How do you measure the impact of Andon and Poka Yoke on quality, productivity, and customer satisfaction?

1 What are Andon and Poka Yoke?

Andon and Poka Yoke are two Japanese terms that refer to methods of preventing and detecting errors in a production process. Andon means "signal" or "lamp" and is a system of lights, sounds, or displays that alert workers and managers of problems or abnormalities. Poka Yoke means "mistake-proofing" or "error prevention" and is a system of devices, mechanisms, or procedures that prevent or correct errors before they cause defects or waste.

2 Why use Andon and Poka Yoke?

Andon and Poka Yoke are based on the principle of Jidoka, which means "automation with a human touch" or "intelligent automation". Jidoka is one of the pillars of the Toyota Production System (TPS), which is the origin of Kaizen. Jidoka empowers workers to stop the production line when they encounter a problem, identify the root cause, and implement countermeasures. This way, defects are not passed on to the next process or to the customer, and quality is built into the process. Poka Yoke helps workers avoid making mistakes in the first place, by providing clear guidance, feedback, or control. Andon helps workers communicate problems quickly and effectively, by providing visual or audible signals that can be seen or heard by everyone in the workplace.

3 How to measure quality?

Quality is the degree to which a product or service meets or exceeds customer expectations and requirements. Quality can be measured by various indicators, such as defect rate, scrap rate, rework rate, warranty claims, customer complaints, customer satisfaction, and customer loyalty. To measure the impact of Andon and Poka Yoke on quality, you can compare these indicators before and after implementing these systems, and monitor them regularly to identify trends and opportunities for improvement. You can also use tools such as Pareto charts, fishbone diagrams, or 5 whys to analyze the sources and causes of defects, and implement corrective or preventive actions.

4 How to measure productivity?

Productivity is the ratio of output to input, or how efficiently and effectively a process uses resources to produce results. Productivity can be measured by various indicators, such as cycle time, throughput, utilization, capacity, inventory, lead time, and value-added time. To measure the impact of Andon and Poka Yoke on productivity, you can compare these indicators before and after implementing these systems, and monitor them regularly to identify bottlenecks, wastes, and opportunities for improvement. You can also use tools such as value stream mapping, takt time, standard work, or kanban to optimize the flow and balance of the process.

5 How to measure customer satisfaction?

Customer satisfaction is the degree to which a customer is happy or satisfied with a product or service. Customer satisfaction can be measured by various indicators, such as customer feedback, surveys, ratings, reviews, referrals, repeat purchases, retention, and net promoter score. To measure the impact of Andon and Poka Yoke on customer satisfaction, you can compare these indicators before and after implementing these systems, and monitor them regularly to identify gaps, expectations, and opportunities for improvement. You can also use tools such as voice of the customer, Kano model, or quality function deployment to understand and prioritize customer needs and preferences.

6 How to use visual management and feedback loops?

Visual management and feedback loops are essential for measuring and improving the impact of Andon and Poka Yoke on quality, productivity, and customer satisfaction. Visual management involves using visual aids, such as charts, graphs, boards, signs, or colors, to display information, goals, progress, problems, or solutions in a clear and accessible way. Feedback loops provide the mechanisms for communication, collaboration, learning, and adjustment among workers, managers, customers, and suppliers. By utilizing visual management and feedback loops you can monitor performance of your Andon and Poka Yoke systems; identify and resolve problems quickly; share best practices; engage and motivate team members; align actions with goals and customer needs; and continuously improve your process and results.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?