Manufacturing Technology for Reducing Mistakes and Increasing Efficiency in the Manufacturing Process Using Poka-Yoke

Poka-Yoke is a prevention method for mistake-proofing or inadvertent errors occurring in manufacturing processes. Those mistakes or errors may be due to man, machine, method or material. From the results of the working process study, the mistake of shipment by attaching a tag alternately between the 2 models was found because of 3 main causes: man, method and material. Waste in such a manufacturing process was also found. Then, the Poka-Yoke technique was employed to determine the solution to problems for reducing such mistakes and increasing the process efficiency in manufacturing, resulting in reducing such mistakes to zero. In addition, the ECRS principles were brought to apply for improving the working process. It was found that the working time in processing the product can be decreased 139 minutes or 28.55% and the total distances for transportation in the process can be reduced by 112.5 meters or 90.87%.