent automation eliminates the need for human visual inspection, which is only 85% effective and enables 100% effective screening of defects. I have seen these methods used well in molding processes, screening out defects during the process, usually removing defects when discovered instead of waiting for an inspection at the end.

As a manufacturing company we have to follow the poka-yoke and jidoka instructions in whole production line of electronic and mechatronic components (such as ECU, APM ,ETB and ABS modulators for quality and customer satisfaction. Through the combined power of poka-yoke and jidoka, the company achieved remarkable results. The cost of quality decreased, defects were minimized, and customer satisfaction soared. Their dedication to safety, reliability, and continuous improvement solidified their position as an industry leader.

Customer satisfaction is essential for businesses to grow and stay profitable. Building a culture where everyone is considering the customer’s needs is key to the success of reducing quality costs & improving customer satisfaction. The use of quality tools can inspire operators and engineers to get involved in continuous improvement projects. Kaizens are a great tool to build engagement with employees at all levels and utilizing a cross functional team creates solutions that would not be possible using one functional group.

The Connector's Journey: Poka-Yoke and Jidoka in Electrical Component Manufacturing" Armed with this knowledge, the company assembled a cross-functional team to brainstorm innovative solutions. They utilized PDCA cycles, Failure Mode and Effects Analysis (FMEA), and TRIZ to generate and evaluate ideas for poka-yoke and jidoka techniques or devices. The team explored possibilities such as foolproofing mechanisms, error detection sensors, and automated inspection systems. To validate the effectiveness and feasibility of these solutions, the company conducted small-scale or pilot projects. They employed A/B testing, prototyping, and simulation techniques to measure the impact of the proposed poka-yoke and jidoka measures.

Implementation of polka-yoke and jidoka In my experience a Kaizen is a good opportunity to get a project started, process mapping identifies the defects and errors in the process. The DMAIC process gives you a good roadmap to work through Defining the problem you want to solve or improve, Measure the baseline of previous performance, Analyze the root causes impacting the metric you want to improve, use FMEA to prioritize the most impactful root cause, define solutions to Improve and put Control measures to monitoring effectives of your actions. During this process you can trial solutions on a small scale to test them out before going full scale. During this process it is essential to include input from all process owners and operators.

The team began by integrating a non-stop Automated Optical Inspection (AOI) controller and counter into their production line. This state-of-the-art technology would continuously monitor the injection process, inspecting each bottle cap for defects, such as imperfections, warping, or incorrect dimensions. Any faulty caps would be immediately identified and separated from the production line. The benefits of implementing poka-yoke and jidoka quickly became apparent. The quality of the bottle caps skyrocketed, virtually eliminating defects and reducing customer complaints. The AOI controller and counter acted as an ever-vigilant guardian, ensuring that only flawless caps moved forward in the manufacturing process.

Benefits and Challenges Poka yoke and jidoka are not applicable to all manufacturing processes. Poka yoke is very applicable in assembly type processes, especially if it is possible to design mating components so that they can only be assembled in a unique way. Jidoka is applicable where automation is heavily used in the process as you are likely to have the technical support you need to support these solutions. If operators are involved in designing solutions and understand them change management is easier.