oiiiiilll I 3846 I 1 I Control: Source Inspection and the Translated by Andrew P. Dillon New York Originally published as Fury6 = 0 e no ch6sen: Genryzi .kensa to poka-yoke shisutemu; Zero QC h6shiki e no tenkai, copyright O 1985 by the Japan Publisher's Message Management Association, Tokyo English translation copyright O 1986 by Productivity Press, a division of The Kraus Organization Limited. All rights reserved. No part of this guide may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from the publisher. Additional copies of this book are available from the publisher. Discounts are available for multiple copies through - the sales department (888-319-5852) Address all other inquiriesAto: Productivity Press 444 Park Avenue South, 7th Floor New York, NY 100 16 Telephone: 212-686-5900 Telefax: 212-686-541 1 email:
[email protected] Cover design by Russell Funkhouser j& .. .&. ..............A.. .....J E : ,l.. Printed in the United States of America Library of Congress Catalogrgrng-in-Publication data Shingo, Shigeo, 1909-1990 Zero quality control Translation o f : Fury6 zero e no chdsen Includes index 1. Quality control. I. Title TS156.S4722513 1985 658.5' 85-63497 CIP According to Shigeo Shingo, there are three types of engineers in America: table enginem, who spend all of their time in meetings argumg about problems on the shop floor; catalog engingers, who scour the latest catalogs for new equipment to solve these problems; and ccnyt9J~ngineers,who vote against almost every improvement suggestion. Mr. Shingo, inventor of the SMED (Single-Minute Exchange of Die) system and the pob-yoke (mistake-proofing) system, and a key developer of the Toyota Production System, was in America at the invitation of three companies to help them search for ways to improve the efficiency of their production systems. He urged his audiences at these companies to become i m p e m e n t engineers and, calling himself "Dr. Improvement," demonstrated the essence of his ideas by spending the majority of his time on the shop floor observing problems, making suggestions, and working with both the workers and management to find solutions. "My medicine works," Shingo remarked, "but only if the patient takes it." The title of this book refers to three critical and interrelated aspects of quality control as taught by Shigeo Shingo. Zero Qwdity Control (Zero QC) is the ideal production system - one that does not manufacture any defects. To achieve this ideal, two things are necessary. Bkayoke (in Enghsh, ccmistake-proofing")look at a defect, stops the production system, and gives immediate feedback so that we can get to the root cause of the problem and prevent it from happening again. Sowce inspection looks at errors before they become defects and either stops the system for correction or automatically adjusts the error condition to prevent it from becoming a defect. Using poka-yoke devices and source in