Monitoring and preventing errors during manufacturing

In Toyota's manufacturing system, the Pokayoke concept is used to prevent, monitor, detect and handle issues or errors, help control work processes, minimize errors to improve quality and efficiency in manufacturing.

Pokayoke is the system use a set of standard and visual step-by-step procedures to help workers comply, detect errors in each operation, guide, orient and control wrong actions. This system may include instruction boards, signs, signal lights, buzzer, etc to identify and alert throughout the operation. These resources are coded using the standard color set, easy to see, track and control, eliminate wrong operations, omissions, non sequential activities … will help to eliminate the maximum of defective products, improve quality of output product. Pokayoke can also be understood as a component in the Andon system.

Functions of Pokayoke:

• Error detection: Errors and errors that occur during the production process are inevitable in any model. Failure to detect early will lead to the failure of semi-finished products, defective components go to the following stages, forming defective products.
• Error handling: When detecting problems, errors quickly and instantly will help to fix simply, quickly and more effectively.
• Error prevention: the system helps detect errors quickly, alert immediately to the relevant operator and stop production. Therefore, the elimination of semi-finished products is eliminated, resulting in no longer defective products.

Pokayoke application process:

• Developing standards set: issuing working process sets and standard operating sets;
• Building Pokayoke: depending on the characteristics of the industry, the system will be surveyed and built by sensors, signal lights, buzzer alerts … to operate properly with the standard operation sets already available.
• Pokayoke application:
  • Guide by signal lights, when the worker needs to do next action, the light in that position will light for navigation.
  • Activities will be instructed to collect in the correct order and position.
  • Wrong activities will warn with red lights and horns
  • Sequentially turn around for each product.
  • Use the instructional video/slide if needed through the on-site screen

For effective implementation of Pokayoke systems, contact Avani – The first manufacturer and implementation of the Andon solution in Vietnam, with leading position and experience through many projects for multinational factories, such as Japan, Korea, USA and Europe for the most effective solution advice.