Poka Yoke

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來自 University System of Georgia 的課程

Six Sigma and the Organization (Advanced)

246 個評分

University System of Georgia

Six Sigma and the Organization (Advanced)

246 個評分

課程 1（共 4 門，Specialization Six Sigma Green Belt）

This course is for you if you are looking to dive deeper into Six Sigma or strengthen and expand your knowledge of the basic components of green belt level of Six Sigma and Lean. Six Sigma skills are widely sought by employers both nationally and internationally. These skills have been proven to help improve business processes and performance. This course will introduce you to the purpose of Six Sigma and its value to an organization. You will learn about the basic principles of Six Sigma and Lean. Your instructors will introduce you to, and have you apply, some of the tools and metrics that are critical components of Six Sigma. This course will provide you with the basic knowledge of the principles, roles, and responsibilities of Six Sigma and Lean. Every module will include readings, videos, and a quiz to help make sure you understand the material and concepts that are studied. You will also have the opportunity to participate in discussions and peer review exercises to give you the opportunity to apply the material to your daily life. Registration includes online access to course content, projects, and resources but does not include the companion text The Certified Six Sigma Green Belt Handbook (2nd edition). The companion text is NOT required to complete the assignments. However, the text is a recognized handbook used by professionals in the field. Also, it is a highly-recommended text for those wishing to move forward in Six Sigma and eventually gain certification from professional agencies such as American Society for Quality (ASQ).

從本節課中

Lean Principles in the Organization

In this module, Dr. Bill Bailey will introduce you to the history of lean as well as new lean concepts. Dr. Bailey will also explain the five lean principles. In addition, this module will introduce you to more quality tools used in lean. This module also begins with a Yellow Belt Refresher Area, since some learners may have entered this course without having taken the previous yellow belt material. This refresher area does not serve as a "replacement" for taking the yellow belt material. It is only a "patch" for those who already have some knowledge of six sigma, but find the yellow belt specialization to be too introductory for their current situation. If you find yourself struggling with the green belt material in this course, it is highly recommended that you travel through the yellow belt specialization before attempting the green belt content.

Explaining Yellow Belt Refresher Areas1:26

Purpose of Lean5:54

Value Stream Mapping3:58

JIT and Kan Ban8:05

Value to the Organization2:45

Suboptimization6:07

Kaizen and Kaizen Blitz4:04

Cost Benefit Analysis3:50

Cost of Quality4:15

與講師見面

David Cook, PhD
Assistant Professor of Mechanical Engineering Technology
Department of Mechanical Engineering Technology
Bill Bailey, PhD
Assistant Professor of Industrial Engineering
Department of Systems and Industrial Engineering

"Poka yoke" is a Japanese phrase meaning mistake proofing.

It is meant to shape behavior at the level of execution.

There are two approaches to this.

One is to prevent humans from making a mistake,

to physically prevent it.

If it's not possible to prevent the mistake,

you can use poka yoke to anticipate and warn of mistakes.

Perhaps the easiest way to understand poka yoke is to see some examples.

There are many applications of mistake proofing,

many of them are related to safety.

The microwave oven will not operate if the door is open,

rumble strips on a highway let you know if you're wandering off the road,

and speed bumps cause you to check your speed.

If you've ever painted a white ceiling you know that it's extremely

difficult to see if you've missed any spots because you're painting white over white.

Later, when the light changes,

you can see your mistakes.

Glidden makes a ceiling paint that goes on pink,

making it easy to see if you've covered everything;

then when it dries, it turns white.

You know why manhole covers are round?

That's the only shape that cannot possibly fall in the hole.

Most sinks have small slots or holes at the front or the back near the top.

Their purpose is to prevent overflow if you leave the water on.

In developed countries many restrooms have motion-sensitive lights in commodes.

The lights are not on except when needed,

saving energy, and commodes flush automatically.

In manufacturing most machines are well-guarded these days.

Injection molding machines, for example, have mechanical, hydraulic,

and electrical interlocks that all engage to prevent

the machine from working when you slide open the door.

This is a novel poka yoke to ensure that bolts are tight.

There's a washer with bits of plastic on it that goes under the head of the bolt.

When the bolt is properly tightened,

the plastic squirts out.

This is a common jack for phone or internet.

The tab marked B keeps the connector from being inserted upside down.

The tab marked A is designed to protect tab B and keep it from being broken off.

Knowledge in the world is information that's embedded,

encoded, or implicitly resides in the components of a task.

Here, the shape of the dipsticks communicates their purpose.

The yellow dipstick is shaped like an O and is used to check the oil level.

The orange dipstick is shaped like a T and is used to check,

you guessed it, transmission fluid level.

It's ironic that this design is very language-specific but comes on a Japanese brand.

New lawnmowers are required to have

a safety bar on the handle that must be pulled back in order to start the engine.

If you let go of the safety bar the mower blade stops in three seconds or less.

This is a medical example.

A tube is inserted into the patient's lungs.

But how do you know if it's in the right place,

in the lungs, not the stomach?

Squeeze the plastic bulb and then put it on the tube.

If the bulb inflates with air,

the tube is in the lungs.

If not, then an error has occurred.

This final example has three poka yokes designed in.

In countries where they drive on the left side of the road visitors can get confused.

Offset crosswalks and accompanying railings force pedestrians

to turn and walk toward oncoming traffic so they can see what's coming.

Instructions printed on the blacktop or curb say "look left" to direct

pedestrian vision in the proper direction and

the jagged lines warn drivers that they're approaching a crossing.

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