Poka-Yoke for Quantity Shortage caused by Human Error

KCIPOH

Quite Involved in Discussions
#1
Hello All,

I'm happy to be back again in Elsmar.

Well, just want to get some inputs as lately there are quantity shortage issue in carton box detected by OQA.

The packing is the will plastics layer to be fill up with parts according to the qty per layer.

Layer have empty slots to put in parts of 3 pcs per slots and there is occurence of shortage part in slots, sometimes found 2 pcs or 1 pc in a slot.

I'm thinking whether could apply poka-yoke concept to avoid human error by operator.
 
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KCIPOH

Quite Involved in Discussions
#5
Hello All,

Thanks for all your inputs. I have common thinking as Mike S suggestion but 1 slot per part, i will need to check whether this will need approval from customer and it also affects certain documentation to be revise like QA, warehouse, production guide as well, will check upfront.

Also, i'm thinking for those part which the put into individual plastic bag before put in a slot of 4 pcs, i will ask operator to prepare and put all 4 parts in a slot instead of put them in 1 piece at a time, still under monitoring.

Kindly advise if the above is workable or any further enhancement could be made and you are always welcome.

Thanks.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#6
Have you observed the packing process? What happens when they get it right? What happens when they pack short?

I believe you said the boxes are packed in layers? If so, are the short cells always in one layer like the top? Or are they random throughout the box?

Are the shorts in all boxes or in only the first or last boxes packed?

How are the parts presented to the packers? Are they the exact number of parts that are supposed to go in the box? Are there a lot of parts and a lot of boxes?

Have you asked them why they pack short? By the way it's better to use 'what' rather than 'why' to avoid defensiveness and blame pointing...ask things like
'What prompted you to do that?"
'What is the intent of this step?'
Etc.

It's always easier to develop successful pokeyokes - or any other solution - when we truly understand the causal mechanism
 

KCIPOH

Quite Involved in Discussions
#7
Hello Bev D,

Thanks for your trigger points. The packing process is observed and found that operators are lack of knowledge for doing things sequentially whereas by this, will help them to place the part in each slot with the required qty instead of random placement.
 

Ninja

Looking for Reality
Trusted Information Resource
#8
Hello Bev D,

Thanks for your trigger points. The packing process is observed and found that operators are lack of knowledge for doing things sequentially whereas by this, will help them to place the part in each slot with the required qty instead of random placement.
In my experience, sequential vs random approach is not about knowledge, but about temperment and core personality. It is a default approach that cant be changed. ..only overridden.

If sequential fill vs random fill is what you are seeing, then you are asking about pokayoke in the wrong place....dont put it as a check for layer fill, put it as a forcing for sequential fill. (Better if you have both)
 
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