POKA Yoke

[Music] various types of sequencers and indicators are assembled on the fifth floor and different work procedures and parts are used for this reason the cell production method was employed more than 10 years ago the cell production method is suited to manufacturing various products in small Lots mistakes occur because a single worker performs the entire work in addition to skilled workers quite a few inexperienced workers including newly assigned ones work at the production site to reduce mistakes Nagoya Works started to work on improvement more than 10 years ago over the past 10 years the number of mistakes has been reduced to one-tenth the e Factory technologies were fully mobilized to achieve zero mistakes and renovate the sequence or assembly cell on the fifth floor collaboration between workers and machines has been ensured [Music] this assembly cell features a job instruction system which was built by combining our sequencers and indicators [Music] now let's take a look at the screw tightening job instruction system there are two key points in the work using the correct parts and installing the parts according to the correct method in the screw tightening job instruction system the indicator screen in front of the worker displays the type and number of screws and the type of electric screwdriver to be used the LED lamp lights up to indicate the next screwdriver to be used the worker can accurately take out screws and select the next screwdriver without checking the job instruction the indicator displays the screw tightening position and tightening order the color of the tighten screws changes on the display so that the next screw tightening position can be checked at a glance in addition to instructing the word procedures the system can automatically determine the quality of screw tightening by using the sensor installed in the back of the screwdriver if a screw is not properly tightened the red patrol light and buzzer informs the worker of a problem and the screwdriver is turned off to prevent the worker from performing the next job all the data of screw tightening torque and time is collected by sensors the data is linked with the products workers and dates and times of work and is stored in a database on a real-time basis to ensure traceability management this instruction system has made it possible to standardize the work and eliminate dependence on the experience and senses of skilled workers this cell production enables newly assigned workers to ensure high quality in their work the work improvement is facilitated by analyzing the huge amount of data derived from the instruction system for example the work time of each worker can be identified based on the graph of the average work time intensive training can be offered to workers who take a long time to complete their work the number of improperly tighten screws can be displayed for each worker effective training can be offered to workers who often caused screw tightening defects the quantitative data is automatically collected and the effect of the training can be checked at a glance the graph showing the number of defects by work process helps identify the processes in which screw tightening defects often occur improvements can be made quickly by g'd replacement and design change the instruction system has helped standardize the assembly work the man hours required for training newly assigned workers have been reduced to one third through pinpoint improvement activities the familiarization period has been have resulting in a significant increase in productivity

Channel: Jakmutam

Views: 64,374

Rating: 4.928205 out of 5

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Id: hJk7ILvjy_0

Length: 5min 4sec (304 seconds)

Published: Fri Jun 02 2017