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poka yoke or quality by mistake proofing design and construction systems iris d tommelein1 abstract the japanese concept poka yoke translated into english as mistake proofing has been mentioned at ...

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                                                       ‘POKA YOKE 
                                                                OR
                            QUALITY BY MISTAKE PROOFING DESIGN 
                                      AND CONSTRUCTION SYSTEMS 
                                                         Iris D. Tommelein1
                        ABSTRACT
                        The Japanese concept ‘poka yoke’, translated into English as ‘mistake proofing,’ has 
                        been mentioned at previous IGLC conferences. This notwithstanding, mistake 
                        proofing appears to not have been (nor be) systematically researched or practiced in 
                        the lean construction community. To raise awareness of opportunities provided by 
                        thinking with mistake proofing in mind as a means to build quality into project 
                        delivery, this paper summarizes the philosophy that underlies mistake proofing. 
                        Examples illustrate how mistake proofing applies to the work done within one 
                        specialty trade, how manufacturers and fabricators can design their products so they 
                        cannot be constructed defectively, and how architects and engineers may conceive of 
                        system designs that are less likely to fail during construction or in a product’s life 
                        cycle. Reader contributions to an online repository of mistake proofing applications in 
                        the architecture-engineering-construction (AEC) industry, posted at 
                        http://p2sl.berkeley.edu/pokayoke/, will be gratefully acknowledged.  
                        KEY WORDS 
                        poka yoke, mistake proofing, jidoka, autonomation, design, engineering, system, 
                        specification, construction, safety, quality, constructability, tolerance management, 
                        life-cycle performance, lean construction 
                                                                        translated as ‘autonomation’ in 
                        INTRODUCTION AND                               English, as together they form a pillar 
                        DEFINITION                                     of the Toyota Production System.  
                        Shingo (1986), a master mind of the                Autonomation refers to machines 
                        Toyota Production System, introduced           built to detect problems and stop by 
                        the concept of ‘poka yoke’ in                  themselves, so as to “relieve the 
                        Japanese, translated as ‘mistake               burden of constantly supervising a 
                        proofing’ in English, in his book titled       machine, and allow [people] to use 
                        Zero Quality Control: Source                   their talents for more beneficial things 
                        Inspection and the Poka-yoke System.           (like adding value)” (Liker and Meier 
                        This concept goes hand-in-hand with            2006 p. 177) “The purpose of 
                        the concept of ‘jidoka’ in Japanese,           autonomation is the rapid or immediate 
                                                                       address, identification and correction 
                                                                                  
                        1
                            Director, Project Production Systems Laboratory, http://p2sl.berkeley.edu/, and Professor, 
                            Engineering and Project Management Program, Civil and Environmental Engineering Department, 
                            215-A McLaughlin Hall, University of California, Berkeley, CA 94720-1712, Phone +1 510/643-
                            8678, FAX +1 510/643-8919, tommelein@ce.berkeley.edu  
                                                                 195
                   ‘Poka Yoke’ or Quality by Mistake Proofing Design and Construction Systems 
                   Iris D. Tommelein 
                   of mistakes that occur in a process…             proofing examples. The aim of this 
                   Once the line is stopped, a supervisor           effort is to develop a community 
                   or person designated to help correct             knowledge base and to spur discussion 
                   problems give immediate attention to             around mistake proofing opportunities 
                   the problem the worker or machine has            in the architecture-engineering-
                   discovered. To complete jidoka, not              construction (AEC) industry.
                   only is the defect corrected in the 
                   product where discovered, but the                APPLICABILITY OF MISTAKE 
                   process is evaluated and changed to              PROOFING IN THE AEC 
                   remove the possibility of making the             INDUSTRY 
                   same mistake again. This ‘mistake-               Shingo’s premise of ‘zero quality 
                   proofing’ of the production line is              control’ is to ‘do it right the first time.’ 
                   called poka yoke.” (Superfactory                 Bodek stressed this idea in his preface 
                   2008).                                           to Shingo’s book (1986 p. vii) by 
                      Many online glossaries with lean              stating that we should “drop the idea 
                   production terms include ‘poka yoke’             that defects are a normal part of 
                   (e.g., http://www.nummi.com/tps.php)             manufacturing.” In the AEC industry, 
                   and at least one website has been                this thinking is contrary to the reliance 
                   dedicated to this topic  of practitioners on inspection and 
                   (http://www.mistakeproofing.com/).               punch lists as means to work towards 
                   Books have been written on the                   an acceptable end product, hopefully 
                   application of mistake proofing in               one that is satisfactory and of quality! 
