Application of Pokayoke: Experiences from a Process Industry

摘要

This paper presents a longitudinal study of a process company XYZ Ltd. which is a leading cigarette manufacturer of Nepal with annual turnover above 500 Crores of Rupees. Before use of pokayoke devices the company is facing several quality and productivity problems like increased cigarette wastage, packet missing in outers, print missing of cigarette, packet without tear off tape, down time due feeder jam etc. For these, it was initiated to tackle the problems by using several pokayoke devices; using (1) tear off tape (TOR) sensor, which results in a saving of 4.80% in Product Quality Rating System (PQRS), (2) modified feeder: results in a saving of 15 minutes down time/making machine/day, (3) print missing sensor: results in a reduction of market complaint from 1 to nil, (4) packet missing detector: results in a reduction of market complaint from 5 to nil, and (5) rod break sensor: results in a saving of Rs. 250/machine/day. These devices contributed significantly in increasing quality and productivity in the respective areas of the industry.