10.2 Poka Yoke

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9 hours 3 minutes
Video Transcription
Hi, guys. Welcome to improve days, Polka. You okay? I'm Catherine Nick Iver. And today we're going to understand Polka you okay? And its applications and identify Pokey OK in your workplace. So this is it for me, guys? Like, if I could just do organizational capabilities and maturity
and poker, You okay? I'd be the happiest practitioner in the world.
I love this.
What is it?
Okay. Okay. Is mistake profane? So rather than fixing defects or fixing processes or eliminating waste, you
move your improve things such that they never happened in the first place. So rather than being reactive, where we're going back in fixing something or doing re work we're doing to make projects to make sure that it doesn't happen again in the future, we just do it right the first time. And we do it right the first time by creating guard rails
so ways to know that you are always doing it right. So
okay, okay. Reduces defects and rework because you do it right the first time. It also decreases the need for auditing and supervision. And the reason that it does that is because it creates this almost automated oversight of the work that you're doing. So when you think about doing poker, you okay? What you're going to think about is
what are the ways that I can eliminate the decision
10 points in my process. So if you think to our previous module about future state process mapping, one of our decision points was Is the customer ready to order? Well, we could We used some pok pok okay in our example,
but not having the process start until the customer is ready to order. So there is no decision point that's associated with it. So
I really love this because it's mistake proofing. There are two ways that you can do mistake proofing. The first way is did you mean to do this? So it is still a little bit reactive because it happens after the task has taken place. But it is a Are you certain that this is what you want to d'oh
on? My the best example I've ever seen is spell check in the Microsoft products, or spellcheck is a hole where it pops up and says, Are you sure you meant to say this? One of the even better examples that was very customers to a person is one of my black belts. Um,
once upon a time,
really liked to send very aggressive e mails, the emails that would be described as flaming, um, or very inflammatory. So he liked to send these very strongly worded e mails. And as his manager, I had to have these conversations with him like that.
That's not how you play nice in the sandbox. Like
remember, lean six Sigma people. We we work a little bit in relation equities. So you got to kind of have to have people want to work with you. Otherwise you have no project teams. So the solution that he and I came to was we identified
you. What are the most common phrases that he used in the strongly worded e mails?
So think about like a hist a gram where we have a frequency distribution of these phrases. And he and I created a rule in his email that gave him a pop up. If any of those phrases were in there. So in addition to spelling and grammar, if he had a email that perhaps had the words say
innit? You he when he goes to click to send, he would get a pop up. That says, These have some of your inflammatory phrases. Are you sure you want to send this? And it was brilliant.
It really solved the problem of people not liking him in the workplace because it made him be thoughtful about whether or not he really wanted to send this email or if it was in a moment of passion.
So it decreased the number of flaming emails that he sent an increased people satisfaction with. Working with him is a practitioner, so a very customized solution related to a problem back to spelling and grammar. This is going to be a very broadly applied solution, but the problem was, people needed help with their spelling and grammar.
The other way that you can do polka Yok is make sure that it can only be done one way. So if you think about a three pronged outlet, it only goes in one way because the prongs air different shaped a huge miss in This is a USB drive
like why didn't we just put a notch on the top of it? So it only goes in one way because I don't
I don't understand why, but it only it always goes wrong the first time. So if we were to redesign the USB drives, which I get doesn't happen because we've we've missed the boat on that one. We would part maybe a notch, or maybe make it triangle shaped or quad
quadrangle shape whatever shape the DHD, my ideas.
In that way, it only goes in one way. So now you don't have rework and defects from where you have to pull it out and flipping in the correct way. So when we think about only done one way, we're going to think about not only physical measures but also some informational measures. So if you think about it can only be done one way.
A data validation or a rule set on data entry is a only done one way.
Polka, You okay? You cannot submit this form until you have completed all of these fields, which I would recommend you go back to the very beginning when we talked about DPM Oh, and your defects. And if you can create a way such that you can on Lee submit things or only do things
where is not a defect for you. It changes your DPM. Oh, which then, of course, decreases the number of defects and we're being proactive
and how we are solving our problems. So
when I think about how we can apply Pokey okay, in an improved state, when we think about what our solutions are, we wanna ask ourselves, Do we have a reactive? Are you sure you meant to do this feedback loop built in? Or do we have a proactive It can only be done one way type of process built in.
So Okay, okay. Prevent is mistake proofing. That's Japanese for mistake proofing to prevent waste from occurring in the first place. So it is a very preventative, proactive tool. I wanted to go over this one first because I think that this this tool is integral in your improved days because
rather than going back to that domestic cycle where remember in your organization domestic is a cycle,
you finished control. You start with defined and you do it all over again. You are decreasing the need to ever have to look at this process again because you are being preventative. So that's the reason why it is my favorite tool. It can be done two ways, either. Slightly reactive. Are you sure you meant to do this or more proactive in?
You can't even do it the wrong way the first time out. So
with that, we're gonna move into more of our improved phase tools and welcome again to our improved these guys.
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