                   specific industries (e.g., Grout 2007 is         To eliminate the need for quality 
                   on health care processes). Lean                  control, the practice of mistake 
                   construction researchers have  proofing sets out to prevent errors or 
                   mentioned the concept for many years             defects from occurring in the first 
                   at previous IGLC conferences and                 place.
                   elsewhere (e.g., Koskela 1992, dos                   Mistake proofing is particularly 
                   Santos et al. 1998, 1999, dos Santos             well suited for the AEC industry with 
                   and Powell 1999, Moser and dos                   its low-volume and mixed production 
                   Santos 2003, Adbelhamid and Salem                systems where statistical quality 
                   2005). This notwithstanding, the                 control methods cannot be 
                   practice of mistake proofing still               implemented due to lack of data and 
                   appears to not be systematically                 un-timeliness of findings that result 
                   pursued by researchers and  from after-the-fact data processing. 
                   practitioners in the lean construction           Mistake proofing requires a different 
                   community. To raise awareness of                 way of thinking about production 
                   opportunities provided by thinking               processes and its constituent 
                   with mistake proofing in mind as a               operations, but once practitioners have 
                   means to build quality into project              learned to recognize mistake proofing 
                   delivery, this paper summarizes the              devices, their new mind-set will enable 
                   philosophy underlying mistake  them to spot numerous opportunities 
                   proofing, illustrates opportunities for          available to mistake proof their 
                   application of this concept in practice          workplace. They will find that many 
                   by means of examples, and solicits               mistake proofing practices can be 
                   contributions from readers who may               implemented at a minimal cost, though 
                   wish to volunteer other mistake 
                                      th
                   Proceedings for the 16  Annual Conference of the International Group for Lean Construction 
                   Production System Design 
                                                              196
                          ‘Poka Yoke’ or Quality by Mistake Proofing Design and Construction Systems 
                          Iris D. Tommelein 
                          some do require investment in new                 and-by itself yields advantages, 
                          product development.                              practitioners will reap the greatest 
                              Mistake proofing could be thought             benefits from mistake proofing when 
                          of as a practice that is part of pursuing         applying it in concert with other lean 
                          constructability, that is, changing a             practices.
                          design so that it could be built ‘better’             Shingo (1986 p. 135) “thought that 
                          (e.g., more easily, cost effectively,             explaining poka-yoke methods by 
                          safely, so it will last longer, etc.), but it     means of examples would be 
                          differs from constructability in two              extremely effective when it came to 
                          regards. First, the goal of mistake               actually adopting the poka-yoke 
                          proofing is to improve production                 system” and he goes on to present 
                          system performance by eliminating                 numerous examples (ibid pp. 139-
                          waste, e.g., avoiding product and                 261). Likewise, this paper includes a 
                          process defects, reducing variation,              selection from nearly hundred AEC 
                          and not tolerating poor quality.                  examples I have collected to date, to 
                          Second, efforts at mistake proofing do            show the broad applicability of 
                          not necessarily coincide with the                 mistake proofing in various phases of 
                          timing of constructability review in a            project delivery. Tommelein and Grout 
                          project’s delivery process. Simply put,           (2008) describe and analyse many 
                          pursuing constructability sometimes               more examples and offer more detail 
                          means cutting costs after a design                than is presented here. Examples in 
                          already has been substantially                    this work are not intended to be 
                          developed but exceeds budget. In                  endorsements of the products they 
                          contrast, examples in this paper                  refer to. 
                          illustrate that mistake proofing is a 
                          practice for all project participants             MISTAKE PROOFING IN 
                          (designers, manufacturers, fabricators,           DESIGN, CONSTRUCTION, OR 
                          builders, and others) to pursue in their          MAINTENANCE
                          day-to-day work and throughout                    Mistake proofing applies to work done 
                          project delivery.                                 by a single specialist or by several 
                              The purpose of this paper is to               specialists. In example 1 (Figures 1 
                          raise awareness of how mistake                    and 2), specialists in design and in 
                          proofing practices support lean                   construction have color coded 
                          implementation, specifically on                   distinctions that matter for their 
                          products and processes in the AEC                 specific work and phase of a project so 
                          industry. Mistake proofing practices              as to avoid mix-ups. In examples 2, 3, 
                          contribute to improving a system’s                and 4 (Figures 3, 4, 5,and 6), work has 
                          performance, for example, by reducing             been ‘productized.’ Manufacturers 
                          the time it takes to perform a task               have made devices to address a 
                          while also narrowing the variation of             specific need and thereby reduced the 
                          that task’s duration, by making sure              amount of work, and simplified the 
                          hand-offs from one task to the next are           nature of the work required of field 
                          sound (not defective), and by reducing            personnel. In example 4 (Figures 5 and 
                          variation in products and process                 6), a component is added to the system 
                          outcomes. Though the focus in this                in order to fail safe maintenance work. 
