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CHAPTER 1
INTRODUCTION
This chapter introduces the background for the project, defines the problem statement, set objectives and scope for this study. An overall structure of this project is also
provided.
1.1 Background
1.1.1 History of Poka Yoke
Poka Yoke was coined in Japan during the 1960s by Shigeo Shingo who was one of the industrial engineers at Toyota. Shigeo Shingo is also credited with creating and
formalizing Zero Quality Control Poka Yoke techniques to correct possible defects plus source inspection to prevent defects equals zero quality control.
Originally described as Baka-yoke, but as this means “idiot- proofing” the name was changed to the milder Poka Yoke. Poka yoke pronounced “POH-kah YOH-keh” means
“fail-safing” or “mistake proofing”. Avoiding yokeru inadvertent errors poka is a behavior-shaping constraint or a method of preventing errors by putting limits on how an
operation can be performed in order to force the correct completion of the operation. Where this is not possible, Poka Yokes perform a detective function, eliminating defects
in the process as early as possible.
In 1963, a worker at Arakawa Body Company refused to use baka-yoke mechanisms in her work area, because of the term’s dishonorable and offensive connotation. Hence, the
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ensure that proper conditions exist before actually executing a process step, preventing defects from occurring in the first place. Where this is not possible, Poka Yoke perform
a detective function, eliminating defects in the process as early as possible.
1.1.2 Company Background
Hicom Engineering is a member of DRB-HICOM group of companies, offering state-of- art manufacturing capabilities to our customers. Hicom Engineering manufacture,
machine precision castings and assemble components for automotive and general engineering purposes. Located in Selangor, Malaysia, Hicom Engineering was
commissioned in 1991 with a total paid-up capital of USD8.07 million and a total investment of over USD18.4.
As one of Malaysias leading manufacturers of cast-iron automotive components, we have a strong commitment to constantly improve the quality of our products. The MS
ISO 9002 certification has only enhanced our commitment. Utilize the latest technological advances in support of our commitment to continuous improvement and
provide the highest quality castings.
Hicom Engineering employs a diverse group of dedicated individuals with extensive experience in foundry and machining. Our employees are committed to the growth of
the company and to achieving consistent quality for every Hicom Engineering product. Everyone at Hicom Engineering is responsible for hisher contribution to total quality
that is a result of a unified approach at providing our customers with products that meet
and exceed their expectations.
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1.2 Problem Statement
