Archive for Poka-Yoke
Marketing E-book on using Lean Tool of Poka Yoke
Posted by: | CommentsCreated a short e-book on Mistake Proofing your Marketing by using the Lean tool of Poka-Yoke. The e-book is not meant to be a complete diagram of Poka-Yoke but an alternative apporach to help facilitate and create some additional ideas on how to improve your marketing.
Free download, just please keep the tags and links intact.
What to do with the Root Cause?
Posted by: | CommentsWe have found the root cause but how do we correct it? The correction may seem easy at this point but how do we know it is just not a band-aid. My preference is to go back to the Fishbone diagram and use the same method we use in discovering the root cause to discover the best solution. I also use the matrix to visualize and confirm the final choice. 
One of the important things you now must do is to consider the control device you will use to monitor the progress. In manufacturing we consider limit switches, stop/no go gauges. However, in service industries it can be much more difficult. In event planning though it could be something like an ineffective advertisement. You could build into it milestones that if it not achieved that certain positive or negative consequences occur.
Another example may be in developing advertisement copy; you may have certain acceptance criteria that are built into the process. It could be time sensitive, for example. You must remember even what seems like the best solution, if is uncontrollable will not lead to good results. You may want to consider another alternative and a result is that the perceived best action may change or become clearer as you improve. The method:
- Start with the Root Cause of the mistake. Brainstorm ways to eliminate the mistake(Fishbone).
- Note on each idea how you will handle the mistake: Don’t Accept, Don’t Make, Don’t Pass On.
- Consider the cost and time of solving the problem
- Place in matrix on Easy/Hard to do, Big/Low Payoff.
- Review the controls to use.
- Make your choice.
- Proceed and monitor.
Other Related Posts:
You can implement Poka-Yoke
Posted by: | CommentsThese are the the tools I use for Poka-Yoke Implementation. It will make you as “Smart as a 5th Grader.” Yes, this is not rocket scientist stuff. It is easy and simple. Now, these methods alone will not get you to Six Sigma Quality levels but they will start you on the path of continuous and measured improvement. So what are the tools?
The first tool I use may not be considered a tool at all, it is a mind set, This is NOT WHAT to DO. I keep this diagram around and embed it in most of things that are printed. It is very simple but the key to making a successful Poka-Yoke campaign.
The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.
Organize your mistakes(errors) and group them according to the Matrix. This will simplify the selection process on what mistake to tackle first.
I also have a list of Common Red Flag Conditions. These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first “WHY” in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing.
- Frequent changes to a job
- Complex processes
- Lack of Standards
- Lack of measurement systems
- Lack of training
- Long cycle times
- Infrequent jobs
- High output
- Environmental conditions
- Attitude ( Motivation)
The one tool that I left is the project sheet. We will start completing the components of this in the next blog and start creating a Poka-Yoke process in it’s entirety.
