Original Date: 10/10/2005
Revision Date: / /

Raytheon Integrated Defense Systems uses Poka-Yoke, or mistake-proofing, concepts to lower the cost of poor quality by preventing defects before they occur. This approach has been successfully applied to mechanical fixturing, electronic assembly, and cost estimating. By including Mistake Proofing in their Manufacturing Excellence Model, Integrated Defense Systems ensures that appropriate emphasis is placed on implementation and sustainment of mistake-proofing approaches and applications.

The Raytheon Six Sigma™ (R6σ) system employs a Manufacturing Excellence Model (MEM) that is based on 20 critical elements needed to implement and sustain the principles of Six Sigma and the Toyota Production System. MEM element 20 addresses continuous improvement and includes consideration for defect prevention. A key element of defect prevention at Raytheon Integrated Defense Systems (IDS) is Poka-Yoke, or mistake proofing. Prior to 2004, this concept was considered “idiot proofing” and created more of a negative environment than it promoted good manufacturing practices. With the corporate realignment of Raytheon IDS in 2004, this concept was renamed “mistake proofing” and tied directly to the MEM. Goals are established annually for improvement in the MEM rating for each value stream and work center. As such, IDS places emphasis on the effective use of Poka- Yoke in all areas of operations.

Raytheon IDS has seen significant use of Poka-Yoke in mechanical fixturing, electronic build and testing, and cost estimating. One hundred percent of the fixtures used in cabinet manufacturing have undergone Poka-Yoke analysis. All fixture design guidelines have also been modified to address mistake proofing. Poka-Yoke has been implemented in electronic assembly, reducing quality defects and build errors. Mistake-proofing principles have also been incorporated in cost estimating by identification of critical cost elements and process elements that ensure no bid is released without all needed cost elements.

The most cost-effective way to negate the cost of poor quality is to prevent a defect from occurring. IDS’ implementation and emphasis on Poka-Yoka provides an effective method to systemically address preventable defects and lower the lost revenue from poor quality. This ensures that customers are supported at the lowest possible cost and are provided the highest quality product and services.

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