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PLANEAMIENTO Y CONTROL
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1
“Poka Yoke”or
QUALITY BY MISTAKE PROOFING DESIGN AND CONSTRUCTION SYSTEMS
IGLC16, Manchester, UK, 16-18 July 2008
“Poka Yoke”or
QUALITY BY MISTAKE PROOFING DESIGN AND CONSTRUCTION SYSTEMS
IGLC16, Manchester, UK, 16-18 July 2008
Iris D. TommeleinProject Production Systems Laboratoryhttp://p2sl.berkeley.edu/
Iris D. TommeleinProject Production Systems Laboratoryhttp://p2sl.berkeley.edu/
Shigeo Shingo (1986) Zero Quality Control: Source Inspection and the Poka-Yoke System
Shigeo Shingo (1986) Zero Quality Control: Source Inspection and the Poka-Yoke System
Paraphrased”“Inspection and statistical quality control come too late in the process to totally eradicate all quality problems.”Quality must be tackled up-front. Quality must be built into each process.
WORKERFOREMAN
INSPECTORGC
PUNCHLISTSNAGLIST
COMMISSIONINGREPORT
OPERATIONFAILURE
LAWSUIT?feedback
to worker
AEC Examples of Mistake-proofingColor Coding Drawings/BIMAEC Examples of Mistake-proofingColor Coding Drawings/BIM
(Source: DPR, Inc., Camino Medical Project)
Color coding shows locations for sheet metal straps and pipe hangers.
Source: John Mack, Southland Ind., presentation at 2007 LCI Ann. Conf.
AEC Examples of Mistake-proofingColor Coding on Site
AEC Examples of Mistake-proofingColor Coding on Site
Mistake Proofing to Accommodate Dimensional VariationMistake Proofing to Accommodate Dimensional Variation
Flexible hose (Source: Picture by Iris D. Tommelein,
Boston, MA, 2007)
?
Connect plug and wiring of light fixtures
(Source: Finelite product literature)
Mistake Proofing to Accommodate OversightMistake Proofing to Accommodate Oversight
Instruction label on outside of
fixture(Source: Picture by Iris D.
Tommelein taken at Finelite, Union City, CA, 2008)
Wiring plug for ballast inside light fixture
(Source: Picture by Iris D. Tommelein taken at Finelite, Union City, CA, 2008)
Preformed sealant grooves and guides in system panels promote accurate sealant placement between panels.
Source: http://www.butlermfg.com/images/level3_pages/returnleglink-large.jpg visited 5/23/06.
Roofing sealant grooveRoofing sealant groove
Sketch with Side View of Sink, Drain, and
Exaggerated Sloping Floor
Sketch with Side View of Sink, Drain, and
Exaggerated Sloping Floor
Sketch with Plan View of Sink Layout with Sloping Floor and Drain
Sketch with Plan View of Sink Layout with Sloping Floor and Drain
‘Bare’ Sink in San Francisco Airport, California (© 2006 Iris D. Tommelein)
‘Dressed-up’ Sink in Mich. State Univ. Conf. Center, East Lansing, Michigan (© 2007 Iris D. Tommelein)
Sink with Covered Apron in Brussels ZaventemAirport, Belgium (© 2007 Iris D. Tommelein)
Swing-away apron Provides Clearance
Swing-away apron Provides Clearance
Source: Photo by Iris D. Tommelein, Oakland Airport.
Why use Poka Yoke?Why use Poka Yoke?
Eliminate Process Variation – Make work more standard
• Ease of training• Ease of identifying improvement opportunities
– Improve Reliability of Quality– Reduce Process Time and make Time more
Reliable• No rework
– Improve Safety PerformanceALL ESSENTIAL PARTS TO TOYOTA PRODUCTION SYSTEM
Seeking Examples in AECSeeking Examples in AEC
Catalog of 150 examples from medical professionals around the country.
Published in May 2007 by the US Government (AHRQ, HHS).
Will you contribute to developing such a guide with AEC examples?
Table saw safety now: blade guard
Table saw safety now: blade guard
Table saw safety next: SawStopTable saw safety next: SawStop
What other design changes could be implemented in AEC?
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