Industrial Problem Solving Flashcards

What is the purpose of a 'poka-yoke' device in manufacturing?

Answer: To mistake-proof a process so errors cannot occur or are immediately detected

Poka-yoke ('mistake-proofing' in Japanese) refers to devices or designs that prevent errors or immediately signal when an error has occurred.

A machine's output drops by 20% but no alarms trigger. What is the most logical first diagnostic step?

Answer: Check sensors, gauges, and monitoring systems for possible failures

Checking whether sensors and monitoring systems are functioning correctly rules out false readings before more invasive diagnostics.

What does 'FIFO' stand for in industrial inventory and production management?

Answer: First In, First Out

FIFO (First In, First Out) means the oldest inventory or materials are used first, preventing aging, spoilage, or obsolescence.

During a quality check, dimensions are found to be consistently 0.005 inches too large. This type of error is best described as:

Answer: Systematic bias (accuracy error)

A consistent offset in one direction is a systematic bias (accuracy error), often caused by a miscalibrated tool or machine setting.

What is the purpose of a Standard Operating Procedure (SOP) in an industrial workplace?

Answer: To provide step-by-step instructions ensuring tasks are performed consistently and safely

SOPs provide documented, step-by-step instructions so that tasks are performed consistently, safely, and correctly by all workers.

When prioritizing maintenance tasks, which category should receive attention FIRST?

Answer: Equipment failures that create safety hazards or halt production entirely

Safety hazards and complete production stoppages represent the highest-priority maintenance needs and must be addressed first.