The Operational Exceed team would like to share a new tool that aims to eliminate defects in and errors from occurring in a product or service. In lean methodology this is known as Poka-Yoke, which is a form of Error Proofing, designed to stop mistakes and errors from occurring in the first place This is something we should be doing wherever possible, to safeguard our business.
Error Proofing is achieved by using a mechanism, device or system that prevents mistakes from being made, or failing this, detects them before the customer or end user does. At home, a good example of error proofing is a medicine bottle equipped with child resistant locks and clips, or washing machine that cannot start until the door is locked shut.
How can this be implemented at Cemex?
An example of how the Poka-Yoke methodology can be used on our sites: many of our sites have AdBlue tanks. Fuel nozzles look similar and it could be easy to get them mixed up and use the wrong fuel causing operational downtime! Applying the error proofing methodology would equip fuel nozzles with a magnetic mechanism that will only allow the release of AdBlue when the nozzle is inserted into the correct filler cap.
By removing mistakes, the reliability of our processes can be greatly enhanced, demonstrating a commitment to the quality of our products and services.
The Exceed Operational Excellence Team are pleased to share this interactive Toolbox Talk, utilising Microsoft Sway. This Toolbox Talk gives you an overview on the history of Poka-Yoke, the importance of eliminating errors, and examples of how we can implement Poka-Yoke at Cemex. You’ll also have the opportunity to share where you have eliminated errors in your work.
If you would like to know more about Poka-Yoke, or Error Proofing, please contact a member of the Exceed Operational Excellence Team.
Click here to access the Toolbox Talk Sway. You can also download a poster designed to give a brief overview of the Error Proofing methodology for sharing on notice boards. You can find this here.