IMPROVING QUALITY AND REDUCING REJECTS IN THE PRODUCTION LINE VIA POKA-YOKE TECHNIQUES

In the current era of competition, any organization has to produce quality products that are free from defect at the costof optimum. New culture of total productive management, total quality management in manufacturing and servicessector produced new methods for ensuring quality of product. Applying some tools of TQM such as KAIZEN, SixSigma, JIT, JIDCO, POKA YOKE, FMS etc., organization is planned to establish culture of quality. During actualproduction of any product there are too many repetitive and mundane steps which are performed by operators. Thesemundane work operations lead to mental fatigue and boredom in work which eventually lead to silly operator mistakesand we know that human is error-prone even if he doesn't want it. To prevent these silly mistakes, poka yoke conceptplay critical role. By applying some simple solutions we can prevent errors. Long term success of poka yoke providesoutput of saving time and we free the work pressure from mind of worker. We can utilize creativity and special skills ofworkers for more creative operations rather than putting more pressure for monotonous works