Poka Yoke is a series of techniques used to error proof, mistake proof or create a fail-safe process that is designed to prevent errors, defects or mistakes. Even more specifically a poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to errors as they occur. The concept was formalized, and the term adopted, by Shigeo Shingo as part of the Toyota Production System.
Reference: Wikipedia - Poka-Yoke
PDCA or plan-do-check-act is a four step method used in lean, quality improvements and other continuous improvement strategies. In the first stage plan, a plan based on historical background data and root cause analysis is formed. This plan is designed to invoke or effect change in a positive way. In the second stage of PDCA (do) the plan is carried out. This is generally a small scale pilot or initial test run of the plan. The third stage of PDCA is the check stage. Here the outcome of the plan is analyzed or studied as it is often referred to in PDSA. The fourth step is act which is focused on adjusting the do based on lessons learned in the check stage. You may hear the PDCA cycle referred to as the Shewhart cycle because Walter A. Shewhart discussed the concept in his book Statistical method from the viewpoint of quality control.
A problem is a deviation or gap between what is actually happening and what should be happening. A problem can also be defined as any customer need that is not met on-time in the right amount and in acceptable quality (according to the customer).
Problems can typically be categorized into one or more of the following categories:
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Process variability is the variation or lack of consistency in a process. The variation causes the process to deviate from a fixed pattern in such a way that results in inconsistent, unpredictable and non-repeatable outputs (Y).
Process Stability is the consistency of a process in relation to important/critical process characteristics such as dimensions. When a processes outputs show consistency over a period of time that process can be considered stable or in control. Processes often become stable when variation in a process is reduced, resulting in a more consistent, repeatable outcome.
The ABC's of