Principles of error minimization

poka yoke

It is a technique that aims to introduce some modifications to some parts of the product or operating devices and equipment to ensure the safety of operation and the absence of any damage to the product or equipment or any injuries to individuals, and this activity is considered part of the activities of industrial engineering.

Since man is an essential party in most industrial and production processes, and even automated processes are also carried out under his supervision, so he is present in all cases, so a large area of continuous improvement work has been directed to protect people and protect equipment and products from any problems, accidents, or errors that occur as a result of human omission, error, or A defect in the equipment, but many of the international security and safety specifications for the design of the equipment included many controls, and most of the equipment, especially the automated ones, became equipped with safety devices, and even written on some equipment in clear handwriting (please make sure of the safety and performance of the safety devices).

Although the basis for improvement is sometimes directed at preventing errors, it usually brings positive results in all areas of reducing waste and improving productivity and quality.

Improvement usually results in all directions, and therefore companies are keen mainly to continue the improvement work at all levels.

These innovations are usually of low cost and have positive results, and the workers doing the same work must participate in the improvement after receiving appropriate training and education.


Methodological foundations to reduce error

1- Applying the concepts of improving the work site as a basic step to reduce the possibilities of accidents and errors, as well as applying security and safety instructions for work sites.

2- Applying the concepts of reducing human stress (principles of movement economy).

3- Encouraging improvement innovations that reduce dependence on concentration when performing various works and prevent completion of the work in the event of installing a part in the wrong way or operating a function of the equipment in the wrong way, and this includes the use of jigs for production processes that prevent various operating errors

4- Concepts of teamwork (small groups and work teams) should be employed and these groups and teams should be trained on the mechanism of preventing mistakes on the basis of:
o Data collection and analysis.
o Finding and fixing errors.
o Search for solutions on the basis of a protection device for each fault, and the number of devices that each equipment is equipped with depends on the equipment itself and the number of its functions.

5- Studies and research should be classified taking into account the elements and components on which the industrial activity is based, namely:
Manpower (training and increasing their skills).
Equipment and technical facilities (provided with appropriate safety devices).
Methods and methods (good design of processes reduces chances of error).
Physical work climate (presence of dirt, dust and feathers – temperature – appropriate lighting – noise and noise – – – etc.)
Moral work climate (Management style to encourage competition, cooperation and motivation – removing psychological work obstacles – – etc.

Any defect in any of these elements could be a cause of errors.

Error prevention techniques can be employed in product inspection work by using mechanical or physical monitoring devices (suitable to the physical nature of the product) in order to achieve 100% inspection efficiency. These devices can be a tool to control the production process (stopping the equipment or production line) or an alarm to alert the worker to speed Acting, or automatic error correction.

Employing the technique of examination at the source (which does not mean dealing with defects after they appear, but rather means discovering errors before they turn into defects and stopping the system until the error is corrected or corrected automatically), along with the use of error prevention devices, are the complete guarantee to prevent the production of a product. Defective, as it is applied to the product by one hundred percent, and this provides better results than using statistical quality tools, as the corrective action is delayed until samples are collected and studied, and it is only samples examined and does not include the whole product, and therefore the statistical quality is not sufficient to reach a product without defects ( Zero defective product ) .

The alarm system must be chosen appropriate to the nature of the work site and the response of the workers. The sound warning is appropriate if the worker does not pay attention to the traffic light, and so on.


Examples and examples of error prevention techniques





In light of the tremendous and rapid progress in the technological fields, production equipment has become more advanced than before and includes many systems necessary to perform its tasks and functions, such as:

¨ Hydraulic system: It includes hydraulic pumps, cylinders and valves and needs to monitor oil temperature, pressures and travel distances.

For cylinders – – – – etc

¨ Pneumatic systems: Similar to hydraulic systems in their work.
¨ Thermal systems: It includes heaters, coolers and heat exchangers.
¨ Electrical systems: It includes electric motors as well as all electrical control circuits such as switches and sensors.
¨ Mechanical systems: include means of transmission, and mechanical linkage elements between the different parts.

Different types of sensors have been placed inside each system to suit the type of system (hydraulic – thermal – electrical – mechanical … etc.) so that these sensors transmit the actual values of the variable elements such as (speed, pressure and temperature) directly to the computer .

These sensors play a major role in the safety system as they stop the equipment directly or through the control system in the event of an operating error or a deviation in the specifications.

Sensors include stroke end switches, proximity sensors, fluid pressure switches, temperature sensors, and others



Visual observation

The visual control is considered as a mechanism that makes the natural and abnormal matters clear for the speed of action and taking any necessary corrective actions, which reduces the possibilities of error, such as:
Warning signs of dangerous areas.
Warning bells.
· Signs to guide individuals to avoid operating hazards.
· The use of transparent covers for some parts of the equipment that need monitoring.
Markings for thermal zones and electric voltage zones.
Special colors for tubes according to their types.
Marks on the ground for places of operation and walking places.
The operating control panels of the production lines with the production system on time is another example.

And the efficiency of visual monitoring can be measured on the basis of the ability of a strange visitor (an important customer, for example) to collect the largest amount of information about the work site (approximately 75%), including information about the criteria for measuring efficiency (through billboards), without the need for a procedure Conversations of any kind with any party.


industrial engineering website that contains engineering information, engineering books, projects, exams, manufacturing, quality, project management, health and safety.

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Check Also
Back to top button