Lean Manufacturing Tools – II : Visual Management and PokaYoke

Description

INTRODUCTION

This course on Lean Manufacturing Tools – II : Visual Management and PokaYoke is part of the Lean Manufacturing Tools Specialization series that is designed to give an introductory and intermediate level of familiarization on Lean manufacturing which is based on principles of the Toyota Production System.

ANDON is a visual control device in the form of visual indicators, displays and controls used to improve communication of information. An Andon system is one of the principal elements of the quality control method pioneered by Toyota as part of the Toyota Production System and therefore now part of the Lean approach.

Andon boards have not only helped in reduction of “work in progress” or lag time between cycles but have  also helped organizations not to rely on white boards, clip boards and word of mouth and even emails and intranet as a communication tool.

A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. Either the operator is alerted when a mistake is about to be made, or the poka-yoke device actually prevents the mistake from being made.

LEARNING OBJECTIVES

The course is designed as a very powerful pedagogic package interspersed with videos so that all related principles are captured as very important learning.

An understanding of the principles is essential for all – both in management and technical workforce.

On completion of this course, the user will have a good knowledge of

• Principles of visual management such as ANDON which focus attention on problem areas
• Several examples of POKAYOKE used for embedding the principle of mistake proofing into the process and aimed to not make defective parts and pass

This course is ALSO part of the is a Bundled Specialization course titled Lean Manufacturing Tools Specialization.

After this series, the participant can appreciate any course on TPS or lean manufacturing which are at intermediate or advanced levels.

ALL of our courses in this series is developed based on decades of front-line industry experience of the instructor. 

WHO SHOULD TAKE THIS COURSE

Anyone who is involved with any process, be it manufacturing or transactional. Several TPS principles can be applied in any context. It is uniformly applicable across any function. This course is equally important to any operator or management staff, , especially a new employee

You might also want to consider  to take the course on Six Sigma Specialization along with this course.

COURSE CONTENT 

• INTRODUCTION
• VISUAL MANAGEMENT
  • Fundamentals with Examples
  • Why Visual Management
  • How Visual Management
  • Steps to Visual Management
  • Andon
  • Andon – Movie
  • Tips for Visual Management
• POKAYOKE
  • What is POKAYOKE
  • 1-10-100 Rule
  • Purpose of Poka Yoke
  • Types of Poka Yoke
• EXAMPLES OF POKAYOKE
  • Poka Yoke Example #1
  • Poka Yoke Example #2
  • Poka Yoke Example #3
  • Poka Yoke Example #4
  • Poka Yoke Example #5
  • Poka Yoke Example #6
  • Poka Yoke Example #7
  • Poka Yoke Example #8
  • Poka Yoke Example #9
  • Poka Yoke Example #10
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