                          paper is on mistake proofing and                  These devices literally or figuratively 
                          though application of this concept in-            turn work into ‘plug-and-play.’ 
                                              th
                          Proceedings for the 16  Annual Conference of the International Group for Lean Construction 
                          Production System Design 
                                                                      197
                    ‘Poka Yoke’ or Quality by Mistake Proofing Design and Construction Systems 
                    Iris D. Tommelein 
                        Figure 1: Color coding of design drawing shows        Figure 2: Color coding shows locations for sheet 
                         different wall types for drywall cost estimate        metal straps and pipe hangers on metal decking 
                         (Source: DPR, Inc., Camino Medical Project)           (Source: John Mack, Southland Industries, Inc., 
                                                                            presentation at 2007 Annual Conference of the Lean 
                                                                                 Construction Institute, San Francisco, CA) 
                    EXAMPLE 1: COLOURCODING TO                             hose that solves a typical fit-up 
                    IMPROVEIDENTIFICATION                                  problem. At one end, the toilet bowl 
                    Figure 1 shows colour codes a                          (commode) is seated on waste-water 
                    construction estimator has assigned to                 pipe located in the floor, and the water 
                    distinguish various wall types. This                   tank rests on and connects to that base 
                    helps in clarifying and categorizing the               of the fixture. At the other end, the 
                    design requirements specified by the                   water supply pipe runs in the wall and 
                    architects, in performing a quantity                   stubs out of it, ending with a valve. 
                    take off and preparing a cost estimate,                The challenge is to connect the pipe at 
                    and in planning the work. Figure 2                     this valve to the entry into the water 
                    shows colour codes being used on site,                 tank, recognizing that all construction 
                    to highlight which metal-decking                       work that precedes this connection step 
                    inserts belong to which trade. This                    is subject to dimensional variation 
                    helps, among other things, in making it                (tolerances), that is, things do not get 
                    easy to assess whether or not all inserts              physically located exactly where 
                    are in place prior to casting the                      drawings or computer models showed 
                    concrete slab on this decking. These                   them to be. Rather than requiring 
                    two examples illustrate mistake                        bending of more rigid tubing or pipe 
                    proofing approaches that help reduce                   and cutting it to size, a flexible hose of 
                    the likelihood of occurrence—though                    approximate (standard) size suits this 
                    not 100% prevention—of mistakes.                       purpose without requiring accurate 
                                                                           measurement.  
                    EXAMPLE 2: FLEXIBLE CONNECTION                             Mistake proofing devices to 
                    TOACCOMMODATE DIMENSIONAL                              accommodate the manifestation of 
                    VARIATION                                              uncertainty in physical geometry 
                    Figure 3 shows plumbing where the                      (dimensions and location), and 
                    mistake proofing device is a flexible                  accumulation of that uncertainty as 
                                                                           work progresses, similarly exist in 
                                          th
                    Proceedings for the 16  Annual Conference of the International Group for Lean Construction 
                    Production System Design 
                                                                    198
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...Poka yoke or quality by mistake proofing design and construction systems iris d tommelein abstract the japanese concept translated into english as has been mentioned at previous iglc conferences this notwithstanding appears to not have nor be systematically researched practiced in lean community raise awareness of opportunities provided thinking with mind a means build project delivery paper summarizes philosophy that underlies examples illustrate how applies work done within one specialty trade manufacturers fabricators can their products so they cannot constructed defectively architects engineers may conceive system designs are less likely fail during product s life cycle reader contributions an online repository applications architecture engineering aec industry posted http psl berkeley edu pokayoke will gratefully acknowledged key words jidoka autonomation specification safety constructability tolerance management performance introduction together form pillar definition toyota prod...

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