PRODUCT QUALITY IMPROVEMENT THROUGH POKA YOKE TECHNIQUE

Abstract

This paper focuses on a quality improvement project at JWS (company's name
abbreviated for confidentiality) using mistake proofing technique or Poka Yoke.
The study is aimed at providing improvement ideas for existing problems at the
manual assembly stations for product at D73A line. Investigations were conducted
to identify causes ofdefects. Using results ofunstructured interviews, and relevant
data and from factory observations, the problem was analyzed using cause and
effect diagram where the main causes were identified. To improve the existing
problems, alternatives are generated using Poka Yoke and successive inspection
techniques. Each alternative is evaluated in terms of its expected potential
improvement and estimated cost of implementation . The evaluation indicates that
Poka Yoke device proved to be the best alternative. This alternative was later
presented to the company's management for further evaluation and comments.
The study culminates with proposed solutions to improve productivity at the
factory and future study.