Productivity improvements through Poka Yoke concept in food industry

Baharud-Din, Nursyuhada (2022) Productivity improvements through Poka Yoke concept in food industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Poka-Yoke concept is an approach for eliminating or minimize human error without losing efficiency in a production process. In today’s competitive environment, any firm must make high-quality, defect-free items at lowest possible price. Various operations are carried out by operators during the real manufacture of any product throughout the actual manufacturing process all of the mistake or errors made by the operator. The Poka-Yoke mechanism is critical in homebased food industry as most processed are still in manual. Poka-Yoke concept helps to prevent human mistakes from occurring on the production line. The aim of this project is to eliminate human errors using Poka-Yoke concept. The three objectives of this project are; (i) to identify human errors in home-ased food business at production processes, (ii) to analysis the root causes of human errors in SME’s food industry, and (iii) to propose solution with control mechanisms for each problem. All the data obtained through observation of severity and occurrence of human mistake in each process are collected from all three companies in order to identified critical problems need to be solve. Next, all data that obtained through observation and 4M (Man, Machine, Material, and Method) are collected from each company to identify the possible root cause of each problem. The root cause was identified using Ishikawa Diagram and further analyzed with 5Why analysis. In total 13solutions with control mechanisms have been proposed based on root causes analysis, which is for NB Emerald Resource Company is reducing quantity snacks in packaging, using scrap collecting bowl by attached at tabletop, use color coding and label, Design of Experiments (DOE), and Change material of secure bottle cap. CNoah Bakery Company Changing material of piping bag, maintenance sheet, Fridge or Chiller Lock, Schedule of delivery time, and vehicle maintenance sheet. Diva’s Kitchen Company is schedule of delivery time, vehicle maintenance sheet, Material Requirements Planning (MRP) Table, and oven maintenance sheet.

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