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“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?