We have a problem currently with operators not following the instructions - the problem occurs in project-driven production (not serial or even short series, mind), so the assumption was taken that poka-yoke will not be cost effective. I could argue this, comparing the poka-yoke costs with bad quality (internal and external) costs - but never mind. I see a big problem - how we could effectively transfer a huge amount of knowledge? This is a complicated hand assembly. Operators are demotivated by seeing an instruction of, say, 10 pages. And there are dozens of them, appropriate for specific products, components or operations.
That can be one reason of not following the procedures, too. When people asses the process of GETTING TO INFORMATION too tiresome and time-consuming; although the information is available.
Agnieszka,
Agreed, using the 10 page work instruction to hammer the official plan into the brains of the operators probably will not be effective.
If the problem is not costly enough to invest in mistake-proofing then why not ask the operators to develop their own plan of assembly in the form of photographs, diagrams, cartoons, audio clips, video clips and other media?
They may also come up with inexpensive mistake-proofing ideas.
Perhaps require new operators to create their own version of the plan/instruction to evaluate and verify their understanding from the training in the
whys and
hows of the assembly process and its controls.
Is the team self-directed so the process is monitored and evaluated for ongoing conformity of the process and effectiveness of the plan/work instruction?
Enable progress this way and the operators may motivate themselves to use their aids to getting the assemblies assembled faster and right the first time.
John
