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LIST OF FIGURES
2.1 Three Possible States of Mistakes with Three Functions of Poka Yoke
19
2.2 Poka Yoke for Assembly
23
2.3 Framework of Implementation Process
25
2.4 Mistake-Proofing Levels
26
3.1 Process Flow Chart
31
4.1 Exhaust Manifold Campro
37 4.2
Jigs Before Hold the Products 38
4.3 All Products Tie at the Jigs
38 4.4
Numbers of Product Rejects in 2008 40
4.5 Percentage of Product Rejects in 2008
40 4.6
Fishbone Diagram Illustrating Possible Defect Causes 41
4.7 Poka Yoke Device
43 4.8
Gap between the Product and Jig Block at 0.5 mm 45
4.9 No Gap between the Product and Jig Block
46 4.10
Gap between the Product and Jig Block at 0.8 mm 47
4.11 Circuit Diagram
49 4.12
Schematic Diagram 50
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LIST OF ABBREVIATION
HICOM -
Hicom Engineering Sdn. Bhd Mm
- Milimeter
Pcs -
Pieces PSM
- Projek Sarjana Muda
Sdn.Bhd -
Sendirian Berhad -
Percentage
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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
2 term was changed to Poka Yoke, which means ‘mistake-proofing’. Ideally, Poka Yokes
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
Poka Yoke is 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. It can perform a
detective function, eliminating defects in the process as early as possible. From this method, it can improve the production efficiency. The factor that effect the production
efficiency are cycle time, loading and unloading time, machine breakdown, absenteeism, shortages of materials, down time of machine include machine setting, tool setting,
parameter setting and quality problems, as well as factors that are outside the control of the operation manager.
At HICOM Engineering Sdn.Bhd, the problems of miss-loading occur frequently due to full-proof system was not incorporated to the production jigs. This lead to occurrence of
product rejects and machine down time as a result of miss-loading. To solve this problem, many company implements this full-proof concept that called Poka Yoke.
Evidence shows, it have a lot of improvement after the implementation of that system.
1.3 Objectives
