from the conferences organized by TANGER Ltd.
Poka-yoke (mistake-proofing) is one of the lean manufacturing methods. It ensures that proper conditions exist before actually executing a process step, preventing mistakes from occurring in the first place. Where this is not possible, poka-yoke has a detective function, eliminating defects in the process as early as possible. The application of simple poka-yoke methods in product and process design can eliminate both mechanical and human errors. Modern production systems are based on principles and instruments of the lean, agile and resilient approaches to manufacturing. For these conditions the poka-yoke system preventing errors is the most desirable. This paper deals with design of the complex methodology for poka-yoke implementation for such manufacturing. The methodology is based on the following principles: 1. principle of prevention; understanding poka-yoke as a change and innovation; implementation of poka-yoke as a change and innovation management. In the paper there are described particular steps of the designed methodology: 1. identification of all potential risks; 2. giving reasons for suitability of the poka-yoke implementation; 3. selection of the poka-yoke type; 4. design verification and its realization; 5. description and documentation. In the last part of the paper two cases of implementation of the designed methodology in conditions of the production of welded steel tubes are described: poka-yoke preventing usage of the non-correct rollers and poka-yoke preventing undesirable interchangeability and loss of the production dispatch notes.
Keywords: lean approach, agile manufacturing, resilience, poka-yoke© This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.