B

• key element in or capability to implement Kaizen

  lean manufacturing systems
• lean manufacturing is a methodology that focuses on manufacturing systems while simultaneously maximizing productivity
• Making processes better leads to reduced

  • Rework
  • Scrap
  • Warranty costs
  • Inspection costs
• everything we do that costs something without adding value to the product

  waste
• Value added = Maximum

  Non-value added = Minimum
• producing in excess of customer demand or earlier than required

  overproduction
• product, people, or machines pending action

  delays
• processing in excess of customer requirements

  excess processing
• people or product moving between processes

  transportation
• materials and product in excess of immediate customer requirements

  inventory
• people and machines movement while performing tasks

  motion
• repeating task due to poor quality

  defects
• is the continuous elimination of waste


  continuous improvement
• Elimination of waste

  • Identify waste
  • Search for causes
  • Implement continuous improvement
  • Check and Measure results
• Japanese term or technique used in manufacturing and process management to prevent errors or defects from occurring during production or operations.

  Poka-Yoke
• ZDQ stands for?

  Zero Defect Quality system
• No finger pointing! Operators and Machines will sometimes make mistakes
• almost any business activity can be considered a process
• production processes involve the flow of material, machining, assembly, and packaging
• To reduce quality defects, we must

  • Understand the process of its relationship to other business processes
  • Identify the inputs and outputs of the process
  • Know who are the suppliers and customers of the process
• a component of ZDQ which is one of the basic approaches to inspection


  point of origin inspection
• Point of Origin Inspection

  • Check optimum process conditions before processing is done and errors can be made
  • Instant feedback
  • Corrections made before defects occur
• 4 components of ZDQ

  • Point of Origin Inspection
  • 100% Audit Checks
  • Quick Feedback
  • Poka-Yoke
• a method that uses sensors or other devices to catch errors that may pass by operators or assemblers

  Poka-Yoke
• Poka-yoke an Point of Origin Inspection are what type of approach


  Proactive approach
• Poka-yoke and Informative Inspection are what type of approach


  Reactive approach
• this Poka-yoke system approach shuts down the process when an error occurs 


  Control approach
• This type of Poka-yoke system approach signals the operator to stop the process and correct the problem

  warning approach
• This primary method of Poka-yoke functions by detecting whether a sensing device makes contact with a part or object within the process

  contact method
• photoelectric switches can be used with objects that are translucent or transparent upon the need
• this switch makes contact with a metal barb sensing its presence


  limit switch
• This primary method of Poka-yoke functions is used when a fixed number of operations are required within a process or when a product has a fixed number of parts that are attached to it

  counting method
• This primary method of Poka-yoke functions uses sensors to determine if amotion or a step in a process has occurred

  motion-sequence method
• these devices work by physically touching something

  physical contact sensors
• this switch is used to physically detect the presence or absence of an object or item-prevents missing parts

  touch switch
• these devices work by using energy to detect whether or not an defect has occurred

  energy sensors
• these sensors signal the operator that there is a problem using colors, alarms, lights to get the workers' attention

  warning sensor
• to avoid = yokeru

  inadvertent errors = poka
• eliminates the possibility of a mistake to occur


  control
• signals that a mistake can occur


  warning